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Condor Maintenance Manual.book

1. reference s RFI radio frequency interference Te A right hand RHDR right hand drive Alla removal and installation RMA return material authorization ROM read only memory rpm revolutions per minute RiR removal and replacement Condor Maintenance Manual March 2004 General Information List of Abbreviations 00 17 RSG road speed governor RTV room temperature vulcanizing RV AAA recreational vehicle SAE Society of Automotive Engi neers SP service bulletin SD evitaci n severe duty SDU step deployment unit SEL tiros shutdown engine light Sd service information A Syst me International SID subsystem identifier SMC sheet molded compound SIN serial number SPACE seat pretensioner activation for crash survival enhancement SA Ticas standard repair time SSD side sensor display SST stainless steel std standard SIN R software SW switch TAM thermocouple amplifier module TBS turbo boost sensor TCU transmission control unit TDC top dead center TDR technician diagnostic routine temp temperature UE tungsten inert gas TPS thermal protection switch TPS etnia throttle position sensor TRS timing reference sensor Lo AA ruck sales order
2. 32 3 32 Suspension to the top of the axle U bolt pad See Fig 6 Ref A See Table 1 for the correct distances Suspension Height Adjustment Distances Distance in Inches mm Suspension Type Minimum Target Maximum 20 40K AirLiner 2 3 8 60 2 5 8 67 2 7 8 73 23 46K AirLiner 2 3 4 70 3 76 3 1 4 83 Low Mid Ride Height AirLiner 2 1 4 57 2 1 2 64 2 3 4 70 Table 1 Suspension Height Adjustment Distances 08 16 96 i 320453 A Measure height here 1 Left Forward most Axle Stop Fig 6 AirLiner Axle Stop Measurement 5 Ifthe axle stop measurement is not correct See Group 32 of the Condor Workshop Manual for adjustment procedures 6 Apply the parking brakes and remove the chocks American LaFrance TufTrac Inspect all suspension fasteners for the proper torque values See Group 00 of this manual for proper bolt 32 4 torque specifications Visually inspect the frame for elongated holes or abnormal wear at the suspension mounting points and have the frame repaired as needed If elongated holes are found on the frame check the suspension alignment Check brackets and torque rods for damage or loose fasteners Chalmers Tandem Axle Suspension 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 o
3. Condor Maintenance Manual March 2004 00 General Information M2 Maintenance Interval Operations 00 10 The M2 Maintenance Interval Operations tables list all operations to be performed Perform all M1 mainte maintenance operations that are to be performed at the nance interval operations at the M2 maintenance inter M2 maintenance interval Maintenance operation num val bers are reference numbers used to help you find detailed instructions in this manual on the maintenance M2 Maintenance Interval Operations M2 Maintenance Interval Operations ee sinionancs interval Operations OOOO O WR Desen A 91500 Engine Noise Paner Trspection Noise Erisson Gone f E ER LI A ER Ierpel REES ER OTE O En I gmneeer CS ER EEE A 00 14 Condor Maintenance Manual March 2004 General Information The M3 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M3 maintenance interval Maintenance operation num 00 M3 Maintenance Interval Operations 00 11 bers are reference numbers used to help you find detailed instructions in this manual on the maintenance M3 Maintenance Interval Operations operations to be performed Perform all maintenance interval operations in M1 and M2 when performing M3 maintenance interval operations M3 Maintenance Interval Operations Deelen Operation Description Check 00 09 M1 Maintenance Interval Operation
4. ASTM American Society for Testing and Materials ATC automatic temperature control ATC automatic traction control Alivio automatic transmission control ATF automatic transmission fluid attn attention AUX sides auxiliary AV avoirdupois British weight sys tem AWG American wire gauge AWS American Welding Society BAT battery BBC bumper to back of cab BOM bill of material BTDG before top dead center Btu s British thermal unit s Guia common terminal CAC charge air cooler CAN controller area network CARB California Air Resources Board CAT Caterpillar CR circuit breaker CR citizens band CCA cold cranking amperes Condor Maintenance Manual March 2004 CD ROM compact disc read only mem ory constant discharge tempera ture control check engine light chlorouorocarbons refrigerant 12 cubic feet per minute Code of Federal Regulations coolant level sensor centimeters cubic centimeters Canadian Motor Vehicle Safety Standard company cab over engine corporation central processing unit centistokes unit of measure ment for describing the viscosity of general liquids cubic feet cubic inches Cummins collision warning system direct current Detroit Diesel Allison Detroit Diesel C
5. UD underdrive UNC unified national coarse UNF unified national fine US United States U S A United States of America USC United States customary mea sures Venen volts VDC vehicle data computer Vdc volts direct current VIN vehicle identification number VIP vehicle instrumentation and protection Kysor volatile organic compounds volt ohmmeter variable speed governor Condor Maintenance Manual March 2004 vehicle speed sensor wire braid work instructions wide open throttle minus or negative plus or positive plus or minus greater than less than by used in fastener size descriptions inches degrees of an angle degrees Celsius centigrade degrees Fahrenheit number percent and copyright trademark registered trademark 00 00 26 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Belt Inspection enie erea e aeee eea Elea AECE KEEA Ean ETNE KAA E A 01 02 Engine Noise Panel Inspection Noise Emission Control 01 01 Condor Maintenance Manual September 2000 Engine 01 01 Engine Noise Panel Inspection Noise Emission Control If equipped inspect for torn engine noise panels See Fig 1 for Caterpillar noise panel locations If panels are torn replace them with new panels see Group 01 of the Condor Workshop Manual for procedures Cum mi
6. cubic feet fts Weight Force ounces av oz pounds av Ib U S tons t U S tons t Torque Work Force inch pounds Ibf1 in foot pounds Ibf1 ft Pressure Vacuum inches of mercury inHg pounds per square inch psi When You Know degrees Fahrenheit _F 00 20 Subtract 32 1 8 Multiply A When You Multiply By To Ger Metric Know Metric By To Get U S Customary 0 03937 0 3937 3 281 1 094 0 6215 millimeters mm inches in centimeters cm inches in feet ft yards yd miles mi meters m meters m kilometers km square millimeters mm2 0 00155 0 155 10 764 square inches ne square centimeters cm2 square inches nz square meters m2 square feet ft 16387 0 16 387 0 01639 29 54 0 47318 0 94635 3 7854 28 317 0 02832 0 000061 0 06102 61 024 0 03381 2 1134 1 0567 0 2642 0 03531 35 315 cubic millimeter mms cubic inches ins cubic centimeters cms cubic inches ins liters L i milliliters mL liters L liters L liters L liters L cubic meters ms cubic inches ins fluid ounces oz pints pt quarts qt gallons gal cubic feet fts cubic feet fts 28 35 0 454 907 18 0 90718 0 03527 2 205 0 001102 1 1023 grams g ounces av oz kilograms kg pounds av Ib U S tons t kilograms kg U S tons t metric tons t 11 298 1 3558 0 08851 0 7376 Newton centimeter
7. use one part kerosene to three parts SAE 10 heavy duty engine oil API service classi cation SD sulfated ash content must not exceed1 85 This cold weather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures do not mix it with kerosene 3 Apply asmall amount of Loctite 242 or equivalent sealant to the threads of the fill plug Install the fill plug finger tight then using a wrench tighten it 1 1 2 turns past finger tight Condor Maintenance Manual September 2000 Rear Axle Axle Breather Check Axle housing breathers must remain clean and unclogged Whenever the axle lubricant level is inspected check the axle breather to be sure that it is open Check more often under adverse operating con ditions If the breather is plugged clean or replace it as needed See Fig 4 K a 2 3 06 07 94 f350062a 1 Axle Housing 2 Carrier Oil Fill Plugs Breathers 3 Interaxle Differential Fig 4 Fill Plug and Axle Housing Breather Locations 35 02 Axle Lubricant and Filter Changing and Magnetic Strainer Cleaning A CAUTION Failure to change lubricant as recommended could result in axle damage Meritor Single drive axles equipped with traction equalizers may require a limited slip friction modifier to correct a slip stick condition as described in the
8. 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 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 American LaFrance 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 ubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 5 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads Condor Maintenance Manual March 2004 00 21 00 Torque Specifications Tables 00 16 General Information Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads Regular Hex Flanged ie Grade 5 or B Grade 8 or 8 2 Grade 8 or C Grade 8 or 8 2 gee 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 S i A 230003 Ge 1230005 X 2 SSF 0008 1 4 20 8 11 10 14 1 4 28 9 SS 12 16 5 16 18 5 20 22 30 22 30 5 16 24 7 23 25 34 3 8 16 8 38 40 54 40 54 3 8 24 1 42 45 61 7116 14 5 61 65 88 65 88 7116 20 0 68 70 95 1 2 13 0 95 95 129 95 129 1 2 20 75 Se 1
9. 42 07 Disc Brake Caliper Lubrication 46 02 Drag Link Lubrication 46 03 Power Steering Gear Lubrication Table 2 Maintenance Operation 00 06 Chassis Lubrication at M2 00 8 Condor Maintenance Manual March 2004 General Information 00 Lubrication and Fluid Level Check Locations 00 07 2 2 3 0 3 4 4 5 l 5 6 6 S 7 a 7 8 8 e 1 1 B 10 10 141 ET 4 5 12 12 6 10 11 13 10 12 12 e 08 14 2000 5 4 4 5 1001028 Fig 4 Lubrication and Fluid Level Check Locations Condor Maintenance Manual March 2004 00 9 00 Lubrication and Fluid Level Check Locations 00 07 General Information Y 14 y 08 14 2000 A B 1720376 1 Standard Door 2 Stand Up Right Hand Drive Fold Up Door Fig 5 Lubrication and Fluid Level Check Locations 00 10 Condor Maintenance Manual March 2004 General Information Power Steering Reservoir MOP er E 00 Lubrication and Fluid Level Check Locations 00 07 26 02 Transmission Axle Lubricant Front Suspension No Nee Component Remarks Check that the power Rear Refer to the maintenance steering fluid is at the full 12 32 02 Suspension operation for detailed mark and add fluid as procedures needed Fifth Wheel Reter to the maintenance Check that the 13 31 02 Inspection operation for detailed transmission oil level is procedures correct Door Seal Lubricate all door seals Add the proper fluid as 14 72 01 Door Latch door la
10. Stage 1 Stage 2 Stage 3 Stage 4 Hand Tighten 200 271 180 to 230 245 to 313 3 4 16 Stage 1 Stage 2 Stage 3 Stage 4 Hand Tighten 200 271 270 to 330 367 to 449 Spring Assembly U Bolt High Nuts 7 8 14 Stage 1 Stage 2 Stage 3 Stage 4 Hand Tighten 200 271 420 to 500 571 to 680 Stage 1 Stage 2 Stage 3 Stage 4 Hand tighten 200 271 520 to 600 707 to 816 Tighten in a diagonal pattern as shown in Fig 16 Table 4 U Bolt Torque Values 01 05 99 2 320783 Fig 16 Tightening Pattern for U bolt High Nuts 32 12 Condor Maintenance Manual September 2001 Front Axle Title of Maintenance Operation MOP All Axle Alignment Checking Knuckle Pin Lubrication Tie Rod Inspection Tie Rod Lubrication Condor Maintenance Manual June 2001 33 Index Alphabetical MOP Number Front Axle 33 01 Knuckle Pin Lubrication When lubricating knuckle pin bushings do not raise the front axle Wipe the lube fittings clean and apply multi purpose chassis grease NLGI Grade 1 6 12hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease until new grease is seen at the bushing grease seal opposite the fittings The grease seal will accept grease pressure without damage and is designed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate
11. stands Have someone turn the steering wheel to full lock left and right Capture the fluid flowing from the hose in a drain pan Add fluid to the reservoir as needed When clean power steering fluid flows from the hose into the drain pan remove the plug from the reservoir and reconnect the steering gear to reservoir hose to the reservoir Remove the jack stands and lower the vehicle 6 With the larger opening at the top install a new fil ter into the reservoir Install the filter top plate so its center fits into the opening at the top of the filter Install the filter spring 7 Clean the reservoir cover and O ring seal Inspect the O ring and the cover for cracks deformities or damage Replace the O ring seal or cover as needed 8 Install the reservoir cover over the threaded shaft Apply a slight downward pressure while installing the rubber washer and the flanged nut Tighten the nut until it is snug 9 Fill the power steering reservoir with approved power steering fluid see Table 1 to the FULL COLD mark on the dipstick 10 Start the engine and operate it at idle Turn the steering wheel to full lock left and right to adjust the fluid level and remove any existing air from the power steering pump and gear Recheck the fluid Condor Maintenance Manual September 2001 46 level Add fluid as needed The system is properly bled when the steering pump does not labor when turning the wheel 11 Check for leaks in
12. switch NO number NPT national pipe thread NPTF national pipe thread fitting NSBU neutral start backup NI n nylon tube or nylon tubing DCH ooi open circuit voltage 0 0 outside diameter OD overdrive OEM original equipment manufac turer OSHA Occupational Safety and Health Administration One ounces ozfin ounces force inches Dee positive front axle wheel align ment specification parm parameter RG etc personal computer PCB printed circuit board PDC parts distribution center PDM power distribution module PEEC programmable electronic engine control PID parameter identifier power line carrier Pumpe Linie D se pumpline nozzle Dm post meridiem noon to mid night P M EE part number PSA pressure sensitive adhesive PS pounds per square inch psia pounds per square inch atmo sphere psig pounds per square inch gauge Plica pints Plisson points PTCM pressure time control module PTO power take off PVC polyvinyl chloride PWM pulse width modulation Qt snk quarts qty quantity R amp O rust inhibitors and oxidants RA refrigerant 12 CFC R 134a refrigerant 134a HFC RAM random access memory recirc recirculation Ref s
13. 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 hit ting the plug and knocking it out contact your Condor Maintenance Manual September 2000 Driveline Regional Service Office for assistance in determin ing the correct driveshaft length Attempt to move the sleeve yoke and splined shaft back and forth 05 27 93 f410012a Fig 4 Slip Joint Spline Wear Checking 41 02 Driveline Lubrication Universal Joint Lubrication NOTE Vehicles equipped with Meritor RPL Series driv elines do not require periodic lubrication 1 Park the vehicle on a at surface apply the parking brakes and chock the tires Wipe all old grease and dirt from each U joint grease fitting See Fig 5 Ref 8 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate U joints If a low pressure adapter is not used U joints may not receive enough grease Using lithium 12 Hydroxy stearate grease NLGI Grade 1 or Grade 2 with EP additives lubricate until new grease can be seen at all four U joint seals Fresh grease must be seen escaping from all four bearing cap seals of each U joint On yokes equipped with a yoke bearing cap if most of the grease being added to a U joint can be seen escaping from just one of the U joint seals check the torque on the capscrews at that seal Tighten the bear
14. 305 373 Bar Pin Locknut 1 8 450 600 610 813 7 16 20 50 60 70 80 Spring Center Bolt 1 2 20 65 75 90 100 Rebound Spacer Locknut 1 2 13 38 45 51 61 Table 3 RTE Series Suspension Torque Values 32 8 Condor Maintenance Manual September 2001 Suspension 32 05 27 93 f320112a 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 DEER Fig 11 RTE Suspension unloaded Neway Suspension Inspect the components and check their operation Failure to perform these inspections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury and property damage 1 Park the vehicle on a level surface Apply the park ing brakes and chock the tires to prevent the vehi cle from moving 2 Inspect the rear suspension for any signs of dam age loose components wear or cracks Replace any damaged components to prevent failure or equipment breakdown Condor Maintenance Manual September 2001 08 16 96 3 1320422 Wood Block Pry Bar 1 Frame Bracket 3 2 Leaf Spring 4 Fig 12 Hendrickson RTE Series Frame Bracket Inspection 3 Inspect all bolts and nuts at the pivot and axle con nections to assure they are properly torqued Check all other nuts and bolts for proper torque See Group 00 of this manual for proper torque specification
15. 56 315 1750 42 8th M1 M2 and M3 40 000 64 360 2000 48 9th M1 45 000 72 405 2250 54 10th M1 and M2 50 000 80 450 2500 60 11th M1 55 000 88 495 2750 66 12th M1 M2 and M3 60 000 96 540 3000 72 13th M1 65 000 104 585 3250 78 14th M1 and M2 70 000 112 630 3500 84 15th M1 75 000 120 675 3750 90 16th M1 M2 and M3 80 000 128 720 4000 96 17th M1 85 000 136 765 4250 102 18th M1 and M2 90 000 144 810 4500 108 19th M1 95 000 152 855 4750 114 20th M1 M2 and M3 100 000 160 900 5000 120 Condor Maintenance Manual March 2004 00 3 00 Cab Tilting 00 04 Cab Tilting A hydraulic pump is used to raise and lower the cab The tilt system consists of four major parts A The hydraulic pump which consists of the pump body reservoir and manual pump B A tilt cylinder C A tilt strut on the right side tilt cylinder Hydraulic Lockup Hydraulic lockup can occur for the following reasons e Very cold weather Use of the wrong hydraulic fluid Air in the system e Sudden cab movement A ruptured hydraulic line Any of the above situations will cause the velocity fuse to function as safety check valves and lock up the tilt cylinders To unlock the cylinders the cab must be moved in the opposite direction of travel IMPORTANT If the tilt cylinder locks up check for a major problem such as a ruptured line or leaking fit ting before trying to unlock the tilt cylinders If such a problem is found make any necessary repairs befo
16. 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 2006 American LaFrance LLC All rights reserved No part of this publication in whole or in part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of American LaFrance LLC American LaFrance LLC Customer Support 1090 Newton Way Summerville SC 29483 Introduction Descriptions of Service Publications American LaFrance LLC distributes the following major service publications Workshop Service Manual Maintenance Manual Driver s Operator s Manual Parts Technical Manual Service Bulletins Recall Bulletins Field Service Modifications Condor Maintenance Manual May 2003 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 Eac
17. Ah CAUTION Continued vehicle operation with loose fasteners could result in bracket or frame damage Inspect and check the fasteners at the following loca tions Axle Stops Engine Trunnion Supports Equalizer Brackets Exhaust Brackets Frame Crossmembers and Gussets Frame Brackets Front Suspension Brackets Radius Rods Rear Engine Supports Rear Suspension Brackets Shock Absorbers e All Other Frame Fasteners Any component that shows signs of cracking or other damage must be repaired or replaced See the vehicle workshop manual for repair or replacement information in the respective section for the component in question Condor Maintenance Manual March 2003 31 31 02 Fifth Wheel Inspection All fifth wheel maintenance adjustment and rebuilding must be done only by a qualified mechanic Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor which could result in per sonal injury or property damage Parts are under spring compression Wear safety goggles while servicing the fifth wheel Failure to do so can result in personal injury due to parts ejecting with force Fontaine 1 Disconnect the tractor from the trailer For instruc tions see the vehicle operator s manual Thoroughly steam clean the fifth wheel Look for cracks in the fifth wheel assembly mount ing brackets and mounting parts 4 Check the jaw and stationary jaw for mushroomi
18. Approved Antifreeze Caterpillar 20 6 Condor Maintenance Manual August 2003 Engine Cooling Radiator Maximum Coolant Protection in F C at Various Antifreeze Concentrations ETHYLENE GLYCOL BASE ANTIFREEZE REQUIRED STO gallons liters CAPACITY 3 3 4 5 6 7 8 9 10 11 12 13 14 15 gal L 8 10 15 19 23 26 38 42 45 49 53 57 928 o PETE 1029 es 652 MN 1068 da Tele ken lesa an EE ees E ee A UN 20 Oy ca mm ds an 14 53 Se EH 15 57 Ze 16 61 a EE EE WS 18 68 19 72 S EI 9 412 516 19 24 30 37 44 Ki EH a es em eta er Cea Cen Cea ca Cae ey For cooling system capacities not shown the required amount of antifreeze can be calculated using the following Ethylene glycol base antifreeze in a 25 solution protects to 10 F 12 C 33 to OF 18 C 40 to 12 F 24 C 50 to 34 F 37 C and 60 to 62 F 52 C 1 60 ethylene glycol base antifreeze and 40 water by volume gives maximum coolant protection 62 F 52 C Exceeding 60 antifreeze diminishes coolant protection concentrated ethylene glycol base antifreeze will freeze at approximately 0 F 18 C Table 3 Maximum Coolant Protection in F C at Various Antifreeze Concentrations Condor Maintenance Manual August 2003 20 7 20 COOLING SYSTEM gal L 22 8
19. End Cover 6 Housing 16 Purge Valve Bolt 7 Nylok Nut 17 Exhaust Diaphragm 8 3 8 Special Washer 18 Purge Valve 9 Desiccant Cartridge 19 1 4 Tapping Screw Fig 1 Air Dryer exploded view of Bendix AD 9 shown 42 2 Condor Maintenance Manual September 2000 Brakes 09 20 94 1420544a Fig 2 Bendix AD 9 End Cover to Housing Torque Pattern 42 03 Bendix AD 9 Air Dryer Inspection Check for moisture in the air brake system by opening the reservoir drain cocks Examine the discharge Some trace of water in the discharge is normal A discharge of a milky gray liquid indicates excessive moisture is present in the air system and the desiccant cartridge needs to be replaced See Group 42 in the vehicle workshop manual for trou bleshooting procedures The following conditions could cause small amounts of moisture to be found in the air system An outside air source has been used to charge the air brake system This air did not pass through the drying bed Air usage is unusually high and not normal This may be due to accessory air demands or some unusual air requirement that does not allow the compressor to load and unload in a normal fash ion Check for air system leaks The air dryer has been installed on a system that had previously been operated without an air dryer This type of system will be saturated with moisture and several weeks of operation may be needed to fully dry the system Condor Maintenance
20. Fleetrite PSF Power Steering Fluid Texaco TL 1833 Do not mix oil types Refer to the text in this group for a detailed warning statement Table 1 Recommended Power Steering Fluids Condor Maintenance Manual September 2001 46 2 3 4 7 8 9 5 6 11 28 95 1461070 SADA Vented Fill Cap and Dipstick Flanged Nut Rubber Washer Reservoir Cover Filter Spring Filter Top Plate Reservoir Filter Threaded Shaft Power Steering Reservoir Fig 1 Power Steering Reservoir exploded view 46 02 Drag Link Lubrication Using a clean rag wipe all dirt from both drag link grease fittings See Fig 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 8 12 hydroxy lithium stearate grease or NLGI Grade 1 6 12 hydroxy lithium stearate grease Grade 2 is preferred 46 1 46 We 2 1 11 27 95 1461072 NOTE The grease fitting is on inboard side of ball stud 1 Grease Fitting at Pitman Arm 2 Grease Fitting at Axle Steering Arm Fig 2 Drag Link 46 03 Power Steering Gear Lubrication AR CAUTION Apply grease to the sector shaft only with a hand type grease gun See Fig 3 Use of a high pressure power grease gun will supply grease too quickly and could affect the high pressure seal contami nating the hydraulic fluid Using a hand type grease gun apply NLGI Grad
21. Manual September 2000 42 The temperature range in your area fluctuates more than 30 degrees in one day Small amounts of water can accumulate in the air brake system due to condensation Under these conditions the presence of moisture is normal and should not be considered an indication of poor air dryer per formance Visually inspect the air dryer for external damage and check that the unit is mounted tightly on the frame lf the air dryer mounting is loose see Group 42 of the Condor Workshop Manual for mounting instructions Turn on the ignition switch but don t start the engine Disconnect the harness connector from the air dryer Connect a voltmeter to circuit 94 on the air dryer s harness connector and to a body ground point Check for battery voltage If voltage is not found check and repair the open or short to ground in wire 94 Connect a voltmeter between the two terminals on the air dryer s harness connector If voltage is not found repair the open in the ground circuit wiring Use an ohmmeter to check resistance between the terminals on the end cover See Fig 3 The end cover contains the heater thermostat If the heater thermostat is between 40 and 90 F 5 to 32 C the heater thermostat measured resistance will be infinite ohms If the measured resistance is less than infinity replace the heater thermostat Remove the heater thermostat assembly and place itin a freezer for about five mi
22. and out If there is any movement replace the torque arm lf a torque arm needs to be replaced See Group 32 of the Condor Workshop Manual for instructions 4 Inspect the weld seams between the torque arm tube and the shorter bushing tubes If there are cracks replace the torque arm Do not weld the torque arm for any reason 5 Inspect the rubber bushing ends See Fig 2 Replace the torque arm for any of the following reasons If there are gaps between the rubber bushing and the pin or outer steel sleeve If either bushing end contacts a torque arm pin mounting bolt If there are cracks in the bushing If part of the rubber bushing extends beyond the outer circumference of the outer bushing sleeve Suspension 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 Condor Workshop Manual for instructions 05 27 93 f320022a Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer aN 05 27 93 f320021a Fig 2 Torque Arm Bushings 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 32 2 Fig 3 Side View of the Equalizer 7 With the vehicle unloaded attempt to move the equalizer side to side using a pry bar b
23. belts before replacing the drive belts Do not use belt dressing on any belt 3 Check the belt for a jagged or streaked sidewall See Fig 2 Ref C Jagged or streaked sidewalls are the result of foreign objects such as sand or gravel in the pulley or a rough pulley surface 4 Check for tensile breaks breaks in the cord body See Fig 2 Ref D Cuts in a belt are usually caused by foreign objects in the pulley or by prying or forcing the belt during removal or installation 5 Check for uneven ribs on serpentine poly V belts See Fig 2 Ref E Foreign objects in the pulley will erode the undercord ribs causing the belt to lose its gripping power 6 Check the drive belts for cracks See Fig 2 Ref F Small irregular cracks are usually the signs of an old belt 7 Visually inspect the pulleys for excessive play or wobble Excessive play or wobble indicates a fail ure 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 stethoscope on the component being checked not the pulley to isolate the area from outside interference 8 Inspect all pulleys for foreign objects oil or grease in the grooves 01 1 01 Engine C 11 21 94 A Glazing D Tensile Break B Separating Layers E Uneven Ribs C Side Streaked walls F Cracks f150010a Fig 2 Drive Belt Replacem
24. 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 pat tern in the pockets If the X pattern is worn away replace the fifth wheel top plate 7 3 Install the fifth wheel top plate bushing pins and roll pins Inspect for fatigue or cracked welds 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 hard ened washers Do not re use bolts nuts and washers on fifth wheel mountings 10 After inspecting the fifth wheel lubricate all moving parts with a chassis or multipurpose grease See Maintenance Operation 31 03 for lubrication instructions 31 03 Fifth Wheel Lubrication To maintain proper fifth wheel operation always lubri cate the fifth wheel after an inspection has been per formed IMPORTANT Lubricate the fifth wheel Condor Maintenance Manual March 2003 31 After power washing or steam cleaning If the vehicle operates in harsh conditions such as salt spray from road surfaces or in extremely dusty environments After any service that requires the removal of lubrication from the fi
25. denser fins See Group 83 of the Condor Work shop Manual for cleaning instructions Condor Maintenance Manual June 2001 83 08 25 94 1830641 Fig 1 Drive Plate Clearance Inspection Refrigerant Checking Find the moisture indicator sight glass on the receiver drier and check the color of the moisture indicator See Fig 2 11 21 95 7 1830746 1 Moisture Indicator Fig 2 Receiver Drier 83 1 83 If the indicator is a deep cobalt blue the refrigerant charge is dry If the indicator is not blue the system is contaminated with water If the system is contaminated the refriger ant must be recovered and the receiver drier must be replaced See Group 83 of the Condor Workshop Manual for instructions Cab Air Filter Cleaning or Replacement The cab HVAC heating ventilation and air condition ing air filter must be cleaned or replaced once a year to permit proper operation of the HVAC system The fil ter can be cleaned a maximum of three times before replacement is needed IMPORTANT When replacing the air filter use only American LaFrance LLC approved air filters Use of unapproved air filters could decrease the ow of air into the cab 1 Park the vehicle on a level surface apply the park ing brake shut down the engine and chock the rear tires 2 Remove the cab front grille See Group 88 of the Condor Workshop Manual for instructions 3 From under the front of the c
26. exhaust pipe to the turbocharger exhaust outlet See Fig 2 If leakage exists tighten the nut on the V band coupling 10 Ibf ft 14 N m If leakage persists install a new V band coupling 4 Inspect the turbo outlet pipe and replace it as needed 5 Check the U bolt clamps for tightness and tighten as needed 6 Check for leakage at all wide band exhaust clamps See Fig 3 Fig 4 or Fig 5 If leakage exists tighten the nuts 40 to 60 Ibf ft 54 to 81N m If leakage persists install a new wide band exhaust clamp Do not re use Sealclamps Condor Maintenance Manual September 2000 49 4 4 3 4 SC S 07 12 2000 1490231 1 Exhaust Clamp 2 Lower Heat Shield Fastener 3 Heat Shield 4 Upper Heat Shield Fastener Fig 1 Vertical Exhaust Stack and Heat Shield 49 1 49 Exhaust 5 IN 1 2 j S 10 05 94 f490005a o C 3 N Fig 4 Torca Torctite Wide Band Exhaust Clamp 07 13 2000 4 1490232 1 Flex Hose 2 Turbocharger Exhaust Outlet 3 V Band Coupling o 4 Exhaust Pipe EUREN Fig 2 V Band Coupling and Flex Hose i 09 30 99 f490214a d Fig 5 Gemi Wide Band Exhaust Clamp 05 28 93 i 1490025a Fig 3 Donaldson Sealclamp Wide Band Exhaust Clamp 49 2 Condor Maintenance Manual September 2000 Cab 60 Index Alphabetical Title of Maintenance Operation MOP MOP Number Cab Tilt Pump Reservoir Fluid Level and System Check 60 01 Condor Maintenance Manua
27. for Replacement Parts Replacement parts used for maintenance or repair of noise emission controls should be genuine American LaFrance parts If other than genuine American LaFrance parts are used for replacement or repair of components affecting noise emission control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine Ameri can LaFrance parts in performance and durability American LaFrance Noise Emission Controls Warranty Refer to the vehicle owner s warranty information book for warranty information concerning noise emission controls Tampering With Noise Controls is Prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance 00 18 repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 The use of the vehicle after such device or element of design has been removed or rendered inopera tive by any person Among those acts presumed to constitute tamper ing are the acts listed below A Removal of engine noise deadening panels D Removal of cab tunnel noise deadening panels C Removal of or rendering inoperative the engine speed governor so as to allow engine speed to exceed manufacture
28. kg front axle are fitted with mainte nance free rubber bushings and do not require lubrica tion Rear Suspension American LaFrance TufTrac No lubrication is required on the TufTrac rear suspen sion 32 10 Chalmers No lubrication is required on the Chalmers rear sus pension American LaFrance Spring Single Axle No lubrication is required on American LaFrance single axle rear Suspensions Tandem Axle Lubricate the equalizer cap and tube assembly bush ings by applying multi purpose chassis grease at the grease fitting until the old grease is forced out from the cap and tube assembly See Fig 14 Hendrickson HN Series No lubrication is required on Hendrickson HN Series rear suspensions Condor Maintenance Manual September 2001 Suspension Hendrickson RTE Series For Hendrickson RTE Series lubricate the bronze ball indented bushings in the spring eye as follows 1 Park the vehicle on a level surface apply the park ing brakes and chock the front tires 05 27 93 320020a A Minimum gap of 3 8 9 5 mm 1 Forward no 1 Spring Hanger Fig 14 Equalizer Assembly Lubrication 2 Raise the rear of the vehicle until the rear wheels are suspended in the air then support the vehicle with safety stands This relieves the load on the bushings and pins to allow the proper ow of lubri cant around them 3 Use a multi purpose chassis grease and lubricate the bronze ball indented bu
29. nance checks 31 3 31 Frame and Frame Components 4 3 18 17 t 2 5 15 6 10 T Y 16 8 P 9 15 e 4 gt 14 14 11 12 08 29 95 13 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 Turn on the vehicle ignition while observing the dash mounted indicator lamp The indicator lamp on the dash and at least one LED PAUSE or CONTACT on the control unit should all come on following ignition activation The indicator lamp on the dash will go out after 3 seconds The control unit performs a self diag 31 4 nostic check during this 3 second interval The Initiate a manual override lube cycle by depressing PAUSE or the CONTACT LED on the control unit and releasing the DK button on the control unit will remain lit during the entire ignition on time If The PAUSE LED will go off and the CONTACT LED the system is in PAUSE mode Condor Maintenance Manual March 2003 Frame and Frame Components waiting for the next on the control unit will activate for the preset pump lubrication cycle the PS LED remains lit to show that running time factory preset for 2 6 min utes while monitoring with the pressure swi
30. the HOT RUN band on the dipstick The HOT RUN band is between the HOT FULL and HOT ADD marks If the fluid level is not within the HOT RUN band add or drain fluid as needed to bring the fluid level within the HOT RUN band See Fig 2 Visually inspect the breather valve on the transmission Allison Transmission Electronic Method Before checking the transmission oil level the following conditions must be met The engine must be at idle The transmission must be in neutral The transmission output shaft must be stopped The transmission fluid must be within normal operating temperatures of 140 60 C to 220F 104 C 1 Start the engine allow the transmission fluid to reach operating temperature and place the trans mission in neutral 2 On push button shift selectors press both the up and down arrow buttons once atthe same time and release On lever shift selectors press the DIAG NOSTICS the button with the Allison Logo button once 3 The ECU performs a system check If a problem is found during the system check an oil level sensor diagnostic code will be displayed Oil level sensor diagnostic codes are listed in Table 3 26 3 26 Oil Level Sensor Diagnostic Codes Code Description O L 5 0 Engine speed too low O L 5 9 Engine speed too high O L 6 5 Transmission not in neutral O L 7 0 Sump Temperature too low O L 7 9 Sump Temperature too high O L 8 9 Output shaft rotating O L 9 5 Sensor
31. 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 Condor Maintenance Manual August 2003 Engine Cooling Radiator eng 20 ine operating temperatures This could cause premature engine wear or damage 8 7 6 19 2 5 en NN 18 17 NEN 3 LANG 21 4 5 14 15 RS i A E Ge 12 a3 10 9 24 03 30 95 f200194a Mounting Bracket 9 Rear Hub Bearing 17 Face Seal Rear Sheave Bearing 10 Bearing Spacer 18 Small O Ring Inner and Outer Bearing Spacers 11 Splined Hub 19 Air Chamber Forward Sheave Bearing 12 Forward Hub Bearing 20 Socket Head Capscrew Sheave 13 Piston Friction Disc 21 Stud Bolt Friction Facing 14 Large O Ring 22 Lockwasher Journal Spacer 15 Locknut 23 Hexnut Socket Head Capscrew 16 Cartridge Assembly 24 Piston Assembly DADARON gt Fig 3 Horton Advantage Fan Clutch Components Remove the surge tank cap Using a radiator cap tester check the pressure cap to see if it maintains pressure to within 10 of the pressure rating marked on the cap If it doesn t replace the cap See Fig 4 Make sure that the replacement radiator cap is correctly rated for the cooling system of the vehicle 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 sup ported when the system cools Insp
32. torque values for lubricated or plated thread fasteners Condor Maintenance Manual September 2000 60 60 1 Door 72 Index Alphabetical Title of Maintenance Operation MOP MOP Number Door Seal Door Latch and Door Hinge Lubrication nn ncnnnnn nr nnnnnnnnns 72 01 Condor Maintenance Manual September 2000 Door 72 01 Door Seal Door Latch and Door Hinge Lubrication Lightly coat door seals with a lubricant that is safe for rubber Apply a few drops of light engine oil to the door latch mechanism to reduce noise and wear Wipe off excess oil Lubricate door hinges every six months In addition lubricate replacement door hinges at installation Lubri cate the hinges by spraying them with a light coating of silicone lubricant Condor Maintenance Manual September 2000 72 72 1 Heater and Air Condition 83 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Conditioner Inspection 44444s4400nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnennn nn 83 01 Condor Maintenance Manual June 2001 Heater and Air Condition 83 01 Air Conditioner Inspection 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 park ing brakes and choc
33. tt A 00 04 Chassis Be WEE 00 06 Initial Maintenance Inspection Operation 00 08 List ege ee EE 00 17 Lubrication and Fluid Level Check 00 05 Lubrication and Fluid Level Check Locations 00 07 M1 Maintenance Interval Opoerations natt tna st nnnstnnnnnn unnn nnen nenen nn nnn 00 09 M2 Maintenance Interval Opoerations nan n cnn narrar 00 10 M3 Maintenance Interval Opoerations nan n cnn narrar 00 11 Maintenance Operation Sets Table seessseesseeeseeeeiesinessiesssknssttnntnntttnnttnntttnnttttnttinastnnnstnnnnnnnnn nnn nn unnn nennen 00 12 Metric U S Customary Conversion Tables oomcnnncicnnnccnnnccccnocccnnnonnnnnrcc rra rr 00 15 Noise Emission Controls Maintenance oonnocccncncnnnnccccnonnnnnncnnncnnnnn nan n cnn cnn 00 13 Scheduled Maintenance Intervals 24 42400444400nnnnenennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 00 01 Service Schedule Table E 00 02 Torque Specifications Tables oo ee cesccesseeeseeecseeecscesenceseeeesneeeseecneneseeeeeeeeeaceseaeesseeeseeeeeeesesaeesaeeeseeseanessaeeenes 00 16 Vehicle Maintenance Schedule Table ooonooconiccnnnncccnnccccnnncnnnoncccnononnnnnnc crac 00 03 Verification of Inspections LoJ cooomccccnnnnnoccnnnnonccccnnnnnnnc cnn 00 14 Condor Maintenance Manual March 2004 General Information 00 Scheduled Maintenance Intervals 00 01 Scheduled Maintenance Intervals Performing regular maintenance on your American LaFrance vehicle
34. vehicle driver s manual Meritor s experience shows that the following additives friction modifiers perform adequately Condor Maintenance Manual September 2000 35 A For all synthetic gear oils other than Mobil add 1 6 ounces 35 mL of additive for each pint 0 5 L of lube capacity e Elco No 2 Friction Modifier Elco Corpora tion e Lubrizol No 6178 Lubrizol Corporation e Hi Tec E 336 Edwin Cooper Inc e Equa Torque No 2411 Sta Lube Corpora tion Equa Torque No 2414 Sta Lube Corpora tion B For Mobilube SHC synthetic use Mobil No 204 Mobil Oil Corporation Add 1 1 ounces 23 mL of additive for each pint 0 5 L of lube capacity IMPORTANT These friction modifiers generally deteri orate faster than conventional extreme pressure addi tives so the lubricant change schedule must be shortened when using these additives The traction equalizer additive and recommended drive axle lubri cant 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 recommended in Table 1 1 Parkthe vehicle on level ground apply the parking brakes and chock the tires 2 Remove the axle carrier fill plug see Fig 1 then remove the drain plug from the bottom of the hous ing and completely drain the lubricant while the unit is warm Allow sufficient time for all old lubri
35. wear greater than 0 062 inch 1 5 mm a Chalmers wear plate must be installed or the walking beam must be replaced 4 Rotate the restrictor cans 360 degrees and visually inspect the cans for cracks severe corrosion and distortion If any of these conditions are present or the restrictor can is missing replace the restrictor can 09 27 95 A Non Wear Area 1 Walking Beam 1320432 B Wear Area Fig 7 Walking Beam End Wear Thickness WARNING Replace all cracked or missing restrictor cans Fail ure to do so could lead to loss of vehicle control Condor Maintenance Manual September 2001 32 which could result in personal injury Vehicles with cracked or missing restrictor cans may be driven slowly to the nearest workshop for restrictor can replacement Chalmers Single Axle Suspension 1 Chock the front tires to prevent the vehicle from moving Place the transmission in neutral and release the parking brakes before inspecting the Chalmers rear suspension 2 Power wash the Chalmers rear suspension or clean it with a hard bristle brush before performing a visual inspection 3 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 for free play Use of a pry bar may lead to premature bushing replacement 4 R
36. will help ensure that it delivers safe reliable service and optimum performance for years to come Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time When the vehicle reaches the period given for a main tenance interval see the Maintenance Interval Opera tion Table for a list of the maintenance operations to be performed at that maintenance interval Use the main tenance operation reference numbers to find detailed instructions in the manual on each operation 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 Condor Maintenance Manual March 2004 00 1 00 General Information Service Schedule Table 00 02 Service Schedule Table Maintenance Interval Maintenance Interval Operation Initial Maintenance IM Maintenance 1 M1 6 Maintenance 2 M2 12 Maintenance 3 M3 24 00 2 Condor Maintenance Manual March 2004 General Information Vehicle Maintenance Schedule Vehicle Maintenance Schedule 00 Vehicle Maintenance Schedule Table 00 03 Ne Maintenance Interval Service Date Miles km Hours 1st IM and M1 5 000 2nd M1 and M2 12 3rd M1 18 4th M1 M2 and M3 24 5th M1 25 000 40 225 1250 30 6th M1 and M2 30 000 48 270 1500 36 7th M1 35 000
37. 1 Safety Stop 3 Tilt Cylinder 2 Tilt Cylinder Rod Fig 3 Safety Stop Released IMPORTANT If the cab stops moving while it is being lowered don t force it to move with the tilt pump The velocity fuses have locked up the tilt cylinders To unlock the tilt cylinders see Hydraulic Lockup of Cab Tilt System 6 Make sure the pump control lever is in the RETURN position 7 Remove the pump handle and return it to its stored location 00 6 General Information Condor Maintenance Manual March 2004 General Information 00 Lubrication and Fluid Level Check 00 05 Maintenance Operation 00 05 Lubrication and Fluid Maintenance operation numbers given in the table are Level Check Operation Table 1 summarizes all opera reference numbers used to help you find detailed tions that must be performed to complete the Lubrica instructions in the manual on the lubrication or fluid tion and Fluid Level Check operation 00 05 called for check Lubrication and Fluid Level Check Locations as an M1 maintenance interval 00 07 can be used as a guide by those who do not need to consult the detailed lubrication and fluid check instructions given elsewhere in the manual Maintenance Operation 00 05 Lubrication and Fluid Level Checks at M1 Operation Operation Description Check Number 26 02 Transmission Fluid Level Inspection Po 31 05 Chassis Lubrication System Inspection P 31 06 Chassis Lubrication System Reservoir Checking and R
38. 10 149 9 16 12 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 8 18 155 210 215 292 3 4 10 240 325 340 461 340 461 3 4 16 270 366 380 515 7 89 385 522 540 732 7 8 14 425 576 600 813 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 5 American LaFrance recom mends that a plated and unplated fasteners be coated with oil before installation Table 6 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads 00 22 Condor Maintenance Manual March 2004 General Information 00 Torque Specifications Tables 00 16 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threadst rea Diameter Pitch Class 8 8 Bolt Class 8 Nut Torque Ibf ft N m Class 10 9 Bolt Class 10 Nut Torque Ibf ft N m 230010 S _10 9_4 230012 M6 5 7 7 9 M8 12 16 17 23 M8 x 1 13 18 18 24 M10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12x1 5 43 58 62 84 M14 66 89 95 129 M14x1 5 72 98 103 140 M16 103 140 148 201 M16 x 1 5 110 149 157 213 M18 147 199 20
39. 3 23 87 24 91 25 95 CAPACITY Engine Cooling Radiator Maximum Coolant Protection in F C at Various Antifreeze Concentrations ETHYLENE GLYCOL BASE ANTIFREEZE REQUIRED 7 26 2 17 16 gallons liters 8 9 30 34 6 14 21 26 3 10 19 23 8 1 5 17 21 10 38 23 31 19 28 15 26 20 29 12 45 47 44 40 EN 34 37 29 34 13 49 59 51 52 47 46 43 40 40 14 53 62 32 58 550 52 47 15 57 62 32 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 1 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 20 8 Table 3 Maximum Coolant Protection in F C at Various Antifreeze Concentrations Condor Maintenance Manual August 2003 Transmission Title of Maintenance Operation MOP Allison Transmission Fluid and Filter Changing Transmission Cooler Inspection Transmission Fluid Level In
40. 3 275 M18 x 1 5 165 224 229 310 M20 208 282 288 390 M20 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 2 392 531 542 735 715 729 988 771 788 1068 715 969 792 1074 American LaFrance recommends that all plated and unplated fasteners be coated with oil before installation 990 1342 1096 1486 t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 7 Torque Values for Metric Thread Fasteners With Lubricated or Plated Condor Maintenance Manual March 2004 Threads 00 23 General Information List of Abbreviations 00 17 The following is a list of definitions for abbreviations and symbols used in American LaFrance publications Alsina amperes ABS antilock braking system ABS acrylonitrile butadiene styrene AG air conditioner AG alternating current ACPU air conditioning protection unit ADLO auto disengagement lockout am cc ante meridiem midnight to noon amplitude modulation ampere s air management unit American National Standards Institute American Petroleum Institute Air Conditioning and Refrigera tion Institute ASA American Standards Associa tion ASF American Steel Foundries ASR ives automatic spin regulator assy nenne assembly
41. 5 97 1470147 1 Beige Mounting Head 6 Bowl Probe Plug 2 Fuel Primer Pump 7 Water Sensor Probe 3 Metal Vent Plug 9 16 SAE 4 Bowl O Ring 8 Heater Connector 5 Bowl Bevel Cut 9 Drain Plug Gasket 10 Sight Bowl Fig 1 Alliance or Racor Fuel Water Separator 47 03 Fuel Tank Band Nut Tightening Hold each fuel tank band retention nut with a wrench while backing off its jam nut Then tighten the retention nuts 30 to 35 Ibf ft 41 to 46 N m After the retention nuts have been tightened hold each retention nut with a wrench while tightening its jam nut 30 Ibf ft 41 N m IMPORTANT Do not overtighten 47 1 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspection Noise Emission Control 49 01 Condor Maintenance Manual September 2000 Exhaust 49 01 Exhaust System Inspection Noise Emission Control 1 On all vehicles check the condition of the muffler body the top stack and the heat shield Fig 1 Check the inlet outlet tubes for leakage dents and corrosion and check for holes in the muffler Replace parts as required Use new parts equiva lent to parts originally installed on the vehicle See Group 49 of the Condor Workshop Manual for replacement procedures 2 Inspect the exhaust ex hose Fig 2 for leakage wear or damage Replace with new parts if replacement is needed 3 Check for leakage at the V band coupling which attaches the
42. 6 Spoke With u E E Non Corrugated Channel Spacer an unite 2005229 2 15309 Rear Wheel Nut 5 and 6 Spoke With 3 4 10 Gunite 240 260 325 350 Corrugated Channel Spacer Torque values given are for lubricated threads t On front axles with over 12 000 Ibs 5448 kg capacity tighten the wheel nuts 240 to 265 Ibf1 ft 325 to 359 N1 m Gunite part number W 854 nut with a phosphate and oil coating must be used Condor Maintenance Manual September 2000 Table 1 Wheel Fastener Torques 40 1 40 Wheels and Tires 7 9 o 2 A B m 09 29 97 A 10 Stud Disc Wheel B 6 Spoke Wheel c f400057a C 5 Spoke Wheel Fig 1 Wheel Nut and Rim Nut Tightening Sequence 40 02 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 American LaFrance dealers must have proof of this calibration history 1 Apply the parking brakes and chock the rear tires If the vehicle is equipped with an all wheel drive brake only the drive axle brake should be applied 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 Us
43. A CONDOR CONDOR MAINTENANCE MANUAL ae Published by American LaFrance LLC 1090 Newton Way Summerville SC 29483 Printed in U S A FOREWORD Scheduled maintenance provides a key element for the safe operation of your American LaFrance vehicle A proper maintenance program also helps to minimize downtime and to safeguard warranties This maintenance manual provides information necessary for years of safe reliable and cost efficient vehicle operation Perform the operations in this maintenance manual at scheduled intervals based upon hours of operation Perform daily or weekly inspection and maintenance as outlined in the vehicle operator s manual Your American LaFrance Dealership has the qualified technicians and equipment to perform this maintenance for you Your dealership can also set up a scheduled maintenance program tailored specifically to your needs Optionally your American LaFrance Dealership can assist you in learning how to perform the maintenance procedures in this manual IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing American LaFrance LLC reserves the right to discontinue models at any time or change specifications and design without notice and without incurring obligation For additional information please contact American LaFrance LLC Customer Support 1090 Newton Way Summerville SC 29483 U S A or refer to http www American LaFrance com ENVIRONMENTAL CONCERNS
44. Reassemble the clutch valve solenoid air fil ter assembly and install on the vehicle 20 1 20 4 Visually check the fan for bent cracked or dam aged blades Replace if damaged Check for ade quate clearance between the fan and other components 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing See Fig 2 Replace the friction facing if it is worn to a 1 16 inch 1 6 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evidence of oil or burn marks are found replace the friction facing 7 Connect the battery cables Lower the cab and start the engine and charge the air system to 120psi 827 kPa Shut down the engine Separate the halves of the fan solenoid connector The fan clutch should engage If the fan does not operate correctly see Group 20 of the Condor Workshop Manual for troubleshoot ing and repair procedures 8 With the air system charged to 120 psi 827 kPa and with the fan solenoid connector halves sepa rated check the fan clutch for audible air leaks using a suitable listening device 08 08 94 1200290 1 System Sentry Fuse 4 Piston Friction Disc 2 Safeguard Hole 5 Air Chamber 3 Friction Facing Fig 2 Horton Advantage Fan Clutch 9 Ifaleak is detected remove the fan blade Using a soapy water solution check the fan clutch at the following locations to locate t
45. Safety Stop Fig 2 Safety Stop In Place Condor Maintenance Manual March 2004 00 Cab Tilting 00 04 9 Continue to operate the pump handle until the cab has reached the 42 degree fully open position To Return the Cab Stay completely clear of the travel path of the cab at all times Once the safety stop has been released don t lean over the frame rails the engine or the transmission for any reason To do so could result in serious injury or death 1 Secure all loose items in the cab and make sure the doors are securely latched 2 Make sure the parking brakes are applied and there are no obstructions in the cab travel path 3 Lift the safety stop up until it no longer rests on the tilt cylinder rod See Fig 3 The cab may need to be raised if the safety stop is resting against the tilt cylinder rod 4 Move the pump control lever to the RETURN posi tion The cab will automatically begin to return to the operating position NOTE To slow the descent of the cab reverse the tilt pump lever 5 After the cab is completely lowered check the indi cator pin on each cab mount The cab mounts are locked when the pins have moved back into the piston and cylinder spring assembly If the pins are out the cab mounts are not locked See Fig 1 Raise and lower the pump handle until the cab is completely lowered and the cab mounts are locked 00 5 00 Cab Tilting 00 04 04 15 93 1310358a
46. Steering Ram Lubrication e 47 01 Fuel Filter Replacement e e 47 02 Fuel Water Separator Sight Bowl Cleaning and Element Replacement e 47 03 Fuel Tank Band Nut Tightening 49 01 Exhaust System Inspection Noise Emission Control e 60 01 Cab Tilt Pump Reservoir Fifluid Level and System Check 72 01 Door Seal Door Latch and Door Hinge Lubrication e e 83 01 Air Conditioner Inspection For synthetic lubricant change intervals see 26 01 Condor Maintenance Manual March 2004 00 17 00 General Information Noise Emission Controls Maintenance 00 13 Noise Emission Controls Maintenance Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to furnish with each new vehicle such written instructions for the proper maintenance use and repair of the vehicle by the ultimate purchaser to provide reasonable assur ance of the elimination or minimization of noise emis sion control degradation throughout the life of the vehicle In compliance with the law the noise emission controls maintenance information in each applicable group of this manual in conjunction with the vehicle workshop manual provides these instructions to own ers IMPORTANT Fire and emergency vehicles equipped with beacons and sirens are exempt from compliance with Part 205 Local regulations however may apply Recommendations
47. Tires 40 A B gt 08 29 94 f330082a NOTE B minus A equals toe in NE gt gt gt lt L Fig 2 Wheel Toe In overhead view 08 30 94 f400100a Fig 4 Setting Trammel Bar Pointers ES 08 30 94 f330014a Fig 3 Trammel Bar Positioning Condor Maintenance Manual September 2000 40 3 Driveline Title of Maintenance Operation MOP Driveline Inspection Driveline Lubrication Condor Maintenance Manual September 2000 41 Index Alphabetical MOP Number Driveline 41 01 Driveline Inspection 1 Park the vehicle on a at level surface apply the parking brakes and chock the tires Ah CAUTION Due to the extreme load occurring at high speed rotation a loose or broken capscrew at any point in the driveline will weaken the driveline connection which could eventually result in serious vehicle damage Do not over tighten bearing cap cap screws or yoke strap capscrews 2 For driveline universal joints with bearing caps tighten bearing cap capscrews 43 Ibf ft 49 N m See Fig 1 Ref 1 For RPL series universal joints tighten bearing cap capscrews 125 Ibf ft 169 N m See Fig 2 For driveline universal joints with yoke straps tighten yoke strap capscrews 125 Ibf ft 169 N m See Fig 3 3 Check the driveline yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes JA WER TO IN 04 13 98 f410155a 1 Self Locking Cap 2 Ad
48. ab access the heater air conditioner housing 4 Remove the two mounting screws that secure the HVAC air filter grille plate to the HVAC housing 5 Slide the filter out of the housing See Fig 3 6 Clean the air filter 6 1 Wash the filter with soapy water and rinse with clear water 6 2 Allow the filter to air dry Then using a spray bottle apply a light coating of filter wetting agent Elixaire P N 6201 to the inlet side of the filter NOTE Applying the wetting agent to the filters will enhance filter performance NOTE If the air filter has already reached a maximum three cleanings or if there is any visible damage to the air filter a replacement should be installed 83 2 Heater and Air Condition 02 02 2001 1831427 1 Grille Plate 2 Air Filter Fig 3 Air Filter Removal 7 Install the air filter 7 1 Slide the air filter into the HVAC housing 7 2 Install the grille plate on the HVAC housing with the two mounting screws Tighten securely 8 Install the cab front grille See Group 88 of the Condor Workshop Manual for instructions 9 Remove the chocks from the tires Condor Maintenance Manual June 2001
49. all the lubrication points are under or over lubricated adjust the control unit timer If an individual lubrication point is over or under lubricated trace the line back to the distribution block Replace the metering cap with a larger one if under lubricated or a smaller one if over 31 5 31 lubricated See the manufacturer s service literature for instructions 31 06 Vogel Chassis Lubrication System Reservoir Checking and Refilling Gain access to the chassis lubrication system reservoir and observe the lubricant level in the reservoir The reservoir is marked with a minimum fill line If the grease level drops below the minimum level air will be pumped through the main line distribution network If this occurs a fault LED will be displayed on the dash for the duration of the ignition ON time and the system will have to be bled See the manufacturer s service litera ture for instructions IMPORTANT Use only fluid grease of NLGI grades00 or 000 See Table 2 for lubricants that have been approved for use to maintain the system warranty of the Vogel lubrication system 1 Refill the reservoir See Fig 3 1 1 Remove the cap on the unit by pressing both hands at the side of the cap and lift it off 1 2 Connect the quick disconnect adaptor to the filling hose of the hand crank pump and con nect it to the refilling connector 1 3 Refill the reservoir Frame and Frame Components NOTE There is not a maximum fill l
50. cant to drain On dual drive axles it is also necessary to remove the plug at the bottom of the interaxle dif ferential housing to drain the lubricant 3 If so equipped replace the axle oil filter Remove the oil filter using a suitable filter strap wrench See Fig 5 Discard the filter NOTE There may be about one pint 0 5 L of lubricant remaining in the filter Be careful not to spill it when removing the filter 4 Using the specified drive axle lubricant coat the face of the gasket on a new oil filter Install the filter over the adapter and tighten the filter one full turn after the gasket contacts the base do not over tighten the filter 35 3 35 Rear Axle JS 05 27 93 f350119a Fig 5 Axle Oil Filter Removal 5 Fora new or reconditioned axle flush the axle with clean flushing oil then drain it thoroughly It is nec essary to flush the axle the first time only that the axle lubricant is changed IMPORTANT Axles should not be flushed with any sol vent such as kerosene 6 Clean the fill and drain plugs For magnetic plugs a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field NOTE Meritor recommends plugs with elements hav ing a minimum pickup capacity of 1 1 2 pounds 0 7 kg of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap be
51. cle operation and shutdown the screw tip may adjust according to tem perature and pressure changes The torque may need to be adjusted for individual applications 12 Place a pan under the coolant filter if equipped to catch engine coolant 13 Remove the coolant filter with a strap or chain wrench Install a new coolant filter and tighten 14 Fill the cooling system with new coolant See Table 1 for the vehicle s coolant capacity Certain equipment such as fuel heaters water filters and 20 5 20 Engine Cooling Radiator auxiliary heaters may increase the coolant capacity 15 Replace the surge tank cap and require additional coolant The cooling system 16 Lower the cab start the engine and turn on the is filled when the coolant level reaches the MAX cab heater Allow the engine to warm up to normal line on the surge tank American LaFrance recom operating temperature Check the radiator and mends the use of a precharged and premixed anti hoses for leaks Repair if necessary freeze when refilling the cooling system See Table 2 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 NOTE Mixing the factory installed purple pink coolant pre charged with a borate nitrate based additive with the common green coolant will cause a color change check that the antifreeze used meets American 17 Shut off the engine then check the
52. coolant level in LaFrance s specifications and is at the proper con the surge tank Add coolant if the level is not area See Table 3 for antifreeze protection infor mation American LaFrance species that the anti freeze must be an ethylene glycol solution that Engine Coolant Capacity meets GM 6038 M Engineering Standards or aeth Capacity with 1100 sq ylene glycol solution that has less than 0 1 anhy Engine inch Radiator quarts drous sodium metasilicate and meets either GM liters 1825 M or GM 1899 M Engineering Standards If Caterpillar CFE 34 4 32 6 supplemental coolant additives are being used Caterpillar C 10 31 5 29 8 add the supplements to the coolant as necessary See the coolant additive manufacturer s instruc Caterpillar C 12 31 5 29 8 tions for the correct amount of additive required Cummins ISC 31 2 29 5 Don t forget to consider the volume of the supple Cummins ISL 31 2 29 5 mental coolant additive being added to the system Cummins ISM 30 5 28 8 when determining the amount of coolant required to refill the system Table 1 Engine Coolant Capacity Approved Antifreeze Manufacturer Antifreeze Type Caterpillar Diesel Engine Contains supplemental additives and Antifreeze Coolant available as a premixed solution Fleetguard Compleat Premixed solution with supplement Cummins D Premix additives Old World Industries Fleet Charge With supplemental additives Table 2
53. counts down 6 pause time tothe next ER Duration of preset pause time PAUSE PS cycle or until manual override occurs A fault has occurred and the system d 7 could not build up pressure during GE press thie DIS Button FAULT Cab Lamp i e occurs and the fault is remedied contact pump running time Table 1 LED Light Sequence 31 05 Vogel Chassis Lubrication System Inspection Inspect the vehicle before it is washed or pressure cleaned as areas of under or over lubrication are best observed at this time Ah CAUTION Vogel lubrication lines cannot be attached to the grease fittings of disc brake calipers The Vogel lubrication system is not compatible with grease used in the disc brake calipers Attaching Vogel lube lines to the grease fittings of disc brake cali pers could cause premature wear and or damage to the disc brakes Condor Maintenance Manual March 2003 If a garage with a pit is available drive the vehicle over the pit as visual inspection is easier from beneath the vehicle Verify that all originally attached lubrication lines are still connected If necessary reattach or replace damaged line s Pay particular attention to those points closest to the road surface See the manu facturer s service literature for instructions Inspect the points being lubricated A seal of lubricant around the outside of the bushings should be visible This assures that the point is being flushed of contami nants If
54. ct the pin hole in the outboard leg of the num ber one spring hangar draw key design for wear or elongation Wear at this point requires hangar replacement or premature fracture of the spring hangar pin may occur with possible separation of components and loss of vehicle control This could result in serious personal injury 4 Visually inspect the cam surface of the number two spring hangar for wear due to operating mileage Also inspect the outside legs for wear which can be caused by worn spring eye bushings NOTE RTE extended leaf spring suspensions require a minimum gap of 3 8 inch 9 5 mm between the cam surface of the number two spring hangar and the top of the main leaf in the unloaded condition See Fig 11 If this gap is less than 3 8 inch 9 5 mm the extended leaf portion of the spring will not perform sat isfactorily for an empty ride 5 Inspect the cam surface on the number three spring hangar extended leaf springs only for wear Excessive wear will reduce the gap available at the number two spring hangar See the previous note 6 Place a block of wood on the leaf spring See Fig 12 Place a pry bar on the block of wood and insert the end of the pry bar under the frame han gar Attempt to lift the frame hangar as shown in Fig 12 Also with an empty chassis and the brakes applied attempt to rock the chassis back and forth while observing the spring eye In either case if 1 8 inch or more of movement
55. e 1 Intake Air Restriction Indicator Values Condor Maintenance Manual January 2004 09 09 1 Alternators and Starters 1 5 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Checking nn nnnnnnn nn n nn nana n nr nnrnnn nn annn Ennen 15 01 Condor Maintenance Manual September 2000 Alternators and Starters 15 01 Alternator Battery and Starter Checking Batteries release a gas mixture that is explosive Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat Make sure the battery compartment has been completely vented before disconnecting or connecting battery cables Battery acid is extremely harmful if splashed in eyes or on skin Always wear a face shield and pro tective 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 Condor Workshop Manual 2 Check that all electrical connections at the alterna tor and starter are clean Clean and tighten all charging system electrical connections as needed 3 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals with a wire brush See Group 54 of the Condor Work shop Manual for troubleshooting instructions and for adjustment repair or replacement instructions 3 1 Clean and tighten the battery
56. e 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal 12 02 97 1461266 1 Sector Shaft Grease Fitting Fig 3 TRW TAS Series Sector Shaft Lubrication 46 2 Steering 46 04 Drag Link Inspection All steering system components are critical for safe operation of the vehicle Failure to maintain the steering system as specified may result in loss of steering control which could lead to personal injury and property damage Have someone turn the steering wheel from left to right Check for movement between the ball stud end at both the pitman arm and the steering arm Also check if the ball stud nut is loose If the ball stud end is loose replace the drag link If the ball stud nut is loose replace the nut and cotter key See Group 00 for proper torque specifications Visually inspect the boot of the drag link at both the pit man arm and the steering arm end for cracks splits or other damage Replace the boot as needed See Group 46 of the Condor Workshop Manual for drag link removal and installation instructions Grasp the drag link near the pitman arm end then push and pull laterally to check for axial movement in the ball stud end If it is loose replace the drag link See Group 46 of the Condor Workshop Manual for replacement instructions If there is 1 8 inch 8 mm movement or more do not drive the vehicle until the drag link is replaced 46 05 Power Steeri
57. e cooler that is worn dented cracked or otherwise damaged Condor Maintenance Manual March 2001 Frame and Frame Components 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fifth Wheel ASPE ici 31 02 Fifth Wheel Bee EE 31 03 Frame Fastener Torque Checkimg nan ncnnrnnn anna 31 01 Vogel Chassis Lubrication System Check 31 04 Vogel Chassis Lubrication System Inspechon cnn nn c cnn rca 31 05 Vogel Chassis Lubrication System Reservoir Checking and PHetllmg nennen 31 06 Condor Maintenance Manual March 2003 Frame and Frame Components 31 01 Frame Fastener Torque Checking Frame brackets and components secured with Huck bolt fasteners do not require a torque check however they should be inspected for damage Frame brackets and components secured with threaded bolts and nuts are to be checked at the Initial Maintenance Inspection 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 pos sible This will give a true torque reading by eliminating bolt body friction When checking the torque of frame fasteners inspect the frame for cracks and other dam age Seta click type torque wrench to the maximum torque of the fastener you are checking Apply pres sure until the torque wrench clicks Do not loosen the bolt to check the torque See the applicable torque table in Group 00 for torque specifications
58. e there are no people or objects in the path the cab will be traveling Move the pump control lever to the TILT position 5 Remove the pump handle from behind the primary driver s seat and attach it to the pump 6 Raise and lower the pump handle several times to unlock the cab mounts IMPORTANT Check the indicator pin on each cab mount The cab mounts are unlocked if the pins are out See Fig 1 NOTE If air is present in the hydraulic tilt system the pump operation may seem spongy or ineffective If this happens bleed the air from the system For instruc tions refer to Group 60 of the Condor Workshop Man ual 7 Continue to operate the pump handle until the cab is tilted open about 30 degrees IMPORTANT If the cab stops moving while it is being raised don t force it to move with the tilt pump The velocity fuses have locked up the tilt cylinders To Condor Maintenance Manual March 2004 General Information unlock the tilt cylinders see Hydraulic Lockup of Cab Tilt System 10 19 94 1310441 Fig 1 Cab Mount Indicator Pin 8 Put the safety stop on the right tilt cylinder in place See Fig 2 The safety stop prevents the cab from dropping below a specific angle Make sure the safety stop on the right tilt cylinder is in place If the safety stop isn t in place and the cab should drop the result could be serious injury or death 04 15 93 1 Tilt Cylinder Rod 2 1310357a
59. ecifications and Fig 1 for the wheel nut tightening sequence Ah 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 rec ommended torque values and follow the tighten ing sequence shown in Fig 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 tightening sequence shown in Fig 1 Wheel Fastener Torques he e Torque dry threads Description Nut Size Wheel Manufacturer Ibf ft N1 m 10 Stud Disc Wheel With Two Piece Flanged Locknuts Front and Rear Wheel Nut Alcoa 450 500 610 680 10 Stud Disc Wheel With Ball Seat Nuts Front and Rear Wheel Nut M22 x 1 5 Budd Uni Mount 10 390 440 530 600 10 Stud Disc Wheel With Inner and Outer Locknuts 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 Front Wheel Nut 6 Spoke 3 4 10 Gunite 200 225 271 305 t Rear Wheel Nut 5 and
60. ect the vac uum relief valve to be sure it is not stuck Condor Maintenance Manual August 2003 4 Make sure that the cap seals properly on the cool ant 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 gas ket shows deterioration or damage 20 03 Radiator Pressure Flushing and Coolant Changing NOTE For additional instructions on cleaning and flushing the engine s cooling system see the applica 20 3 20 ble engine manufacturer s maintenance and operation manual 1 Park the vehicle apply the parking brakes chock the tires and tilt the cab Place a suitable container under the elbow of the heat exchanger for the automatic transmission The container should hold at least 60 quarts 56 8 liters of fluid N 08 15 2000 1200642 1 Low Coolant Level Sensor 2 Surge Tank 3 Surge Tank Cap Fig 4 Surge Tank External Coolant Level Sensor Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause serious personal injury 3 Remove the surge tank cap Do not attempt to drain the cooling system until the coolant and engine are cool D
61. efilling Po 35 01 Drive Axle Lubricant Level and Breather Check Po 46 01 Power Steering Reservoir Fluid Level Check Po 60 01 Cab Tilt Pump Reservoir Fluid Level and System Check A 72 01 Door Seal Door Latch and Door Hinge Lubrication P Table 1 Maintenance Operation 00 05 Lubrication and Fluid Level Checks at M1 Condor Maintenance Manual March 2004 00 7 00 Chassis Lubrication 00 06 Maintenance Operation 00 06 Chassis Lubrication Table 2 summarizes all operations that must be per formed to complete the Chassis Lubrication operation 00 06 called for as an M2 maintenance interval Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in this manual on chassis lubrication General Information Lubrication and Fluid Level Check Locations 00 07 can be used as a guide by those who do not need to consult the detailed lubrication and fluid check instructions given elsewhere in the manual See Fig 4 and Fig 5 for lubrication and fluid level check locations Maintenance Operation 00 06 Chassis Lubrication at M2 Maint Operation Operation Description Check Number 32 01 Suspension Inspection 32 02 Suspension Lubrication 33 01 Knuckle Pin Lubrication 33 03 Tie Rod Lubrication 41 01 Driveline Inspection 41 02 Driveline Lubrication 42 05 Camshaft Bracket Lubrication 42 06 Automatic Slack Adjuster Inspection and Lubrication
62. ent Conditions V Belts Belt Tension Inspection Spring Tension Type On belts equipped with a spring tensioner the belt ten sion is automatically adjusted Check that the tensioner is holding tension on the belt by inserting the end of a breaker bar in the 1 2 inch square hole on the forward face of the tensioner and rotating the tensioner down away from the belt When the breaker bar is slowly released the tensioner should return to its original position If not see Group 01 of the Condor Workshop Manual for replacement instructions 01 2 Condor Maintenance Manual September 2000 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting and Replacing ooooconncncnnncccnnnnnnnnncccnnncnnnnanc cnc rn 09 01 Condor Maintenance Manual January 2004 Air Intake 09 01 Air Cleaner Element Inspecting and Replacing Inspect the air cleaner element for holes or tears at the recommended interval If the air cleaner element is damaged replace it See Group 09 of the Condor Workshop Manual for removal and installation instruc tions Replace the air cleaner element when filter restriction reaches the maximum allowable restriction See Table 1 for specific restriction values for your engine See Group 09 of the Condor Workshop Manual for removal and installation procedures Intake Air Restriction Indicator Values E Service maximum allowable restriction Tabl
63. er element Alliance or Racor Diesel fuel is flammable and can ignite if exposed to 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 re possibly resulting in personal injury or property damage When working on a fuel system have a re extin guisher within arm s reach 1 Drain off some fuel by loosening the vent plug and opening the drain valve 2 Disconnect the water sensor and heater connec tions if equipped 3 Remove the element and bowl together by turning counterclockwise 4 Remove the bowl from the element and clean the O ring 5 Apply acoating of clean fuel or motor oil to the new O ring and element seal 6 Spin the bowl onto the new element then spin them both onto the filter head snugly by hand only IMPORTANT Do not use tools to tighten 7 Connect the water sensor and heater connectors if equipped 8 Prime the fuel separator Condor Maintenance Manual September 2000 47 8 1 Loosen the vent plug Then operate the primer pump until the fuel purges at the vent plug See Fig 1 8 2 Close the vent plug 8 3 Start the engine and check for fuel leaks 8 4 Correct any fuel leaks with the engine shut down 9 Start the engine and check for fuel leaks 10 Shut down the engine and correct any fuel leaks 2 4 3 4 11 Oo d 5 10 9 ene 6 8 06 2
64. eriorated or oil soaked Check slip joints for spline wear by moving the sleeve yoke and splined shaft back and forth See Fig 4 If the slip joint can be twisted in a clockwise or counterclockwise movement greater than 0 007 41 1 41 2 3 4 6 Transmission Output Shaft End 7 8 Yoke yoke strap type Yoke Strap and Capscrew 15 Axle Input Shaft End Yoke U Joint Assembly 9 Slip Joint Assembly yoke strap type Bearing Cap Self Locking 10 Sleeve Yoke bearing cap type 16 Rear Axle Capscrew 11 Dust Cap Bearing Cap 12 Splined Stub Shaft Bearing Cup for yoke strap Driveline inch 0 18 mm replace both the sleeve yoke and the splined shaft 1415 l 13 d E 16 A 3 7 j 7 12 4 11 1 S 10 6 Y 5 4 3 05 01 95 1410067b NOTE Not all fasteners are shown 1 Transmission U Joint Cross 13 Driveshaft Tube 14 Tube Yoke bearing cap type Fig 3 Components of a Basic Driveline Visually examine the driveshaft tubes for dents bends twists or other damage If any tube appears to be damaged see Group 41 of the Con oa dor Workshop Manual for repair and replacement instructions Examine the driveshaft for evidence of missing bal ance weights and for build up of foreign material Remove any foreign material If there is any evi 41 2 dence that balance weights are missing remove the driveshaft and have it balanced For driveshafts with slip joints check to be sure the
65. et until it appears at the slack adjuster end of the bracket See Fig 5 Use an NLGI Grade 1 or Grade 2 multipurpose chassis grease If grease leaks out under the cam head the camshaft bracket grease seal is worn or damaged See Group 32 of the Condor Workshop Manual for grease seal replacement instructions 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 Condor Maintenance Manual September 2000 Brakes 03 06 97 1421549 A Grease Exit 1 Brake Chamber 3 2 Slack Adjuster Non Pressure Relief Grease Fitting Fig 5 Camshaft Bracket Lubrication 42 06 Automatic Slack Adjuster Inspection and Lubrication Automatic slack adjusters must be lubricated periodi cally to ensure proper brake operation Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in per sonal injury or property damage Gunite Lubricate a Gunite automatic slack adjuster at the grease fitting until grease flows from the grease relief opening For operating temperatures of 20 F 29 C and higher use Texaco Multifak EP 2 or Mobil Grease No 77 For operating temperatures between 20 F 29 C and 40 F 40 C use Lubriplate Aero grease Haldex Eaton Lubricate a Haldex Eaton automatic slack adjuster at the grease fitting w
66. etween the equalizer and frame rail Apply hand pressure only See Fig 4 If clearance between the equalizer assembly and any frame component or fastener is less than 1 8 inch 3 mm replace the equalizer bushings See Group 32 of the Condor Workshop Manual for instructions Condor Maintenance Manual September 2001 Suspension 4 05 27 93 5 1320023a 1 8 3 mm Clearance Frame Fasteners 4 Frame Rail 5 Pry Bar Equalizer Equalizer Bracket o gt Fig 4 Side View of the Equalizer American LaFrance AirLiner Suspension Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring assembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Replacement of only visibly damaged parts is no assurance that the spring is safe Failure to replace a damaged spring assembly could cause an acci dent resulting in serious personal injury or prop erty damage Inspect the forward and rear spring brackets for wear cracks and other damage If any of these conditions exist replace the damaged bracket s See Group 32 of the Condor Workshop Manual for instructions Replace worn cracked or damaged spring brack ets Failure to do so could result in bracket break age possibly leading to loss of vehicle control and resulting in personal injury or property damage Inspect the crossmember s and gussets for wear cracks and other damage If an
67. evel reading and repeat the check procedure to verify the reading If the fluid level is within the COLD RUN band the transmission may be operated until the fluid is hot enough to perform a hot check If the fluid level is not within the COLD RUN band add or drain fluid as needed to adjust the fluid level to the middle of the COLD RUN band See Fig 2 Ah CAUTION As the fluid temperature increases so does the fluid level Do not Il above the COLD RUN band if the transmission fluid is below normal operating temperature NOTE Perform a hot check at the first opportunity after the normal operating temperature 160 to 200 F 71 to 93 C has been reached Hot Check 1 Park the vehicle on a at level surface Apply the parking brake and chock the tires 2 Shift the transmission to NEUTRAL La 12 01 97 A Cold Run Band f270002a B Hot Run Band Fig 2 Dipstick Markings 3 Operate the engine at idle 500 to 800 rpm until normal operating temperature is reached Check that the sump temperature is 160 to 200F 71 to Condor Maintenance Manual March 2001 26 93C 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 dip stick 6 Check the fluid level reading and repeat the check procedure to verify the reading Safe operating level is within
68. failure Table 3 Oil Level Sensor Diagnostic Codes 4 Ifthe system check revels any problems as indi cated by an oil level sensor diagnostic code cor rect the problem The system check will automatically perform a recheck 5 After a 2 minute waiting period has passed to allow fluid to drain the digital display will ash a oil level indicator code one digit letter at a time Oil level indicator codes are listed in Table 4 Oil Level Indicator Codes Code Description O L O K Fluid level is within proper limits L O 0 1 Fluid level is 1 quart low L O 0 2 Fluid level is 2 quarts low H I 0 1 Fluid level is 1 quart high H I 0 2 Fluid level is 2 quarts high Table 4 Oil Level Indicator Codes Ah CAUTION On lever shift selectors be prepared for the vehicle to shift into gear 6 On push button shift selectors press the neutral button to exit the oil level mode On lever shift selectors shift the selector to either drive or reverse to exit the oil level mode 7 Check for historical or active fault codes If the codes are displayed contact an authorized trans mission service center for repairs 26 4 Transmission 26 03 Transmission Cooler Inspection Visually check the transmission cooler or heat exchanger which is mounted below the radiator at the front ofthe vehicle Check for loose fittings cracks and loose fasteners Tighten loose fasteners and fittings as needed Replace any part of th
69. fth wheel head or compo nents 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 two grease fittings for the bracket bearing area tilt the top plate for ward and backward to evenly distribute the grease Separate the jaw and wedge with a pry tool and lubri cate 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 fifth wheel s moving parts are lubricated apply a liberal coating of grease to the top plate and the trailer kingpin plate Holland Lubricate all moving parts with a multipurpose chassis grease Lubricate the two grease fittings located on either side of the top plate with a multipurpose chassis grease Once the fifth wheel s moving parts are lubricated apply a heavy coat of grease to the top plate by direct application On slide mount applications lubricate the baseplate rails and the plungers for smooth operation 31 04 Vogel Chassis Lubrication System Check The following system check will verify that the electrical system of the Vogel system is functioning correctly This check should be performed during routine mainte
70. gasket continue pump ing until new grease is seen at the bushing seal oppo site the grease fitting See Fig 1 33 02 Tie Rod Inspection Inspect the tie rod ends as follows 1 Shake the cross tube A loose t 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 2 Replace the components if this cannot be done For instruc tions see Group 33 of the Condor Workshop Manual 09 06 96 1 f320032a A Grease Exit 1 Grease Fitting Fig 1 Meritor Knuckle Pin Lubrication Condor Maintenance Manual June 2001 33 33 03 Tie Rod Lubrication Before lubricating the tie rod ends wipe the grease fit tings clean Then pump multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease into the tie rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck 33 04 All Axle Alignment Checking Drive Axle Alignment Checking Check the axle alignment parallelism and thrust angle measurements for the rear drive axles Use the appli cable procedure and specifications in Group 35 of the Condor Workshop Manual Toe In Checking Front Axle See Gro
71. grease increases the rubber diameter to 1 4 inch 6 4 mm beyond it s normal position Replace the bolster spring if separation of the rub ber from the bonded metal surface to a depth greater than 1 1 2 inches 3 8 cm is found See Fig 10 NOTE Creases formed by folding of the rubber surface under load should be ignored These appear as strips on the surface polished by wear or covered with tacky rubber It is also recommended that all tightening torques on the Hendrickson HN Series suspension be checked once a year See Table 2 for torque specifications Condor Maintenance Manual September 2001 Suspension A y A Y 4 2 10 18 2000 320877 A 3 1 2 9 cm Minimum Height Unloaded 1 Auxiliary Spring 2 Rebound Strap Fig 9 Auxiliary Spring Assembly 4 5 A A Y 10 18 2000 1320876 A Acceptable 1 1 2 3 8 cm Separation of Rubber 1 Bolster Spring 2 Damaged Area of Rubber Fig 10 Bolster Spring Hendrickson RTE Series 1 Park the vehicle on a level surface apply the park ing brakes and chock the front tires Raise the rear of the vehicle until the rear wheels are suspended in the air then support the vehicle with safety stands Condor Maintenance Manual September 2001 32 2 Check the torque of the number one spring hangar double lock bolt design lock bolt nuts If a loose connection has caused pin hole wear replace the hangar See Table 3 for torque specifications 3 Inspe
72. ground cable terminal and clamps 3 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any corro sion 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 3 3 Check that foreign objects such as stones bolts and nuts are removed from the battery box 3 4 After cleaning connect the cables to the bat teries and tighten them to the torque specifi cations listed on the battery generally 10 to 15 Ibf ft 14 to 20 N m Condor Maintenance Manual September 2000 15 3 5 Spray each connection with dielectric red enamel and coat the battery terminals with dielectric grease see Table 1 Protectant Material Approved Brand Dielectric Grease Lubriplate FLP DG ES Dielectric Red Enamel 3M 1602 IVI Spray Sealer Spray Spray On B 6 665 Table 1 Approved Dielectric Protectants 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 clean ing see Table 1 15 1 Engine Cooling Radiator Title of Maintenance Operation MOP Fan Drive and Clutch Inspecting noise emission control Pres
73. h Bendix air valves and a Ben dix air dryer if the air dryer desiccant is replaced as scheduled every 18 months If the desiccant is not changed maintenance will have to be performed to the air brake valves See Group 42 of the Condor Work shop Manual for procedures 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 1 Park the vehicle on a level surface Apply the park ing brakes and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa Drain all air from air reservoirs and air lines Dis connecting an air line that contains compressed air may result in the line whipping as air escapes which could result in personal injury or property damage 3 Identify tag and disconnect the three air lines from the dryer end cover 4 Disconnect the harness connector from the heater and thermostat assembly 5 Loosen the capscrew securing the upper mounting bracket strap 6 Remove the two capscrews securing the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the capscrews to ease installation 7 Remove the upper mounting bracket strap cap screw and remove the air dryer from the vehicle 8 Place the air dryer on a bench and remove the remaining six capscrews 12 washers six Nylok nuts and the air dryer housing See Fig 1 Discard the Nylok nuts Remove the end cover to housing O ring 9 Clamp the desiccan
74. h workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation specifications and troubleshooting Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication pro cedures and tables fluid replacement procedures fluid capacities specifications procedures for adjustments and for checking the tightness of fasteners Mainte nance manuals do not contain detailed repair or service information Driver s operator s manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components Each manual contains a chapter that covers scheduled inspection and mainte nance of vehicle components Driver s operator s manuals do not contain detailed repair or service information American LaFrance LLC publishes this manual to aid in the identification of ser viceable replacement vehicle parts This manual is used in conjunction with the parts book and the service parts catalog microfiche Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to information in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that t
75. he source of the leak 20 2 Engine Cooling Radiator Install a new seal kit See Group 20 of the Condor Workshop Manual for repair procedures 9 1 Check for a leak at the bleed hole on the fan pilot Air leakage means that the cartridge assembly Fig 3 Ref 16 or face seal Ref 17 is damaged 9 2 Check for air leaks between the air chamber and the piston friction disc Air leakage means that the large O ring Ref 14 is dam aged 9 3 Check for air leaks around the safeguard hole on the piston friction disc Air leakage means the small O ring Ref 18 is dam aged 9 4 Check for air leaking from the System Sen try 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 bear ings Before replacing the fuse nd and repair the source of the heat 20 02 Pressure Relief Cap Checking Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause serious personal injury CAUTION The radiator cap currently installed may not be the same one installed when the vehicle was built If the radiator cap must be replaced make sure that it is the correct cap for the cooling system of the vehicle Because
76. hesive Band screw Fig 1 Meritor U Joint Fasteners for Bearing Caps Condor Maintenance Man ual September 2000 41 12 09 97 1410182 Fig 2 Meritor RPL Series U Joint If any end yoke can be moved in or out on its shaft or can be rocked on its shaft disconnect the drive shaft and U joint from the yoke then check the drive component s shaft seal for leakage or other visible damage that may have been caused by the loose yoke Replace the seal if needed then tighten the yoke nut See Group 41 of the Condor Workshop Manual for torque specifications If the yoke is still loose after tightening the yoke nut replace the end yoke and yoke nut Replace the prevailing torque locknut end yoke nut if it was removed for yoke replacement seal replacement or any other reason Check U joint assemblies for wear by moving the driveshaft up and down and from side to side If any movement of the U joint cross in the bearings can be felt or seen replace the U joint assembly Check if the midship bearing and mounting are loose or have deteriorated by attempting to move the driveshaft up and down and from side to side If the bearing is loose on its shaft or rattles replace it If the bearing mount is loose on the frame tighten the mounting fasteners to the proper torque value See Group 41 of the Condor Work shop Manual for torque specifications Replace the midship bearing assembly if the rubber cushion is det
77. ime 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 These bulletins pertain to special situations that involve service work or replace ment of parts in connection with a recall notice Recall bulletins pertain to matters of vehicle safety All bulletins are distributed to dealers customers receive notices that apply to their vehicles This publication is concerned with non safety related service work or replacement of parts All field service modifications are distributed to dealers customers receive notices that apply to their vehicles Introduction Group No Group Title DO as General Information AE BEE Engine E DEE Air Intake E EE Alternators and Starters DON Engine Cooling Radiator G eebe Transmission CN E Frame and Frame Components laa Suspension E E Front Axle EE Rear Axle O o Wheels and Tires HE Driveline EE Brakes Actas Steering NAAA EE id Fuel SE dE EE EE EN Exhaust Oi AAA A a Cab Re rta leida Door Ot Heater and Air Conditioner 1 2 Maintenance Manual Contents Condor Maintenance Manual May 2003 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Cab Tilda dai
78. ine on the reservoir However you can see the fluid in the reservoir as it is being filled Add fluid until it appears to be at the top of the reservoir 2 Manually test the lubrication system using instruc tions found in the manufacturer s service literature 02 12 2003 1310936 A Minimum Fill Line 1 Refill Connector 2 Cap Fig 3 Vogel Chassis Lubrication Pump Assembly Fluid Grease of NLGI Grades 00 and 000 Grade Type Supplier Alvania EP ROO Shell Chevron Dura Lith 00 Chevron EP Conolith 00 Conoco ALI Drydene Lithium EP 00 Dryden Mobilith SHC 007 Mobil Unocal MM Grease Lithium 00 76 Unocal EP Conolith 000 Conoco Lidok 000 Exxon Mobilux EP 023 Mobil NLGI 000 Novatex Grease EP 000 Texaco Drydene Lithium EP 000 Dryden Unocal MM Grease Lithium 000 76 Unocal Biodegradable SL WR AAT 00 Sentinel Grease SL WR AA1 000 Sentinel Table 2 Fluid Grease of NLGI Grades 00 and 000 31 6 Condor Maintenance Manual March 2003 Suspension Title of Maintenance Operation MOP SUSPENSION INSPECTION oocoonncccnncccnnocancnncccnnnannnnnoccnonrnnnnnn cnc Suspension Lubrication Suspension U Bolt Torque Check Condor Maintenance Manual September 2001 32 Index Alphabetical MOP Number Suspension 32 01 Suspension Inspection Front Suspension Check Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring assembly Visible damage cracks o
79. ing cap capscrews 43 Ibf ft 49 N m If the capscrews were already tight or all of the U joint seals still do not purge remove the bearing cap at that seal and examine the seal for Condor Maintenance Man ual September 2000 41 damage If the seal is damaged replace the com plete U joint If grease does not appear at one seal use a prying tool to pry the U joint trunnion away from the non purging seal or tap the driveshaft or yoke with a plastic or rawhide mallet on the side opposite the dry seal while continuing to lubricate If grease still does not appear loosen the capscrews at the bear ing with the dry seal to relieve seal tension Lubri cate the U joint until new grease is seen at the seal then tighten the capscrews to the correct torque specifications If the bearing will not take grease replace the U joint See Group 41 of the Condor Workshop Manual for replacement instructions Check the purged grease If it appears rusty gritty or burned replace the U joint Wipe the purged grease from the seals and any excess grease from the grease fitting Slip Joint Spline Lubrication NOTE Vehicles equipped with Meritor RPL Series driv elines do not require periodic lubrication 1 If equipped with a grease fitting wipe all old grease and dirt from the slip joint grease fitting See Fig 5 Ref 1 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate the slip joi
80. ing spray paint or a piece of chalk mark the entire center rib of each front tire 4 Place a scribe or pointed instrument against the marked center rib of each tire and turn the tires The scribe must be held firmly in place so that a single straight line is scribed all the way around each front tire 5 Place a turn plate or turntable under both front tires Remove the safety stands from under the axle then lower the vehicle Remove the lock pins from the gauges make sure the tires are exactly straight ahead NOTE If turn plates or turntables are not available lower the vehicle Remove the chocks from the rear 40 2 tires and release the parking brakes Move the vehicle backward and then forward about six feet two meters 6 Place a trammel bar at the rear of the front tires locate the trammel pointers at spindle height and adjust the pointers to line up with the scribe lines on the center ribs of the front tires See Fig 2 Lock in place Check that the scale is set on zero 7 Place the trammel bar at the front of the tires see Fig 3 and adjust the scale end so that the point ers line up with the scribe lines See Fig 4 eo Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Condor Workshop Manual If corrections are needed see Group 33 of the Condor Workshop Manual for instructions on adjusting the toe in Condor Maintenance Manual September 2000 Wheels and
81. inum cab Conventional FM frequency modulation FMCSA Federal Motor Carrier Safety Administration failure mode identifier Friction Materials Standards Institute FMVSS Federal Motor Vehicle Safety Standard FRP fiberglass reinforced plastic y field service authorization Mana feet Mer cubic feet ft min cubic feet per minute FTL Freightliner 00 24 F U E L fuel usage efficiency level e WEE grams gal gallons GAWR gross axle weight rating Alia gear lubricant GND ground gpPmM gallons per minute GPS global positioning system GVWR gross vehicle weight rating HCU hydraulic control unit HD heavy duty HEPA high efficiency particulate air filter HFC hydrogenated fluorocarbons refrigerant 134a bp horsepower IR eiert high pressure HRC Rockwell C hardness hr s hour s hir heater HVAC heating ventilating and air conditioning HM hardware ICU instrumentation control unit A inside diameter TR identification Ll AAA Industrial Fasteners Institute IGN ignition ILO in lieu of in the place of IN ia inches IN u cubic inches ING ccoo co incorporated inH20 inches of water inHg inches of mercur
82. 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 hangar through the wrapper eye of the second leaf In this case the main leaf or the complete spring should be replaced immediately 32 7 32 Suspension Hendrickson HN Series Suspension Torque Values Description Hendrickson Thread Grade Torque Ibf ft N m Shock Absorber Locknut 5 8 18 UNF 2B Grade C 70 90 95 122 Bolster Spring Bolt Locknut 7 16 20 UNF 2B Grade C 33 45 45 61 Auxiliary Spring Locknut 1 2 13 UNC 2B Grade C 75 105 101 142 Transverse Rod Locknut tapered stud 1 1 18 12 UNC 2B Grade 5 175 225 237 305 Bar Pin Bushing Locknut 1 8 UNC 2A Grade 8 450 600 610 813 Bar Pin Bushing Bolt Head 1 8 UNC 2A Grade 8 Vee Bracket Locknut 3 4 10 UNC 2B Grade C 500 650 677 881 220 300 298 407 Table 2 Hendrickson HN Series Suspension Torque Values RTE Series Suspension Torque Values Description Size Torque Ibf1 ft N1 m Top Pad to Spring Aligning Setscrew 100 150 135 200 Top Pad Nut 275 400 375 542 Spring Hanger Pin Double Locknut 1 2 13 45 63 61 85 Spring Hanger Pin Draw Key Nut 1 2 13 75 100 101 135 Torque Rod Straddle Mount Nut 5 8 11 190 260 Saddle Cap Stud 7 8 14 55 65 75 90 Saddle Cap Locknut 7 8 14 225 275
83. ith any extreme pressure NLGI Grade 1 or Grade 2 grease if the operating tempera Condor Maintenance Manual September 2000 42 ture is 20 F 29 C and above If the operating tem perature is below 20 F 29 C use a low temperature extreme pressure grease Meritor Lubricate the slack adjuster at the grease fitting see Fig 6 Ref 7 until grease is forced past the pressure relief capscrew Ref 5 or past the gear splines around the inboard snap ring Use high temperature NLGI Grade 1 waterproof grease Some Meritor slack adjusters may be permanently lubricated 42 07 Disc Brake Caliper Lubrication Lubricate the two grease fittings on each disc brake caliper if the vehicle is fitted with disc brakes Lubricate the disc brake slides when replacing the cali pers 03 06 97 1421548 Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or lube plug NAO NP Fig 6 Meritor Automatic Slack Adjuster 42 5 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Link Inspection os 46 04 A LEE 46 02 Power Steering Cooler Inspection 46 06 Power Steering Fluid and Filter Changing 44srss00nnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenn 46 05 Power Steering Gear Lubrication 4 s440444440nnnnnnnnnnnnnnnnnnnnnnnn
84. k the tires 2 Check the appearance of the air conditioner com pressor pulley assembly If the friction surface of the pulley shows signs of excessive grooving due to belt slippage replace both the pulley and the drive plate Visually inspect the refrigerant com pressor drive belt for damage and check that the belt is set at the proper tension Also check the tightness of the compressor mounting fasteners For instructions and torque values see Group 01 of the Condor Workshop Manual 3 Inspect the drive plate If the friction surface of the drive plate shows visible signs of damage due to excessive heat replace the drive plate and pulley assembly See Group 83 of the Condor Workshop Manual for removal and installation procedures 4 Ona Sanden A C compressor use a feeler gauge to check that the drive plate clutch clearance is 0 016 to 0 030 inch 0 4 to 0 8 mm See Fig 1 If the drive plate clutch requires adjustment see Group 83 of the Condor Workshop Manual 5 Inspect the compressor clutch coil wire Check that the connector is not damaged or loose Replace the wire if it is damaged 6 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on the hoses Replace damaged hoses See Group 83 of the Condor Workshop Manual for replacement instructions Also check for loose fittings on all of the air conditioning components 7 Check for a build up of road debris on the con
85. l September 2000 Cab 60 01 Cab Tilt Pump Reservoir Fluid Level and System Check Before checking the hydraulic fluid level in the tilt pump reservoir the cab must be in the operating position with the cab latches locked and the valve lever in the down position Let it remain in this position for at least five minutes before checking the reservoir The reser voir is full when the fluid level reaches the threaded area of the fill plug location If the hydraulic fluid level is low check all fittings and lines for leaks If any fittings are loose tighten them fin ger 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 Condor Workshop Manual for instructions Add MIL 5606 fluid or an equivalent oil to bring the level up to the bottom of the fill tube elbow A spongy feel in the operation of the pump indicates that air is present in the hydraulic cab tilt system Bleed the air from the system see Group 60 of the Condor Workshop Manual for instructions Check for wear of the mounting pin on both tilt cylin ders when the cab is in the raised position Check that the pins are securely fastened by visually inspecting the two retaining Torx head screws at the top of each assembly Check the tilt pump mounting bolts for tight ness see Group 00 in this manual for
86. lamps are now standard on hoses with an inside diameter greater than 2 inches 51 mm Condor Maintenance Manual August 2003 Engine Cooling Radiator 20 07 14 2000 2 1261082 1 Coolant Draincock 2 Transmission Cooler Fig 5 Coolant Draincock 02 28 96 200326 Fig 6 T Bolt Type Hose Clamp Condor Maintenance Manual August 2003 08 15 94 l 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 7 Breeze Constant Torque Hose Clamp Installation When installing the Breeze Constant Torque hose clamps the clamps must be tightened to the cor rect torque The screw tip of the clamp must extend about 1 4 inch 6 mm from the clamp housing and the belleville washer stacks must be collapsed almost at Use a torque wrench to install these hose clamps correctly The correct installation torque for Breeze Constant Torque hose clamps is as follows For Breeze Constant Torque hose clamps with a 5 16 inch tightening screw hex 55 Ibf in 620 N cm For Breeze Constant Torque hose clamps with a 3 8 inch tightening screw hex 90 Ibf in 1020 N cm NOTE All hose clamps will lose torque after installation due to compression set However when correctly installed Breeze Constant Torque clamps will hold enough torque to automatically adjust and keep consis tent sealing pressure During vehi
87. manual on the mainte at the IM maintenance inspection Maintenance opera nance operations to be performed Initial Maintenance Inspection Operations Initial Maintenance Inspection Operations Operation Description Check Allison Transmission Flfluid and Filter Changing Frame Fastener Torque Checking Maintenance Operation Number 26 01 32 03 Suspension U Bolt Torque Check 33 04 All Axle Alignment Checking 35 02 Axle Lubricant and Filter Changing and Magnetic Strainer Cleaning 00 12 Condor Maintenance Manual March 2004 General Information 00 M1 Maintenance Interval Operations 00 09 The M1 Maintenance Interval Operations tables list all detailed instructions in this manual on the maintenance maintenance operations that are to be performed at the operations to be performed M1 maintenance interval Maintenance operation num bers are reference numbers used to help you find M1 Maintenance Interval Operations M1 Maintenance Interval Operations bailo nk Operation Description 00 05 Bulk Fifluid and Lubrication Checks EEE 01 02 Engine Drive Belt Inspection 15 01 Alternator Battery and Starter Checking 20 01 Fan Drive and Clutch Inspecting 20 02 Pressure Relief Cap Checking 26 03 Transmission Cooler Inspection 40 01 Wheel Nut and Rim Nut Checking 42 04 Telmae Axle Retarder Brake Inspection 49 01 Exhaust System Inspection Wei 83 01 Air Conditioner Inspection 1 00 13
88. mis sion damage Do not overfill the transmission Do not mix types and brands of fluid because of possible incompatibility Do not use fluid additives friction modifiers extreme pressure gear fluids or multi viscosity lubricants Cold Check Clean all dirt from around the end of the fluid fill tube before removing the dipstick Do not allow foreign mat ter to enter the transmission Dirt or foreign matter in the hydraulic system may cause undue wear of trans mission parts make valves stick and clog passages It is important to check the fluid level cold to determine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed 1 Park the vehicle on a at level surface 2 Apply the parking brake and chock the tires 26 2 Transmission 3 Run the engine for at least 1 minute 2 2 o 4 3 4 1 4 09 29 97 f260317a 1 Filter Cover 4 Square Cut Seal 2 Filter Element 5 Drain Plug 3 Filter Element O Ring Fig 1 Allison Transmission Filter Location and Components 4 Shift from DRIVE to NEUTRAL and then shift to REVERSE to Il the hydraulic system 5 Shiftto NEUTRAL and allow the engine to idle at 500 to 800 rpm Condor Maintenance Manual March 2001 Transmission 6 With the engine running at idle remove the dipstick from the tube and wipe it clean 7 Insert the dipstick into the tube and remove thedip stick 8 Check the fluid l
89. mission See Fig 1 6 Remove the filters from the bottom of the control module 7 Lubricate the new O rings with transmission fluid and install them on the cover assemblies 8 Install a new square cut seal on each cover assembly and install the fluid filter elements on the cover assemblies 9 Install the filter and cover assemblies into the filter compartment 10 Align each cover assembly with the holes in the channel plate sump and push the cover assem blies in by hand to seat the seals CAUTION Do not use the bolts to draw the filter covers to the sump This can damage the covers seals or sump 11 Install six bolts in each cover and torque the bolts38to 44lbf1ft 51 to 61 N m 12 Replace the drain plug O ring and install the drain plug See Fig 1 Tighten the drain plug 18 to 24 Ibf ft 25to 32N m 26 1 26 13 Refill the transmission with fresh Dexron Ill trans mission fluid and check the fluid level See Table 2 for transmission lubricant capacities Transmission Lubricant Capacities Capacity Quarts Liters Transmission Make and Model Allison Table 2 Transmission Lubricant Capacities NOTE Do not overfill the transmission Follow instruc tions in this manual to check fluid 26 02 Transmission Fluid Level Inspection Allison Transmission Dipstick Method Ah CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in trans
90. ne leaf causes hidden damage to other leaves Replacement of only visibly damaged parts is no Condor Maintenance Manual September 2001 32 assurance 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 brack ets Failure to do so could result in bracket break age possibly leading to loss of vehicle control and resulting in personal injury or property damage 1 Inspect the forward and rear spring brackets and equalizer brackets for wear cracks and other damage If any of these conditions exist replace the damaged bracket s See Group 32 of the Condor Workshop Manual for instructions 2 Inspect the drive axle s frame crossmember and gussets for wear cracks and other damage If any of these conditions exist replace the damaged parts See Group 32 of the Condor Workshop Manual for instructions 08 02 2001 1320925 Frame Rail Upper Mounting Bracket Upper Mounting Bolt Bushing Shock Absorber Axle Stop Lower Shock Absorber Bracket Aaron Fig 1 Shock Absorber Mounting front suspension shown 32 1 32 AR CAUTION Failure to replace suspension crossmembers or gussets if cracked worn or otherwise damaged could result in damage to the vehicle chassis 3 Without detaching the torque arms attempt to move by hand each radius rod end up down in
91. ng and check that the serrations at the jaw and wedge are in good condition 5 Test the safety lock latch for free operation NOTE The safety lock latch is located at the front of the fifth wheel on the top plate 6 Visually check for loose nuts or bolts see Fig 1 on the fifth wheel and on the mounting Set a torque wrench to the maximum torque value for the bolt being checked and confirm that the torque is to specification Do not loosen the bolt to check the torque value See Group 00 for bolt torque specifi cations 7 Visually check all springs to see if they are securely fastened and are not deformed Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause serious injury 31 1 31 Frame and Frame Components 07 24 95 1 Cotter Pin 3 inch 9 Bushing Pin 2 Wedge Spring 10 Locknut 1 2 13 3 Timer 11 Pivot Bushing 4 Jaw and Wedge 12 Operating Handle 5 Jaw Spring 13 Flatwasher 1 2 inch 6 Cotter Pin 1 inch 14 Bolt 1 2 13 x 2 7 Retaining Pin 15 Bumper 8 Grease Fitting 16 Bolt 1 2 13 x 1 1 2 1310349 17 Bumper Spring 18 Release Handle 19 Wedge Stoprod Spring 20 Flatwasher 5 8 inch 21 Wedge Stoprod 22 Nut Square 5 8 11 23 Fifth Wheel Top Plate Fig 1 Fontaine 5000 6000 Series Fifth Wheel right side release shown 8 Check wedge adjustment 8 1 8 2 8 3 31 2 Open the kingpin l
92. ng Fluid and Filter Changing Fill only with approved clean fluid Do not mix fluid types Failure to use the proper fluid could cause seal deterioration and leaks Fluid leaks could eventually cause loss of power steering assist This could lead to an accident resulting in personal injury or property damage 1 Apply the parking brakes and chock the rear tires 2 Place a drain pan under the power steering reser voir and remove the steering gear to reservoir return hose at the reservoir Drain the power steer ing fluid into the drain pan and dispose of the fluid Condor Maintenance Manual September 2001 Steering properly Plug the return line fitting on the reservoir 3 Use one hand to apply downward pressure to the power steering reservoir cover Remove the flanged nut and rubber washer See Fig 1 Remove the cover NOTE Always replace the power steering reservoir fil ter when changing the fluid 4 Lift out the filter spring and the filter top plate then remove the filter It may be necessary to wiggle the filter to remove it from its base Do not use pliers to aid in removal of the filter pliers could cause metal chips to enter the steering system Clean the inside of the reservoir using a lint free cloth 5 Place the disconnected end of the steering gear to reservoir hose in a drain pan Do not start the engine while draining the system Raise the front of the vehicle with a floor jack and support it with jack
93. nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnann 46 03 Power Steering Reservoir Fluid Level Check 46 01 Right Hand Steering Ram Lubrication ooooocconnnccnnccnnnncccncccnononnnnnnrn cnn nn nn rca 46 07 Condor Maintenance Manual September 2001 Steering 46 01 Power Steering Reservoir Fluid Level Check Apply the parking brakes and chock the tires to prevent the vehicle from moving With the engine cool use a shop towel or a clean rag to clean the area around the power steering reservoir fill cap See Fig 1 Twist the cap counter clockwise to remove the cap and dipstick assem bly Check the cold power steering fluid level The level should be at FULL COLD with the engine off Start the engine and run it at idle until it reaches operating temperature Remove the dipstick and check that power steering fluid reaches the FULL HOT line If the fluid level is low add enough fluid to bring the level up to the FULL HOT mark on the dipstick See Table 1 for recommended power steering fluids Install the dipstick and remove the chocks from the tires Recommended Power Sieering Fluids Fluid Type Approved Fluid Dexronell Automatic Type E Transmission Fluid Type F Mobil 210 Shell Rotella T 30W Shell Rotella T SAE 30 Chevron Heavy Duty Engine Chevron Custom Oil Mobil Super 10W 40 Texaco Union Union Unocal Guardo 19W40 Chevron Torque 5 Hydraulic Fluid Exxon Nuto H32 f
94. ns engines do not have engine noise panels 08 15 2000 1011834 1 Oil Pan Noise Panel C10 engine only Fig 1 Caterpillar Engine Noise Panels 01 02 Engine Drive Belt Inspection Worn or loose drive belts may cause premature bear ing failure or engine overheating Excessive tension or too little tension on the belt may result in excessive and premature belt wear Poly V belts or serpentine belts are retained by a belt tensioner that requires no tension adjustment Replace the engine drive belt if any condi tions described in the visual inspection are found V belts are installed as individual 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 inspect all drive belts for the following conditions then perform the belt tension inspection Condor Maintenance Manual September 2000 01 Visual Inspection 1 Inspect the belt for glazing See Fig 2 Ref A Glazing is represented by shiny sidewalls and is caused by friction created when a loose belt slips in the pulleys It can also be caused by oil or grease contamination on the pulleys 2 Check the belt for ply separation See Fig 2 Ref B Oil grease or belt dressing can cause the belt to fall apart in layers Repair any oil or coolant leaks that are affecting the
95. nt Add multipurpose chassis grease lithium 12 hydroxy stearate NLGI Grade 1 or Grade 2 with EP additives until it appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger while continuing to apply gun pressure until new grease appears at the slip joint seal See Fig 5 This ensures complete lubrication of the splines Wipe the purged grease from the pressure relief hole and slip joint seal and any excess grease from the grease fitting 41 3 41 A DADARON gt 10 20 93 1410050a After grease appears cover the pressure relief hole while continuing to lubricate Slip Joint Grease Fitting with grease gun attached Yoke Plug Grease Half Round Yoke Yoke Plug Pressure Relief Hole Slip Joint Seal Full Round Yoke U Joint Grease Fitting 41 4 Fig 5 Slip Joint and U Joint Lubrication Driveline Condor Maintenance Manual September 2000 Brakes Title of Maintenance Operation MOP Air Brake System Valve Inspection Automatic Slack Adjuster Inspection and Lubrication Bendix AD 9 Air Dryer Desiccant Replacement Bendix AD 9 Air Dryer Inspection Camshaft Bracket Lubrication Disc Brake Caliper Lubrication Telma Axle Retarder Brake Inspection Condor Maintenance Manual September 2000 42 Index Alphabetical MOP Number Brakes 42 01 Air Brake System Valve Inspection NOTE There is no scheduled air valve maintenance on vehicles equipped wit
96. nutes to cool it below 40 F 5 C Remove the cold heater thermostat assembly and check resistance between the heater thermostat terminals Resistance should be 1 5 to 3 0 ohms As the temperature of the heater thermostat assembly increases the ohm reading will increase When the temperature goes above 45 F 7 C measured resistance should be infinite ohms If the heater thermostat does not operate as outlined replace it 42 3 42 Brakes EN 4 Sa 2 E A or i D P IB ER i 1 DEN z N A SE 2 10 02 97 1410173 06 04 96 1421384 1 Differential 1 End Cover Assembly 2 Axle Retarder Brake 2 Heater Thermostat Terminals Fig 3 Bendix AD 9 Air Dryer Heater and Thermostat Check Location 42 04 Telma Axle Retarder Brake Inspection Visually inspect the condition of the Telma axle retarder See Fig 4 Check fasteners for tightness Using a steam cleaner wash the axle retarder every six months The Telma axle retarder brake which is mounted to the front of the axle does not need lubrication However the Telma driveline retarder which may be used on tan dem axle vehicles does need routine lubrication This type of retarder is equipped with a standard grease fit ting and needs to be lubricated with Supertelmaco 3 a lithium soap grease specifically designed for such applications 42 4 Fig 4 Telma Axle Retarder Brake 42 05 Camshaft Bracket Lubrication Pump grease into the camshaft brack
97. ock and vertically insert a two inch diameter shaft Release the lock by tripping the release latch at the bottom of the throat 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 hard ened washers Do not re use bolts nuts and washers on fifth wheel mountings After inspecting the fifth wheel lubricate all moving parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fill the grooves or depressions on the top plate See Maintenance Operation 31 03 for lubrication instructions Condor Maintenance Manual March 2003 Frame and Frame Components Holland 1 Disconnect the tractor from the trailer For instruc tions see the vehicle driver s manual Thoroughly steam clean the fifth wheel Check for loose nuts or broken bolts on the fifth wheel assembly Inspect for cracks or wear on the mounting bolts 5 Visually inspect for improper locking action and for cracks or wear on the jaw locking mechanism 6 Check the depth of the grease grooves lf the depth of the grooves is 1 8 inch or less replace the fifth wheel top plate See Group 31 of the Condor Workshop Manual 7 Check the condition of the X pattern
98. of fluid change from new fluid 2 percent by volume maximum Total Acid Num ber Solids Table 1 Fluid Oxidation Measurement Limits IMPORTANT For transmissions that are filled with TranSynd the lubricant must be changed every 50 000 miles 80 400 km or 24 months or 2 000 hours whichever comes first Transmissions with petroleum based lubricants must have the lubricant changed at each Maintenance 2 M2 interval NOTE TranSynd is a full synthetic transmission fluid developed by Allison Transmission and Castrol Ltd This fluid meets Allison specifications for Severe Duty Condor Maintenance Manual March 2001 26 and Extended Drain Intervals TranSynd is fully quali fied to the Dexron IIl specification 1 Park the vehicle on a level surface Apply the park ing brakes and chock the tires 2 Operate the vehicle until the transmission reaches normal operating temperature 160 to 200F 71 to 93C CAUTION To prevent burns from hot transmission fluid wear protective gloves when removing the fluid drain plug 3 Clean the area around the drain plug and the trans mission fluid pan Place a drain pan under the transmission and remove the drain plug Examine the fluid as it drains If only the filter is being changed do not drain the fluid 4 Remove the 12 mounting bolts six each from the two filter covers 5 Remove the filter covers O rings and two square cut seals from the trans
99. or Drive Axle Recommended Lubricants e SAE Type SE Viscosity Meritor emp Grade Specif 40F 40C ny Synthetic Gear and up E WE il 9 40F 40C 5140 0 76 M and up 12 20 10F g5W 140 0 76 A and upt 26 10 15F gow 140 0 76 B and up Hypoid Gear Oil 26 1C 15F a Leg API Service and up dl Classification 40C 40F GL 5 and up 75W 140 0 76 E 40C 40F to Son 2C 35F ei Da SE 75W 140 0 76 L and up 05 27 93 f350018a 1 Oil Fill Plug 2 Drain Plug Fig 1 Axle Housing Drain and Fill Plugs Condor Maintenance Manual September 2000 There is no upper limit on these outside temperatures but axle sump temperature must never exceed 250F 121C t There is no upper limit on these ambient temperatures but axle sump temperature must never exceed 121C 250F Table 1 Meritor Drive Axle Recommended Lubricants 4 Install and tighten the fill plug 35 Ibf1ft 47 Nim 5 For a two speed axle with a shift unit check the lubricant level of the shift unit refer elsewhere in this maintenance operation to the shift unit lubri cant level inspection procedure 6 On non drive axles using oil lubricated wheel bear ings check oil level at the wheels and add oil if low Use the same lubricant as specified for the drive axle NOTE When adding to or checking the oil level make certain the hub cap and plug are clean before remo
100. orporation Detroit Diesel Engines Detroit Diesel Electronic engine control diagnostic data reader driver display unit differential global positioning system dia diameter dual inline package switch data link adaptor data logging unit digital multimeter Department of Transportation daytime running lights dryer reservoir module district service manager discharge temperature control digital volt ohm meter 00 EBS electronic braking system ECAP electronic control analyzer pro grammer ECAS electronically controlled air suspension ECI electronically controlled injec tion ECM electronic control module ECU electronic control unit EDM electronic data monitor EEPROM electrically erasable program mable read only memory EM electromagnetic interference EOA electric over air EPs extreme pressure describes an antiwear agent added to some lubricants EPA Environmental Protection Agency engine position sensor et cetera and so forth electronic truck engine control electronic unit fuel injectors Freightliner air suspension figure fluid ounces post 1984 advancements Freightliner COE FLB enhanced Freightliner FLA COE FEG inin steel cab Freightliner 112 Con ventional FLD post 1984 advancements Freightliner 112 120 alum
101. otate the restrictor cans 360 degrees and visually inspect the cans for cracks severe corrosion and distortion If any of these conditions are present or the restrictor can is missing replace the restrictor can Replace all cracked or missing restrictor cans Fail ure to do so could lead to loss of vehicle control which could result in personal injury Vehicles with cracked or missing restrictor cans may be driven slowly to the nearest workshop for restrictor can replacement Hendrickson HN Series 1 Park the vehicle on a level surface apply the park ing brakes and chock the front tires 2 Visually inspect the end beam connection for dis torted or frayed rubber Also look for the equalizing beam being lower in the beam hanger If either of these conditions are found replace the rubber end bushings and all connecting parts The gap at each side of the visible rubber on the lower part of the end bushing is normal See Fig 8 32 5 32 Place a jack stand under each beam end see Fig 8 and check for movement of the rubber end bushing inner casting If movement is noted replace the rubber end bushing and all connecting parts 10 18 2000 Gap in Rubber End Bushing Rubber End Bushing Bar Pin Axle Bracket Jack 1320878 ono gt Fig 8 Beam End Connection WARNING H movement is noted do not operate the vehicle Replace the rubber end bushings and all connect ing parts The above condition can
102. r breaks to one leaf causes hidden damage to other leaves Replacement of only visibly damaged parts is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves loss of vehicle control could occur Failure to replace a damaged spring assembly could cause an accident resulting in serious personal injury or property damage 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 Condor Workshop 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 Check the rubber mounting bushings for cracks cuts swelling and dry rot Also check the bushings for missing pieces Replace the bushings as needed See Fig 1 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 Condor Workshop Manual for replacement instructions Rear Suspension Check American LaFrance Spring Suspension Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring assembly Visible damage cracks or breaks to o
103. r 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 for free play Use of a pry bar may lead to premature bushing replacement 2 Lift the rear of the vehicle and support the frame on jack stands to unload the suspension components 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 Condor Maintenance Manual September 2001 Suspension 3 Manipulate the walking beam so that a micrometer vernier or dial caliper may be used to determine the wear area thickness on the bottom face See Fig 7 Measurements should be taken a minimum of 1 2 inch from the beam flange edges to eliminate any edge wear that may have occurred Subtract the wear area thickness see Fig 7 Ref B from the thickness at the non wear area see Fig 7 Ref A to determine the amount of wear If the beams show any
104. r s specifications D Removal of or rendering inoperative the fan clutch including bypassing the control on any ther mostatic fan drive to cause it to operate continu ously E Removal of the fan shroud F Removal of or rendering inoperative exhaust components including exhaust pipe clamping G Removal of air intake components Maintenance Instructions Scheduled intervals are in the maintenance tables in this group A Verification of Inspections Log Groups01 20 and 49 follows and should be filled in each time noise emission controls on the vehicle are maintained or repaired Condor Maintenance Manual March 2004 General Information 00 Verification of Inspections Log 00 14 Verification of Inspections Log Date Mileage Verification of Inspections Log Groups 01 20 and 49 Item Group 01 Engine Noise Pan e Cost s Maintenance Facility Group 20 Fan Clutch Group 49 Exhaust System Components Condor Maintenance Manual March 2004 00 19 00 General Information Metric U S Customary Conversion Tables 00 15 When You Know U S Customary Length inches in inches in feet ft yards yd miles mi Area square inches in2 square inches in2 square feet ft2 Volume cubic inches ins cubic inches ins cubic inches ins fluid ounces oz pints pt quarts qt gallons gal cubic feet fts
105. raining the cooling 20 4 Engine Cooling Radiator system prior to the system cooling could cause severe personal injury due to scalding 4 Open the draincock located at the heat exchanger See Fig 5 Allow the coolant to drain 5 Close the draincock Tighten the draincock but do not overtighten 6 Disconnect the radiator upper and lower hoses and install the surge tank cap Attach the flushing gun nozzle to the radiator at the lower radiator hose opening Run the water until the radiator is full CAUTION When flushing the radiator do not apply more than 15 psi 103 kPa air pressure Excessive pressure can damage the radiator 7 Gradually apply air pressure to help dislodge sedi ment built up in the radiator core Do not apply more than 15 psi 103 kPa air pressure to the radi ator Pressures exceeding 15 psi 103 kPa could damage the radiator core 8 Shut off the air at the pressure gun nozzle and allow the radiator to refill with water 9 Repeat the previous two steps until clean water flows from the radiator 10 Open the draincock at the heat exchanger and allow the radiator to drain Close and tighten the draincock after the radiator has been drained Do not overtighten the draincock 11 Connect the hoses The hose clamps can be either T bolt clamps Fig 6 or Breeze Constant Torque clamps Fig 7 When working with T bolt type hose clamps tighten the clamps 55 Ibf1 in 620 N1 cm These c
106. rd most edge of the fan belt pulley 5 Compare the two measurements if the difference between the two measurements exceeds 0 150 inches 3 8 mm the clutch lining is worn and must be replaced See Group 20 of the Condor Work shop Manual for clutch lining replacement instruc tions 6 Release the air pressure then disconnect the shop hose from the air inlet of the air cylinder Connect the vehicle air hose to the inlet Connect the electrical cables to the battery 8 Lower the cab and start the engine Then shut down the engine Horton HT S 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 Condor Workshop Manual 1 Raise the cab 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 If the engine starts during this procedure the fan could cause personal injury If the vehicle is equipped with an air starter be sure that the air starter reservoir is drained 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve Filter if equipped 3 1 Unscrew the fan clutch solenoid valve air fil ter assembly and remove the filter element 3 2 Clean the filter element with cleaning sol vent 3 3
107. re unlocking the cylinder If the cab is moving toward the fully open position when the lockup occurs move the pump control lever to the RETURN position and raise and lower the pump han dle for a few strokes This will unlock the cylinder Move the pump control lever to TILT and allow the cab to raise to a fully open position If the cab is moving toward the lowered position when the lockup occurs move the pump control lever to the TILT position and raise and lower the pump handle for a few strokes This will unlock the cylinder Move the pump control lever to RETURN and allow the cab to lower to the operating position 00 4 General Information To Tilt the Cab Before tilting the cab make sure there is adequate 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 engine is running the vehicle could move causing an accident that could result in personal injury or property damage IMPORTANT Before raising or lowering the cab read the warning label on the hydraulic pump 1 With the vehicle parked on a level surface shut down the engine place the transmission in neutral and apply the brakes 2 Secure all loose items in the cab and make sure the doors are securely latched Objects falling in the cab or a door flying open could damage the vehicle or cause personal injury 3 Make sur
108. result in costly repair downtime possible separation of compo nents loss of vehicle control property damage or personal injury 3 Inspect all torque rods and transverse rods for looseness or shredded rubber With the brakes applied slowly rock an empty vehicle while an assistant visually checks the action at both ends of the rod Or with the vehicle shut down a lever check can be made with a long pry bar placed under each rod end and pressure applied Whether the rod ends are straddle mount or tapered stud they can be renewed by pressing out 32 6 Suspension the worn end and installing a cartridge type replacement A two piece rod is also available to cut and weld to the desired length 4 Visually inspect the rebound strap to make sure it is intact and not torn If the rebound strap is not intact or is torn replace it 5 Visually inspect the auxiliary spring The normal height of an unloaded auxiliary spring is 4 inches 10 cm Replacement is recommended when the height of the auxiliary spring decreases to 3 1 2 inches 9 cm or below See Fig 9 NOTE When bolster springs are replaced it is recom mended that both bolster springs on a beam be replaced even if only one shows wear 6 Visually inspect all four bolster springs Make sure that there is no rubber trapped or in contact with sharp metal edges from overhanging metal plates Replace the bolster spring if swelling due to con tamination of oil or
109. reuse the Nylok nuts on the air dryer cover 16 Install the six capscrews 12 washers and six new Nylok nuts Torque the capscrews in a star pattern see Fig 2 270 to 385 Ibf in 3060 to 4340 N cm 17 Install the air dryer on the lower mounting bracket Install the two previously marked cap screws four washers and two new Nylok nuts Torque the two remaining capscrews 270 to 385 Ibf in 3060 to 4340 N cm Install the capscrew 42 1 42 two washers and a new Nylok nut in the upper mounting bracket strap Torque the upper mounting bracket strap capscrew 80 to 120 Ibf in 904 to 1356 N cm Brakes 19 Start the engine build the air pressure and check the air brake system for leaks If any air leaks are present see Group 42 of the Condor Workshop Manual for diagnosis and repair information 18 Connect and tighten the three air lines Connect the harness connector to the heater and thermo stat assembly until the lock tab snaps in place 08 09 95 he 117 Si 1421383 1 5 16 x 4 1 2 Upper Mounting 10 O Ring 20 Purge Valve Housing Bracket Capscrew 11 Safety Valve 21 Heater and Thermostat Housing 2 Upper Mounting Bracket Strap 12 Lower Mounting Bracket 22 Return Spring 3 5 16 Lockwasher 13 3 8 Capscrew long 23 Purge Piston 4 5 16 Nylok Nut 14 Check Valve Assembly 24 3 8 Capscrew 5 Upper Mounting Bracket 15 Purge Valve Assembly 25
110. s 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 solu tion 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 13 to the bottom of the frame rail If the riding height is incorrect adjust the air suspension Teyco 79 KB Inspect all suspension fasteners for the proper torque values See Group 00 of this manual for proper bolt torque specifications Visually inspect the frame for elongated holes at the suspension mounting points 32 9 32 and have the frame repaired as needed If elongated holes are found on the frame check the suspension Suspension alignment Check brackets and torque rods for damage or loose fasteners 09 15 95 1 Frame Rail 2 Axle Housing 1320423 3 Axle Centerline 4 Suspension Ride Height Fig 13 Neway Ride Height Inspection 32 02 Suspension Lubrication Front Suspension Wipe all dirt away from the grease fittings if equipped on the spring eye bushings Apply multipurpose chas sis grease with a pressurized grease gun until the old grease is forced out NOTE Service Schedule IV vehicles equipped with a 12 000 Ib 5452
111. s 00 10 M2 Maintenance Interval Operations 20 03 Radiator Pressure Flushing and Coolant Changing 26 01 Allison Transmission Flfluid and Filter Changing 32 03 Suspension U Bolt Torque Check 35 02 Axle Lubricant and Filter Changing and Magnetic Strainer Cleaning 42 01 Air Brake System Valve Inspection 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 46 05 Power Steering Flfluid and Filter Changing For synthetic lubricant change intervals see 26 01 Condor Maintenance Manual March 2004 00 15 00 General Information Maintenance Operation Sets Table 00 12 Maintenance Operation Sets du Service Schedule Maint No Operation Description Initial Mi M2 M3 00 05 Bulk Fifluid and Lubrication Checks 00 06 Chassis Lubrication e e 01 01 Engine Noise Panel Inspection Noise Emission Control 01 02 Engine Drive Belt Inspection e e 09 01 Air Cleaner Element Inspecting and Replacing 15 01 Alternator Battery and Starter Checking e 20 01 Fan Drive and Clutch Inspecting Noise Emission Control 20 02 Pressure Relief Cap Checking e 20 03 Radiator Pressure Flushing and Coolant Changing 26 01 Allison Transmission Flfluid and Filter Changing e 26 02 Transmission Flfluid Level Inspection 26 03 Transmission Cooler Inspection e 31 01 Frame Fastener Torque Checking 31 05 Vogel Chassis Lubrica
112. s N1 cm inch pounds Ibf1 in Newton meters N1 m foot pounds Ibf1 ft 3 37685 6 895 kilo Pascals kPa 0 29613 kilo Pascals kPa 0 14503 Table 3 Metric U S Customary Conversion inches of mercury inHg pounds per square inch psi Then Divide By When You Multiply Then Know By Add degrees Celsius _C 1 8 32 Table 4 Metric U S Customary Conversion To Get To Get degrees Fahrenheit _F Condor Maintenance Manual March 2004 General Information 00 Torque Specifications Tables 00 16 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged nn Grade 5 Grade 5 Grade 8 Grade 8 Grade 5 Grade B Grade 8 Grade G Pitch Bolt or B Nut or 8 2 Bolt or C Nut Bolt Nut or 8 2 Bolt Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m i Com 1230003 Com 1230008 8 230006 230007 S el dl 1 4 20 7 9 8 11 6 8 14 1 4 28 a 9 12 7 9 2 16 5 16 18 5 20 16 22 13 18 21 28 5 16 24 6 22 17 23 14 19 23 31 3 8 16 6 35 28 38 23 31 7 50 3 8 24 0 41 32 43 25 34 42 57 7116 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54 66 89 1 2 13 4 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
113. se SAE 10 heavy duty engine oil API service classication SD sulfated ash content must not exceed 1 85 When the ambient temperature is below 0 F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classi cation SD sulfated ash content must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures do not mix it with kerosene To prevent component dam age do not mix engine oil and automatic transmission fluid 4 Fill the shift unit housing through the oil fill hole until specified lubricant is level with the bottom of the opening 5 Apply a small amount of Loctite 242 or equivalent sealant to the threads of the fill plug Install the plug finger tight on the rear axle housing Use a wrench and tighten it an additional 1 1 2 turns Condor Maintenance Manual September 2000 35 35 5 Wheels and Tires Title of Maintenance Operation MOP Toe In Inspection Wheel Nut and Rim Nut Checking Condor Maintenance Manual September 2000 40 Index Alphabetical MOP Number Wheels and Tires 40 01 Wheel Nut and Rim Nut Checking IMPORTANT After a wheel has been installed the wheel or rim nut torque must be rechecked after 50 to 100 miles 80 to 160 km of operation See Table 1 for wheel nut torque sp
114. shings in the spring eyes at the grease fitting See Fig 15 Continue to lubricate until grease exits both ends of the bush ing If the pin will not accept lubricant remove the pin and clean the lubrication channels where lubri cant may have hardened Remove the safety Condor Maintenance Manual September 2001 32 stands and lower the vehicle after lubrication is complete 4 2 a 3 TY o fey II UV A Il VAX CTA A ARAN WA ALLEL WKY IT IHN 2 4 1 09 15 95 1320424 1 Bronze Bushing 3 Grease Fitting 2 Lubrication Hole 4 Lubrication Groove Fig 15 Hendrickson RTE Series Bushing Lubrication Neway No lubrication is required on Neway rear suspensions Reyco No lubrication is required on Reyco rear suspensions 32 03 Suspension U Bolt Torque Check AA CAUTION Failure to retorque 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 vehi cle 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 4 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks 32 11 32 3 Remove the chocks Suspension U Bolt Torque Values Description Size Torque Ibf1 ft N1 m 5 8 18
115. spection Condor Maintenance Manual March 2001 26 Index Alphabetical MOP Number Transmission 26 01 Allison Transmission Fluid and Filter Changing Ah CAUTION Transmission fluid and filters must be changed whenever there is evidence of dirt or a high temper ature condition A high temperature condition is indicated when the transmission fluid is discol ored has a strong odor or has exceeded oil analy sis limits shown in Table 1 When draining transmission fluid check for evidence of dirt or water contamination A small amount of conden sation will accumulate in the fluid during operation Water contamination is normally characterized as a milky discoloration of the transmission fluid Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the transmission cooler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 1 Consult your local telephone directory for fluid analysis firms To ensure consistent and accurate fluid analysis use only one fluid analysis firm Refer to the Allison Technician s Guide for Automatic Transmission Fluid GN2055EN for additional information Test Limit Viscosity 25 percent change from new fluid An increase of 3 0mg of KOH to neutralize a g
116. sure Relief Cap Checking Radiator Pressure Flushing and Coolant Changing Condor Maintenance Manual August 2003 20 Index Alphabetical MOP Number Engine Cooling Radiator 20 01 Fan Drive and Clutch Inspecting noise emission control Kysor K22RA Fan Clutch 1 Raise the cab 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 If the engine starts during this procedure the fan could cause personal injury If the vehicle is equipped with an air starter be sure that the air starter reservoir is drained 2 Measure the distance from the back surface of the fan clutch retaining plate to the forward most edge of the fan belt pulley See Fig 1 Ref A 3 Disconnect the line from the air inlet of the air cylin der Connect a shop air hose to the inlet 05 27 93 f200237a With the fan clutch engaged measure the distance at A measure it again with the fan clutch disengaged 1 Bearing Housing 4 Air Inlet from sole 2 Retaining Plate noid valve 3 Fan Pulley 5 Air Cylinder 6 Fan Fig 1 Kysor K22RA Fan Clutch Lining Wear Checking Condor Maintenance Manual August 2003 20 4 Apply a minimum of 100 psi 690 kPa air pressure to the air cylinder the bearing housing will move backwards disengaging the clutch Again mea sure the distance from the back surface of the retaining plate to the forwa
117. t cartridge in a vise Condor Maintenance Manual September 2000 42 CAUTION Clamping the end cover or housing in a vise could seriously compromise the air dryer s ability to hold air pressure which could cause a failure in the brake system 10 Twist the end cover counterclockwise to release the cartridge from the end cover Rotate the end cover until it completely separates from the desic cant cartridge NOTE A substantial torque up to 50 Ibf ft 68 N m may be necessary to remove the desiccant cartridge 11 Inspect the condition of the O ring seals If they are cracked crimped or otherwise damaged replace them to ensure an airtight seal Clean the O ring grooves of any dirt or obstruction AR CAUTION Dirt or obstructions in the O ring grooves can cause an O ring failure that will result in an air leak 12 Lubricate the O rings with silicone or lithium grease and install them in the end cover 13 Install the desiccant cartridge on the end cover Turn the cartridge clockwise until the desic cant cartridge makes contact with the end cover 14 Place the desiccant cartridge in a vise and turn the end cover clockwise an additional 180 to 225 degrees to fully tighten the desiccant cartridge to the end cover NOTE Desiccant cartridge torque should not exceed 50 Din 68 N m 15 Place the housing over the desiccant cartridge and align the mounting holes with the end cover IMPORTANT Replace do not
118. tch is acti vated the power is applied to the pump The PS LED will go off and will light up again once sufficient system pressure has been attained to prefill all lubrication lines The CONTACT and PS LEDs will remain lit for the remainder of the pump running period Following completion of the pump running period the CONTACT LED will go off and the PAUSE LED will light up again 31 as the control unit counts time until the next lubrication cycle starts The PS LED stays lit to show that monitor ing by the pressure switch is preset The LED sequence provides visual confirmation of sys tem performance and failure The CS LED is not used in fluid grease applications and will not light up with the systems described in the Vogel Chassis Lubrication System Table 1 summarizes the control unit LED light sequence Pos Description Duration LEDs 1 EE ignition 5 oti no powerto As long as the ignition is off N A the lubrication system The ignition is switched on lubrica PAUSE PS Cab 2 3 seconds tion system gets power Lamp EE Remainder of preset pump pause time or until 3 down time to the next lubrication H Giel PAUSE PS manual override occurs cycle Countdown complete contact time Preset contact pump running time factory 4 j CONTACT starts pump motor activates preset for 2 6 minutes 5 System pressure of 360 psi 2482 Contact time minus the time the pump needs to CONTACT PS kPa build up pressure e pump turns off
119. tches and door needed and Door Hinge hinges on the cab Check that the axle lubricant is at the proper level Add lubricant as needed Refer to the maintenance operation for detailed procedures Maintenance Operation Number 46 02 Drag Link Lubricate the grease fittings at the pitman arm and the axle steering arm Power Steering Gear Camshaft Bracket Caliper Bushing Automatic Slack Adjuster Knuckle Pin Cab Latch Lubricate the grease fitting at the output shaft trunnion Lubricate the grease fitting Lubricate grease fitting Lubricate the grease fitting Lubricate the 2 grease fittings top and bottom at both ends of the axle Lubricate the two grease fittings one at each tie rod end Lubricate the cab latches and the cab latch piston pin Check that the pump fluid o 60 02 Cab Tilt Pump is at the proper level Reservoir Add the proper fluid as needed Driveline Lubricate each U joint 10 A292 UJoint grease fitting if equipped 11 41 02 Driveline Slip Lubricate the grease Joint fittings if equipped Maintenance Operation Number Condor Maintenance Manual March 2004 00 11 00 General Information Initial Maintenance Inspection Operations 00 08 The Initial Maintenance Inspection Operations tables tion numbers are reference numbers used to help you list all maintenance operations that are to be performed find detailed instructions in this
120. the power steering system and repair as needed Top off the power steering fluid level as needed 46 06 Power Steering Cooler Inspection Inspect the power steering cooler if equipped Check for a build up of insects leaves and other debris on the cooling fins Use a water spray to wash away the debris Replace the cooler as necessary 46 07 Right Hand Steering Ram Lubrication All steering system components are critical for safe operation of the vehicle Failure to maintain the steering system as specified may result in loss of steering control which could lead to personal injury and property damage Visually inspect the steering ram for cracks splits or other damage Lubricate as necessary and replace the ram as needed 46 3 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Filter Replacement 2 32 51 2 Kraemer 47 01 Fuel Tank Band Nut TINAN siaa nae E E EEA EO EA 47 03 Fuel Water Separator Sight Bowl Cleaning and Element Replacement usesnnnnennnnnennnnnnnnnnnn 47 02 Condor Maintenance Manual September 2000 Fuel 47 01 Fuel Filter Replacement Refer to the engine manufacturer s service manual for removal and installation procedures 47 02 Fuel Water Separator Sight Bowl Cleaning and Element Replacement Alliance or Racor Fuel Water Separator Element Replacement The only service necessary on Alliance or Racor fuel separators is to replace the filt
121. tion System Inspection 31 06 Vogel Chassis Lubrication System Reservoir Checking and Refilling 32 01 Suspension Inspection e e 32 02 Suspension Lubrication e e 32 03 Suspension U Bolt Torque Check e 33 01 Knuckle Pin Lubrication e e 33 02 Tie Rod Inspection e e 33 03 Tie Rod Lubrication e e 33 04 All Axle Alignment Checking 35 01 Drive Axle Lubricant Level and Breather Check e 35 02 Axle Lubricant and Filter Changing and Magnetic Strainer Cleaning 40 01 Wheel Nut and Rim Nut Checking e e 41 01 Driveline Inspection 41 02 Driveline Lubrication e e 42 01 Air Brake System Valve Inspection a 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 42 03 Bendix AD 9 Air Dryer Inspection e 42 04 Telmae Axle Retarder Brake Inspection e 42 05 Camshaft Bracket Lubrication 42 06 Automatic Slack Adjuster Inspection and Lubrication 42 07 Disc Brake Caliper Lubrication 46 01 Power Steering Reservoir Flfluid Level Check e 46 02 Drag Link Lubrication e 46 03 Power Steering Gear Lubrication 00 16 Condor Maintenance Manual March 2004 General Information 00 Maintenance Operation Sets Table 00 12 Maintenance Operation Sets Maint No Operation Description zn Server EH Initial M1 M2 M3 46 04 Drag Link Inspection e 46 05 Power Steering Flfluid and Filter Changing e 46 06 Power Steering Cooler Inspection 46 07 Right Hand
122. 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 lubri cation change intervals 7 After cleaning the drain plug s install and tighten to 35 Ibf ft 47 N m 8 With the vehicle on a level surface fill the axle housings to the bottom of the fill hole using speci fied lubricant See Table 1 for recommended axle lubricants and Table 2 for drive axle lubricant capacities 35 4 Meritor Drive Axle Lubricant Capacities Capacity Axle Model pints liters Single Driver RS 23 160 39 5 18 7 RS 23 161 37 2 17 6 RS 23 186 47 3 22 4 RS 26 185 46 6 22 RS 30 185 46 6 22 RS 30 380 46 6 22 Tandem Drive Forward 30 2 14 3 RT 40 145 RT 40 145P Rear 25 8 12 2 Forward 25 2 12 RT 44 145P Rear 22 9 11 Forward 39 1 18 5 Rear 34 4 16 3 RT 46 160 RT 46 164 18 5 16 3 18 6 16 4 Forward 39 3 18 6 RT 46 160P Rear 34 7 16 4 Forward 38 1 18 RT 50 160 Rear 33 2 15 7 RT 52 185 RT 58 185 Forward 56 1 26 5 RT 58 380 Rear 36 1 17 1 Forward 56 1 26 5 RT 52 380 Rear 58 2 27 5 Forward 54 4 25 7 RT 70 380 Rear 53 1 25 1 Quantities listed are approximate Fill axle until lubricant is level with bottom of fill hole with vehicle on level ground t Refer to Traction Equalizer Additives in the te
123. up 33 in the Condor Workshop Manual for wheel alignment procedures 10 13 2005 f320033a NOTE Shown without pinch bolt to provide clarity 1 Cross Tube Split Fig 2 Tie Rod End Adjustment 33 1 Rear Axle 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Lubricant and Filter Changing and Magnetic Strainer Cleaning usersnssnnsennnnnnnnnnnnnnnnnennnnnenn 35 02 Drive Axle Lubricant Level and Breather Check 35 01 Condor Maintenance Manual September 2000 Rear Axle 35 01 Drive Axle Lubricant Level and Breather Check Meritor Axle A CAUTION Failure to keep the rear axle filled to the proper level with the correct lubricant can result in rear axle damage 1 Park the vehicle on level ground apply the parking brakes and chock the tires 2 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier See Fig 1 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 indica tor only and should not be used as a fill or level hole 3 Check that the lubricant is level with the bottom of the fill hole See Fig 2 If low check for oil leaks and correct as needed Add the specified lubricant See Table 1 for recommended drive axle lubri cants 35 Merit
124. ving the plug this will minimize the possibility of dirt and road grime entering the assembly 35 1 35 Rear Axle 06 07 94 f350061a A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole Fig 2 Axle Lubricant Level Inspection Two Speed Axle Shift Unit Lubricant Level Inspection Meritor Axles If equipped with a two speed axle shift unit use the fol lowing directions Ah 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 the area sur rounding the plug See Fig 3 Turn the fill plug ina counterclockwise motion and remove the plug 2 Insert a finger or pipe cleaner into the fill plughole and check the fluid level The lubricant level should be maintained at the bottom of the fill hole If low add the specified lubricant 35 2 08 06 93 f350021a 1 Housing Cover Gasket 2 Oil Fill Plug 3 Shift Unit Housing Cover Fig 3 Two Speed Axle Shift Unit CAUTION Before adding additional lubricant make sure of the type currently in the shift unit To prevent com ponent damage do not mix engine oil with auto matic transmission fluid IMPORTANT When the ambient temperature is above 0 F 18 C use SAE 10 heavy duty engine oil API service classication SD sulfated ash content must not exceed 1 85 When the ambient temperature is below 0 F 18 C
125. xt Table 2 Meritor Drive Axle Lubricant Capacities NOTE Some Meritor axles have a small tapped and plugged hole near and below the housing lubricant fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 9 Install and tighten the fill plug 35 Ibf 1 ft 47 N1 m 10 Whenever the interaxle differential housing has been drained add an additional 2 pints 1 L of Condor Maintenance Manual September 2000 Rear Axle specified lubricant directly into the interaxle differ ential housing 11 For a two speed axle with a shift unit change the shift unit lubricant refer elsewhere in this mainte nance operation to the shift unit lubricant changing procedure 12 Remove the chocks then drive the vehicle unloaded for 1 or 2 miles 2 or 3 km at speeds not to exceed 25 mph 40 km h to thoroughly circu late lubricant throughout the carrier and housing assemblies Two Speed Axle Shift Unit Lubricant Changing 1 Remove the shift unit housing cover See 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 gasket Tighten the housing cover capscrews 7 5 to 9 2 Ibf1 ft 10 2 to 12 5 N1 m then remove the oil fill plug from the cover IMPORTANT When the ambient temperature is above 0 F 18 C u
126. y ege instrument panel Eo AA International Organization for Standardization kilo 1000 kilograms kilometers kilometers per hour kilo Pascals kilowatts liters pounds pounds force feet pounds force inches liquid crystal display light emitting diode 00 25 General Information List of Abbreviations 00 17 LA AAA left hand LHDR left hand drive LHK liters per hundred kilometers LHS low hydrogen steel EEG limited liability company L min liters per minute LPG iiciin liquefied petroleum gas Menari meters max maximum MESA Mining Enforcement Safety Act Mf manufacturer Mlm miles MID message identifier MIL military specification MIN minutes MIN minimum miSC miscellaneous LUS milliliters mm millimeters mod module mp0 miles per gallon Mph o n miles per hour MSHA Mining Safety and Health Administration MVDA Motor Vehicle Dealers Associ ation D Negative front axle wheel alignment specification N A inania not applicable Newton centimeters normally closed terminal or switch NHTSA National Highway Traffic Safety Administration NIOSH National Institute for Occupa tional Safety and Health NLGI National Lubricating Grease Institute Nm Newton meters NO normally open terminal or
127. y of these conditions Condor Maintenance Manual September 2001 32 exist replace the damaged parts See Group 32 of the Condor Workshop Manual for instructions IMPORTANT Before checking the AirLiner suspension height make sure there is no load on the chassis and the trailer is unhitched 1 Park the vehicle on a level surface using a light application of the brakes Do not apply the parking brakes Shift the transmission into neutral and build the secondary air pressure to at least 100psi 690 kPa Shut down the engine 2 Mark the location of the front and rear tires on the floor and chock the tires on one axle only 3 Check the length of the overtravel lever between its pivot points See Fig 5 Ref A If the vehicle is equipped with an adjustable leveling valve the length should be 8 inches 203 mm If the length is incorrect See Group 32 of the Condor Workshop Manual for adjustment procedures a A er 05 15 95 320410 A Measure the length of the overtravel lever between these two points 1 V Shaped Mark 4 2 Adjustment Locknut 5 3 Overtravel Lever Cotter Pin Linkage Rod Fig 5 AirLiner Overtravel Lever and Linkage Rod Measurement 4 Onsingle 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 distance from the bottom of the forward most left axle stop

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