1997-2010 Freightliner Century Class (Argosy Coe, C112 / C120 Conventional, Coronado) Service & Repair Manual

CENTURY CLASS TRUCKS MAINTENANCE MANUAL Models: Argosy ® COE C112 Conventional C120 Conventional Coronado ® STI-341-1 (8/11) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper maintenance program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides information necessary for years of safe, reliable, and cost-efficient vehicle operation. IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other component and body manufacturers’ instructions for specific inspection and maintenance instructions. Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip and post-trip inspections, and daily/weekly/monthly maintenance, as outlined in the vehicle driver’s manual. Major components, such as engines, transmissions, and rear axles, are covered in their own maintenance and operation manuals, that are provided with the vehicle. Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you. They can also set up a scheduled maintenance program tailored specifically to your needs. Optionally, they can assist you in learning how to perform these maintenance procedures. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice. Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com for more information, or contact Daimler Trucks North America LLC at the address below. Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials. NOTICE: Parts Replacement Considerations Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage. © 1996–2011 Daimler Trucks North America LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a Daimler company. Daimler Trucks North America LLC Service Systems and Documentation (CVI-SSD) P.O. Box 3849 Portland, OR 97208–3849

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro ® ) formats. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, and specifications. Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifications, and procedures for adjustments and for checking the tightness of fasten- ers. Maintenance manuals do not contain detailed repair or service information. Driver’s/Operator’s Manual Driver’s/operator’s manuals contain information needed to enhance the driver’s understanding of how to operate and care for the vehicle and its components. Each manual contains a chapter that covers pretrip and post-trip inspections, and daily, weekly, and monthly maintenance of vehicle components. Driver’s/operator’s manuals do not contain detailed repair or service information. Service Bulletins 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 time, the bulletin is usually canceled. The service bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject. IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid. Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures. Web-based repair, service, and parts documentation can be accessed using the following applications on the AccessFreightliner.com website. ServicePro ServicePro ® provides Web-based access to the most up-to-date versions of the publications listed above. In addition, the Service Solutions feature provides di- agnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service personnel. Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data. PartsPro PartsPro ® is an electronic parts catalog system, showing the specified vehicle’s build record. EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro. Introduction Descriptions of Service Publications Century Class Trucks Maintenance Manual, March 2011 I–1

Warranty-related service information available on the AccessFreightliner.com website includes the following documentation. Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety. All recall campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Introduction Descriptions of Service Publications I–2 Century Class Trucks Maintenance Manual, March 2011

For an example of a Century Class Trucks Maintenance Manual, see Fig. 1. f020044 A B C D E 11/20/95 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B. Group Title C. Group Number D. Release Date E. Group Number/Page Number Fig. 1, Example of a Century Class Trucks Maintenance Manual Page Introduction Page Description Century Class Trucks Maintenance Manual, March 2011 I–3

Group No. Group Title 00 ...................... General Information 01 ................................ Engine 09 .............................. Air Intake 15 ................... Alternators and Starters 20 ................... Engine Cooling/Radiator 25 ................................ Clutch 26 ........................... Transmission 31 ............. Frame and Frame Components 32 ............................ Suspension 33 ............................. Front Axle 35 ............................. Rear Axle 40 ........................ Wheels and Tires 41 .............................. Driveline 42 ................................ Brakes 46 ............................... Steering 47 ................................. Fuel 49 ............................... Exhaust 60 .................................. Cab 72 ................................ Doors 83 ................. Heater and Air Conditioner 88 .............. Hood, Grille, and Cab Fenders Introduction Maintenance Manual Contents I–4 Century Class Trucks Maintenance Manual, March 2011

Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals............................................. 00–01 Initial Maintenance (IM) Operations ..................................................... 00–05 Lubrication and Fluid Level Check ..................................................... 00–04 M1 Maintenance Interval Operations .................................................... 00–06 M2 Maintenance Interval Operations .................................................... 00–07 M3 Maintenance Interval Operations .................................................... 00–08 Maintenance Operation Sets Table ..................................................... 00–09 Metric/U.S. Customary Conversion Tables ................................................ 00–12 Noise Emission Controls Maintenance................................................... 00–10 Service Schedule Table ............................................................. 00–02 Torque Specifications Tables.......................................................... 00–13 Vehicle Maintenance Schedule Tables................................................... 00–03 Verification of Inspections Log......................................................... 00–11 General Information 00 Index, Alphabetical Century Class Trucks Maintenance Manual, August 2011

Determining Scheduled Maintenance Intervals Performing regular maintenance on your Freightliner will help ensure that your Freightliner delivers safe reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unsched- uled down time. To determine the correct maintenance intervals for your vehicle you must first determine the type of service or conditions the vehicle will be operating in. Generally, most vehicles operate under conditions that fall within one of the four types of service de- scribed. Before placing your new vehicle in service, determine the type of service (Service Schedule I, II, III, or IV) that applies to the intended use of the vehicle. After determining the vehicle’s type of service, refer to the service schedule table or the vehicle maintenance schedule table, to determine how often maintenance should be performed. When the vehicle reaches the distance given for a maintenance interval, see the Maintenance Interval Operation Table for a list of the maintenance operations to be performed at that maintenance interval. Use the maintenance operation reference numbers to find detailed instructions in the manual on each operation. Types of Service Service Schedule I (severe service) applies to vehicles that annually travel less than 6000 miles (10 000 kilometers) or that operate under severe conditions. Examples of severe service, Schedule I usage include: operation on extremely poor roads or where there is heavy dust accumulation; constant exposure to extreme hot, cold, salt-air, or other extreme cli- mates; frequent short-distance travel; construction- site operation; city operation (fire truck); or farm operation. Service Schedule II (short-haul transport) applies to vehicles that annually travel less than 60,000 miles (100 000 kilometers) and operate under normal conditions. Examples of Schedule II usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high percentage of stop-and-go travel. Service Schedule III (long-haul transport) is for vehicles that annually travel more than 60,000 miles (100 000 kilometers) with minimal city or stop-and-go operation. Examples of Schedule III usage are: re- gional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage. Service Schedule IV (long haul transport for Opti- mized Vehicle Configuration) is for vehicles that annually travel over 60,000 miles (100 000 km) and meet the following qualifications: • Meritor 15-1/2 inch dampened/ceramic Lite Pedal LTD clutch with sealed release bearing. • Synthetic transmission fluid used in transmission. • Meritor FF–961 or FF–981 front axle (12,000 lb. capacity) with synthetic lubricant. • Front suspension with maintenance-free rubber bushings for 12,000 lb. capacity suspension. • Meritor RPL series, or Spicer SPL series driveline U-joints. • Synthetic lubricant used in rear axle. • Equipped with any Freightliner AirLiner suspension. • Equipped with Meritor Q-Plus extended-lube cam brakes and automatic slack adjusters, front and rear. • Standard brake system package including Ben- dix AD-9 air dryer—mounted on the right-hand frame rail, located directly behind the front bumper—with heater, and a Bendix air com- pressor. • TRW TAS–65 power steering. NOTE: Maintenance instructions in this manual are based on average vehicle use and normal operating conditions. Unusual vehicle operating conditions may require service at more frequent intervals. General Information 00 Determining Scheduled Maintenance Intervals: 00–01 Century Class Trucks Maintenance Manual, August 2011 00/1

Service Schedule Maintenance Interval Operation Maintenance Interval Frequency Miles km Hours Schedule I * (Severe Service) vehicles that annually travel less than 6000 miles (10 000 km) Initial Maintenance (IM) first 1000 1600 50 Maintenance 1 (M1) every 1000 1600 50 Maintenance 2 (M2) every 5000 8000 500 Maintenance 3 (M3) every 15,000 24 000 1500 Schedule II ² (Short-Haul Transport) vehicles that annually travel less than 60,000 miles (100 000 km) Initial Maintenance (IM) first 10,000 16 000 — Maintenance 1 (M1) every 10,000 16 000 Maintenance 2 (M2) every 50,000 80 000 Maintenance 3 (M3) every 150,000 240 000 Schedule III ² (Long-Haul Transport) vehicles that annually travel over 60,000 miles (100 000 km) Initial Maintenance (IM) first 25,000 40 000 — Maintenance 1 (M1) every 25,000 40 000 Maintenance 2 (M2) every 100,000 161 000 Maintenance 3 (M3) every 300,000 483 000 Schedule IV ² (Long-Haul Transport for Optimized Vehicle Configuration) vehicles that annually travel over 60,000 miles (100 000 km) Initial Maintenance (IM) first 25,000 40 000 — Maintenance 1 (M1) every 25,000 40 000 Maintenance 2 (M2) every 100,000 161 000 Maintenance 3 (M3) every 300,000 483 000 * For Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance traveled. ² Use Schedule I (severe service) maintenance intervals for vehicles that operate under severe conditions, such as extremely poor roads, heavy dust accumulation, extreme climate, frequent short distance travel, construction-site operation, city operation (garbage truck), or farm operation. Table 1, Service Schedule General Information 00 Service Schedule Table: 00–02 Century Class Trucks Maintenance Manual, August 2011 00/2

1st through 30th Maintenance for Service Schedules I and II Maint. No. Maintenance Interval Service Date Service Schedule I Service Schedule II Miles km Hours Miles km 1st IM and M1 1000 1600 100 10,000 16 000 2nd M1 2000 3200 200 20,000 32 000 3rd M1 3000 4800 300 30,000 48 000 4th M1 4000 6400 400 40,000 64 000 5th M1 and M2 5000 8000 500 50,000 80 000 6th M1 6000 9600 600 60,000 96 000 7th M1 7000 11 200 700 70,000 112 000 8th M1 8000 12 800 800 80,000 128 000 9th M1 9000 14 400 900 90,000 144 000 10th M1 and M2 10,000 16 000 1000 100,000 160 000 11th M1 11,000 17 600 1100 110,000 176 000 12th M1 12,000 19 200 1200 120,000 192 000 13th M1 13,000 20 800 1300 130,000 208 000 14th M1 14,000 22 400 1400 140,000 224 000 15th M1, M2, and M3 15,000 24 000 1500 150,000 240 000 16th M1 16,000 25 600 1600 160,000 256 000 17th M1 17,000 27 200 1700 170,000 272 000 18th M1 18,000 28 800 1800 180,000 288 000 19th M1 19,000 30 400 1900 190,000 304 000 20th M1 and M2 20,000 32 000 2000 200,000 320 000 21st M1 21,000 33 600 2100 210,000 336 000 22nd M1 22,000 35 200 2200 220,000 352 000 23rd M1 23,000 36 800 2300 230,000 368 000 24th M1 24,000 38 400 2400 240,000 384 000 25th M1 and M2 25,000 40 000 2500 250,000 400 000 26th M1 26,000 41 600 2600 260,000 416 000 27th M1 27,000 43 200 2700 270,000 432 000 28th M1 28,000 44 800 2800 280,000 448 000 29th M1 29,000 46 400 2900 290,000 464 000 30th M1, M2, and M3 30,000 48 000 3000 300,000 480 000 Table 2, 1st through 30th Maintenance for Service Schedules I and II General Information 00 Vehicle Maintenance Schedule Tables: 00–03 Century Class Trucks Maintenance Manual, August 2011 00/3

1997-2010 Freightliner Century Class (Argosy Coe, C112 / C120 Conventional, Coronado) Service & Repair Manual

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