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Heavy-Duty Trucks Maintenance Manual

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Heavy-Duty Trucks Maintenance Manual
Foreword
Introduction
- Descriptions of Service Publications
- Page Description
00 General Information
- Determining Scheduled Maintenance Intervals: 00–01
- Maintenance Service Table: 00–02
- Vehicle Maintenance Schedule Tables: 00–03
- Lubrication and Fluid Level Check: 00–04
- Maintenance Operation Sets Table: 00–05
- Initial Maintenance (IM) Operations: 00–06
- M1 Maintenance Interval Operations Table: 00-07
- M2 Maintenance Interval Operations Table: 00-08
- M3 Maintenance Interval Operations Table: 00–09
- M4 Maintenance Interval Operations Table: 00-10
- COE Cab Tilting, FLA/FLB: 00–11
- Noise Emission Controls Maintenance: 00–12
- Verification of Inspections Log: 00–13
- Metric/U.S. Customary Conversion Tables: 00–14
- Torque Specifications Tables: 00–15
01 Engine
- 01–01 Engine Rear-Support Assembly Checking (Noise Emission Control)
- 01–02 Engine Noise Panel Inspecting (Noise Emission Control)
- 01–03 Jacobs Engine Brake Wiring Inspecting
- 01–04 Engine Drive Belt Inspecting
09 Air Intake
- 09–01 Air Cleaner Element Inspecting and Replacing
13 Air Compressor
- 13–01 Bendix Air Compressor Inspecting
15 Alternators and Starters
- 15–01 Alternator, Battery, and Starter Checking
20 Engine Cooling/Radiator
- 20–01 Radiator Cap Checking
- 20–02 Radiator Pressure Flushing and Coolant Changing
- 20–03 Fan Drive and Clutch Checking (Noise Emission Control)
25 Clutch
- 25–01 Clutch Release Bearing Lubricating
- 25–02 Clutch Release Cross-Shaft Lubricating
- 25–03 Clutch Linkage Components Lubricating
26 Transmission
- 26–01 Shift Control Telescoping Tubes Lubricating and Inspecting, FLA/FLB
- 26–02 Shift Control Latch Lubricating and Cylinder Inspecting, FLA/FLB
- 26–03 Shift Lever Pivot Yokes Inspecting, FLA/FLB
- 26–04 Selection Lever and Pivot Rod Ball Stud Lubricating, FLA/FLB
- 26–05 Allison Transmission Fluid and Filter Changing
- 26–06 Manual Transmission Magnetic Plug Cleaning, Oil Changing, and Oil Filter Element Changing
- 26–07 Transmission Air Filter/Regulator Checking, and Cleaning or Replacing
- 26–08 Transmission Oil Level Checking and Breather Checking
31 Frame and Fifth Wheel
- 31–01 Fifth Wheel Inspecting
- 31–02 Fifth Wheel Lubricating
- 31–03 Frame Fastener Torque Checking
- 31–04 Holland Fifth Wheel Sliding Mechanism Inspecting
- 31–05 Trailer Electrical Connector Lubricating
- 31—06 Premier 690 Coupling Inspection
32 Suspension
- 32–01 Suspension Inspecting
- 32–02 Suspension Lubricating
- 32–03 Suspension U-Bolt Torque Checking
33 Front Axle
- 33–01 Knuckle Pin Lubricating
- 33–02 Tie Rod Inspecting and Lubricating
- 33–03 All-Axle Alignment Checking
35 Rear Axle
- 35–01 Axle Breather and Lubricant Level Checking
- 35–02 Axle Lubricant Changing, Oil Filter Replacing, and Magnetic Strainer Cleaning
40 Wheels and Tires
- 40–01 Wheel Nut and Rim Nut Checking
41 Driveline
- 41–01 Driveline Inspecting
- 41–02 Driveline Lubricating
42 Brakes
- 42–01 Brake Adjusting—Cam Brakes With Manual Slack Adjusters
- 42–02 Camshaft Bracket Bushing Lubricating
- 42–03 Manual/Automatic Slack Adjuster Lubricating and Checking (All Models)
- 42–04 Meritor Automatic Slack Adjuster Lubricating
- 42–05 Wedge Brake Checking
- 42–06 Wedge Brake Inspecting and Lubricating
- 42–07 Alcohol Evaporator Checking
- 42–08 Bendix Alcohol Evaporator Cleaning
- 42–09 Bendix Alcohol Evaporator Gasket Replacing
- 42–10 Bendix Air Dryer Checking (AD–2, AD–4, or AD–9)
- 42–11 Bendix Air Dryer or Anchorlok Aftercooler Inspecting (Bendix AD–2, AD–4, AD–9, or Anchorlok)
- 42–12 Bendix Air Dryer Desiccant Replacing (AD–2)
- 42–13 Bendix Air Dryer Desiccant Replacing (AD–4 or AD–9)
- 42–14 CR Brakemaster Air Dryer Cleaning (Model 62 or 68)
- 42–15 Anchorlok Aftercooler Automatic Ejector Valve Clearing
- 42–16 Bendix Air Brake Valve Operation Checking (BP–R1 and E–12)
- 42–17 Bendix Air Brake Valve Disassembly, Cleaning, and Inspecting (BP–1, Double Check Valve, E–6, PP–7, QR–1, R–6, R–14, SR–1, ST–3, TC–7, TP–5, and TR–3)
- 42–18 Bendix Air Brake Valve Disassembly, Cleaning, Inspecting, and Lubricating (DV–2, PP–3, and Single Check Valve)
- 42–19 Bendix Air Brake Valve Inspecting and Testing (BP–1, BP–R1, LQ–5, PP–7, R–14, and TC–7)
- 42–20 Bendix Foot Brake Valve Actuator Lubricating (E–6 or E–12) and Leak-Testing (E–12)
- 42–21 Sealco Moisture Ejection Valve Operation- and Leak-Testing (Model 6300)
- 42–22 Midland Quick Release and Flipper Valve Checking
- 42–23 Meritor WABCO System Saver 1000 Air Dryer Desiccant Replacing
- 42–24 Brake Inspection
46 Steering
- 46–01 Steering Driveline Lubricating
- 46–02 TRW Manual Steering Gear Lubricant Checking, Model 503
- 46–03 TRW Manual Steering Gear Lubricant Changing, Model 503
- 46–04 Drag Link and Power Steering Cylinder Lubricating
- 46–05 Power Steering Reservoir Fluid Level Checking
- 46–06 Power Steering Reservoir Fluid and Filter Changing
- 46–07 Steering Driveline Deck Bearing Lubricating, FLA/FLB
- 46–08 TRW Power Steering Gear Lubricating, TAS Series
- 46–09 Sheppard Power Steering Gear Bearing Cap Lubricating
47 Fuel
- 47–01 Fuel Tank Vent Checking
- 47–02 Fuel Tank Band Nut Tightening, FLA, FLB, and FLD
- 47–03 Fuel Separator Sight Bowl Cleaning and Element Replacing
49 Exhaust
- 49–01 Exhaust System Inspecting (Noise Emission Control)
- 49–02 CAT CGI Bellows Replacement
54 Electrical, Instruments, and Controls
- 54–01 Electrical System Checking
- 54–02 Speedometer/Tachometer Cable Lubricating
60 Cab
- 60–01 Cab-Tilt System Checking, FLA/FLB
- 60–02 Cab-Suspension Spring Center-Bolt Torque Checking, FLC
- 60–03 Cab Latch Checking, FLA/FLB
72 Door
- 72–01 Door Seal, Door Latch, and Door Hinge Lubricating
83 Heater and Air Conditioner
- 83–01 Air Conditioner Inspecting
88 Hood, Grille, and Cab Fenders
- 88–01 Hood Rear Support Lubrication

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