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Maintenance Manual - TransChicago Truck Group

1. Torque Values for Metric Thread Fasteners With Lubricated or Plated Threadst Thread Class 8 8 Bolt Class 8 Nut Class 10 9 Bolt Class 10 Nut Diameter Pitch Torque Ibf ft N m Torque Ibf ft N m N ad N Ss N TOP N F P N uds a E WA 230010 230011 1230012 230013 M6 5 7 7 9 M8 12 16 17 23 M8 x 1 13 18 18 24 M10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12 x 1 5 43 58 62 84 M14 66 89 95 129 M14 x 1 5 72 98 103 140 M16 103 140 148 201 M16 x 1 5 110 149 157 213 M18 147 199 203 275 M18 x 1 5 165 224 229 310 M20 208 282 288 390 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 M27 527 715 729 988 M27 x 2 569 771 788 1068 M30 715 969 990 1342 M30 x 2 792 1074 1096 1486 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 20 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads Columbia Maintenance Manual February 2010 00 23 Engine Title of Maintenance Operation MOP Engine Drive Belt Inspection Engine Support Fasteners Check 2000050 Pacbrake Inspection and Lubric
2. 11 28 95 1310353b 1 Lubricant Grooves 3 Lock Control Handle 2 Safety Latch 4 Mount Fig 3 Simplex Series Fifth Wheel 1 lal Nag 2 09 15 95 1310470 1 Operating Handle 2 Lever Bar Fig 4 Lever Bar and Operating Handle Alignment frame rail to the top of the fifth wheel plate Ref 1 Pry up on the fifth wheel plate Ref 4 below the pin boss and measure the vertical move ment Ref 5 The bracket connection provides a 9 32 inch 7 mm vertical clearance to provide cushioning and to avoid downward pin loading while retaining minimum plate lift If the plate lift Ref A exceeds 5 16 inch 8 mm as a result of wear or rubber deterioration install new stan dard or oversized bracket shoe rubber pads see Group 31 of the Columbia Workshop Manual for replacement instructions 5 N ES a 3 4 08 31 95 1310475 A Extended Top Plate Lift Height Fifth Wheel Top Plate Fifth Wheel Frame Mount Frame Rail Lifting Point Static Top Plate Height N PD Fig 5 Measuring Fifth Wheel Top Plate Lift NOTE Do not measure plate lift immediately after a trailer has been uncoupled from the fifth wheel The rubber may have taken a temporary set which will normally recover after being un coupled for a short period of time 8 Check all mounting bolts for signs of fatigue and tighten them to the proper torque For torque specifications see Group 00 Inspect all angles plates and brack
3. Columbia Maintenance Manual February 2010 00 11 00 General Information M2 Maintenance Interval Operations 00 07 Maintenance Operation Number 83 02 Air Filter Replacement M2 Maintenance Interval Operations for Service Schedules I Il and III Check Replace the HVAC filters every 6 months regardless of mileage Table 12 M2 Maintenance Interval Operations for Service Schedules Il and Ill o Masa Nara r M2 Maintenance Interval Operations for Service Schedule IV Check 00 04 Lubrication and Fluid Level Check includes the following e Clutch Release Cross Shaft Lubrication e Sleeve Assembly Bronze Bushing Lubrication e Transmission Fluid Level Inspection e Knuckle Pin Lubrication Meritor Axles e Tie Rod Lubrication Meritor Axles e Axle Breather and Axle Lubricant Level Inspection e Driveline Lubrication e Power Steering Fluid Level Inspection e Power Steering Gear Lubrication e Drag Link Lubrication 00 06 Perform All M1 Operations 01 01 Engine Support Fasteners Check noise emission control 01 02 Engine Drive Belt Inspection 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief Cap Check 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 32 01 Suspension Inspection 32 03 Suspension U Bolt Torque Check 33 02 Tie Rod Inspection 33 07 Basic Inspection Meritor Unitized Wheel Ends 33 08 End P
4. 1 Tightening Screw Hex Fig 4 Breeze Constant Torque Hose Clamp Installation NOTE All hose clamps will lose torque after installation due to compression set However when correctly installed Breeze Constant Torque clamps will hold enough torque to auto matically adjust and keep consistent sealing pressure During vehicle operation and shut down the screw tip may adjust according to temperature and pressure changes The torque may need to be adjusted for individual applica tions 11 Place a pan under the coolant filter to catch en gine coolant 12 Remove the coolant filter with a strap or chain wrench Install a new coolant filter and tighten 20 IMPORTANT On vehicles with EPA07 compliant engines the coolant capacity varies depending on the engine and accessory installation After servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on the surge tank 13 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 auxiliary heaters may increase the coolant ca pacity and require additional coolant The cooling system is filled when the coolant level reaches the MAX line on the surge tank Freightliner rec ommends the use of a precharged and premixed antifreeze when refilling the cooling system See Table 2 for a list of some of the precharged anti freeze available
5. 46 04 Power Steering Gear Lubrication Sheppard Sheppard power steering gears manufactured with out grease fittings are maintenance free If the power Steering gear has no grease fitting then it requires no periodic lubrication Sheppard power steering gears with grease fittings must be lubricated periodically 1 Wipe off debris from the bearing cap grease fit ting See Fig 1 05 28 93 f460296a 1 Bearing Cap Grease Fitting Fig 1 Sheppard Bearing Cap Lubrication 2 Using a hand type grease gun apply multipur pose chassis grease until grease starts coming out of the bearing cap dirt and water seal TRW TAS Series 4h CAUTION Apply grease to the sector shaft only with a hand type grease gun See Fig 2 Use of a high pressure power grease gun will supply grease too quickly and could affect the high pressure seal contaminating the hydraulic fluid Using a hand type grease gun apply NLGI Grade 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal 46 2 Columbia Maintenance Manual February 2010 Steering 11 28 95 1461071 1 Sector Shaft Grease Fitting Fig 2 TRW TAS Series Sector Shaft Lubrication 46 05 Drag Link Lubrication 1 Using a clean rag wipe all dirt from both drag link grease fittings See Fig 3 2 Using a pressure gun apply clean grease at the grease fittings until old grease is forced out of the socket
6. Duero NO ie M2 Maintenance Interval Operations for Service Schedules Il and Ill Check 00 06 Perform All M1 Operations 01 01 Engine Support Fasteners Check noise emission control 01 02 Engine Drive Belt Inspection 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief Cap Check 25 02 Clutch Release Cross Shaft Lubrication 25 03 Sleeve Assembly Bronze Bushing Lubrication 25 04 Meritor Clutch Release Bearing Lubrication 26 02 Transmission Fluid Level Inspection 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 32 01 Suspension Inspection 32 03 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication Meritor Axles 33 02 Tie Rod Inspection 33 03 Tie Rod Lubrication Meritor Axles 33 07 Basic Inspection Meritor Unitized Wheel Ends 33 08 End Play Check Meritor Unitized Wheel Ends 35 02 Axle Breather and Axle Lubricant Level Inspection 40 01 Wheel Nut Check 42 01 Air Brake System Valve Inspection 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 42 07 Meritor Camshaft Bracket Lubrication 42 08 Meritor Slack Adjuster Lubrication 46 01 Drag Link Inspection 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Steering Inspection 47 01 Fuel Filter Replacement 47 02 Fuel Separator Sight Bowl Cleaning and Element Replacement 83 01 Air Conditioner Inspection
7. 2 Reducer Bushing 8 Sight Bowl Heater 3 Mounting Brackets Rod 4 O Ring when Sight Bowl Assembly equipped with heater 10 Vacuum Breaker Drain 5 Stainless Steel Valve V Clamp when equipped with heater Fig 1 ConMet Fuel Separator IMPORTANT The fitting must be air tight and the valve closed Columbia Maintenance Manual March 2000 47A 47 Fuel 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 reten tion nuts 30 to 35 Ibf ft 41 to 46 N m After the re tention 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 2 Columbia Maintenance Manual March 2000 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspection Noise Emission Control llli 49 01 Columbia Maintenance Manual January 2007 Exhaust 49 01 Exhaust System Inspection Noise Emission Control In addition to inspecting the exhaust system at the scheduled maintenance interval inspect the exhaust system if the noise level of the vehicle has in creased Replace parts that show leakage wear or damage with genuine Freightliner parts Pre EPA07 Exhaust System Inspecting 1 On all vehicles check the condition of the muffler body and the top stack Check the inlet outlet
8. Fig 5 Top View of the Equalizer ditions exist replace the damaged bracket s See Group 32 of the Columbia Workshop Manual for instructions Replace worn cracked or damaged spring brackets Failure to do so could result in bracket breakage possibly leading to loss of vehicle con trol and resulting in personal injury or property damage Inspect the crossmember s and gussets for wear cracks and other damage If any of these conditions exist replace the damaged parts See Group 32 of the Columbia Workshop Manual for instructions IMPORTANT Before checking the AirLiner sus pension height make sure there is no load on the chassis and the trailer is unhitched IMPORTANT To prevent voiding the warranty on Barksdale height control valves note the fol lowing e Do not overtighten the bolts in the Barksdale height control valve housing The bolts should not be loose and should not require tightening Only if necessary tighten the valve housing bolts 45 Ibf in 500 N cm Any damage to the valve housing will void the warranty Columbia Maintenance Manual February 2010 32 3 32 Do not attempt to disassemble the Barksdale valve body or the control lever There are no serviceable parts in the valve and any disas sembly will void the warranty NOTICE When removing or loosening a Barksdale height control valve from a mounting bracket always hold the valve side mounting studs in place with an Allen wr
9. Use multipurpose chassis grease NLGI Grade 2 896 12 hydroxy lithium stearate grease or NLGI Grade 1 696 12 hydroxy lithium stearate grease Grade 2 is preferred 2 1 11 27 95 1 Grease Fitting at Pitman Arm 2 Grease Fitting at Axle Steering Arm 1461072 Fig 3 Drag Link 46 46 06 Rack and Pinion Steering 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 per sonal injury and property damage The rack and pinion steering system is designed to be maintenance free Inspect the system as de scribed below and repair or replace any components that are worn or damaged Figure 4 shows the com ponents of the rack and pinion steering system 1 Park the vehicle on a level surface and chock the rear tires 2 Check the steering I Shaft U joints for evidence of looseness or binding If any is found replace the I Shaft 3 Check the steering I Shaft slip joint for evidence of lateral movement looseness or binding If any is found replace the I Shaft 4 Jack up one axle end at a time and move the tire in and out by hand to check the tie rod ends for free play No free play is allowed If the outer tie rod ends are damaged or worn replace them For repair procedures see Group 46 of the Columbia Workshop Manual 5 Check the rack and pinion
10. seal replacement or any other reason 4 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 bear ings can be felt or seen replace the U joint as sembly 5 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 Columbia Workshop Manual for torque specifi cations Replace the midship bearing assembly if the rubber cushion is deteriorated or oil soaked 6 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 Columbia Maintenance Manual March 2000 41 1 41 Driveline N SN 3 16 1 2 3 05 01 95 1410067b NOTE Not all fasteners are shown 1 Transmission 6 U Joint Cross 12 Splined Stub Shaft 2 Transmission Output Shaft 7 Bearing Cup for yoke strap 13 Driveshaft Tube End Yoke yoke strap type 8 Yoke Strap and Capscrew 14 Tube Yoke bearing cap type 3 U Joint Assembly 9 Slip Joint Assembly 15 Axle Input Shaft End Yoke 4 Bearing Cap Self Locking 10 Sleeve Yoke bearing cap type yoke strap type Capscre
11. tubes for leakage dents and corrosion and check for holes in the muffler Replace parts as required Use new parts equivalent to parts originally installed on the vehicle See Group 49 of the Columbia Workshop Manual for replace ment procedures 2 Inspect the exhaust flex hose see Fig 1 for leakage wear or damage Replace with new parts if replacement is needed 3 Check for leakage at the V band coupling which attaches the exhaust pipe to the turbocharger exhaust outlet See Fig 2 06 01 93 f490024a 1 Flex Hose 4 Turbocharger Exhaust 2 V Band Coupling Outlet 3 Exhaust Pipe Fig 1 V Band Coupling and Flex Hose 49 4 If leakage exists tighten the nut on the V band coupling 85 Ibf in 940 N cm If leakage persists install a new V band coupling 5 Inspect the turbo outlet pipe and replace it as needed 6 Check the U bolt clamps for tightness and tighten as needed 7 Check the isolator at the base of the exhaust stack elbow s see Fig 2 for cracking dam age and dry rot Replace as needed 08 25 95 1 Exhaust Pipe 2 Exhaust Elbow Isolator 3 Mounting Nut 1490127 Fig 2 Exhaust Elbow Isolator 8 Check for leakage at all wide band exhaust clamps See Fig 3 If leakage exists tighten the nuts 40 to 60 Ibf ft 54 to 81 N m If leakage persists inspect the sealclamps If necessary install a new wide band exhaust clamp EPAO7 Exhaust System Ins
12. 000 3 M1 75 000 121 000 4 M1 and M2 100 000 161 000 5 M1 125 000 201 000 6 M1 150 000 241 000 7 M1 175 000 281 000 8 M1 and M2 200 000 322 000 9 M1 225 000 362 000 10 M1 250 000 402 000 11 M1 275 000 443 000 12 M1 M2 and M3 300 000 483 000 13 M1 325 000 523 000 14 M1 350 000 563 000 15 M1 375 000 604 000 16 M1 and M2 400 000 644 000 17 M1 425 000 684 000 18 M1 450 000 724 000 19 M1 475 000 764 000 00 6 Columbia Maintenance Manual February 2010 General Information 00 Vehicle Maintenance Schedule Tables 00 03 1st through 20th Maintenance for Service Schedules II and IV Service Service Schedules Ill and IV Maint No Maintenance Interval Date Miles km 20 M1 and M2 500 000 805 000 Table 6 1st through 20th Maintenance for Service Schedules Ill and IV 21st through 40th Maintenance for Service Schedules Ill and IV Maint No Maintenance Interval a ate Miles km 21 M1 525 000 845 000 22 M1 550 000 885 000 23 M1 575 000 925 000 24 M1 M2 and M3 600 000 966 000 25 M1 625 000 1 005 800 26 M1 650 000 1 046 000 27 M1 675 000 1 086 000 28 M1 and M2 700 000 1 127 000 29 M1 725 000 1 167 000 30 M1 750 000 1 207 000 31 M1 775 000 1 248 000 32 M1 and M2 800 000 1 287 000 33 M1 825 000 1 328 000 34 M1 850 000 1 368 000 35 M1 875 000 1 408 000 36 M1 M2 and M3 900 000 1 448 000 37 M1 925 000 1 4
13. 03 61st through 90th Maintenance for Service Schedules and Il Maint No Maintenance Service Service Schedule I Service Schedule II Interval Date Miles km Hours Miles km 61st M1 61 000 98 200 6100 610 000 982 000 62nd M1 62 000 99 800 6200 620 000 998 000 63rd M1 63 000 101 400 6300 630 000 1 014 000 64th M1 64 000 103 000 6400 640 000 1 030 000 65th M1 and M2 65 000 104 600 6500 650 000 1 046 000 66th M1 66 000 106 200 6600 660 000 1 062 000 67th M1 67 000 107 800 6700 670 000 1 078 000 68th M1 68 000 109 400 6800 680 000 1 094 000 69th M1 69 000 111 000 6900 690 000 1 110 000 70th M1 and M2 70 000 112 700 7000 700 000 1 127 000 71st M1 71 000 114 300 7100 710 000 1 143 000 72nd M1 72 000 115 900 7200 720 000 1 159 000 73rd M1 73 000 117 500 7300 730 000 1 175 000 74th M1 74 000 119 100 7400 740 000 1 191 000 75th M1 M2 and M3 75 000 120 700 7500 750 000 1 207 000 76th M1 76 000 122 300 7600 760 000 1 223 000 77th M1 77 000 123 900 7700 770 000 1 239 000 78th M1 78 000 125 500 7800 780 000 1 255 000 79th M1 79 000 127 100 7900 790 000 1 271 000 80th M1 and M2 80 000 128 700 8000 800 000 1 287 000 81st M1 81 000 130 400 8100 810 000 1 304 000 82nd M1 82 000 132 000 8200 820 000 1 320 000 83rd M1 83 000 134 000 8300 830 000 1 340 000 84th M1 84 000 135 200 8400 840 000 1 352 000 85th M1 and M2 85 000 137 000 8500
14. 63 psi 400 to 435 kPa replace the air filter regulator It can not be repaired Wear safety goggles when using compressed air to clean parts as permanent harm to eyes could result from flying debris 4 Clean the filter element by dipping it in alcohol or other cleaning solvent Blow compressed air through the element inside to outside to loosen surface dirt and to dry the element If it is not damaged the sintered metallic filter element will last the life of the vehicle Wipe out the filter housing with a clean dry lint free rag Clean and inspect the O rings and end cap Replace any parts that are damaged 5 Install the large O ring then the filter element small end first into the filter housing 6 Install the small O ring in the end cap then in stall the end cap and tighten it until firm 4h CAUTION A leaking air filter or air lines can cause slow or hard shifting of the transmission and eventual transmission damage Transmission 7 Start the engine and build pressure in the air system Check for air leaks at the filter housing and air line connections repair any leaks Meritor NOTE This procedure does not apply to FreedomLine transmissions 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Remove the element from the air filter regulator assembly Inspect the O rings in the end cap replace worn or damaged O rings Inspect the element for fluid
15. Fig 6 42 07 Meritor Camshaft Bracket Lubrication IMPORTANT Perform MOP 42 11 before lubri cating the camshaft bracket NOTE If equipped with an extended maintenance Q Plus brake system the cam shaft bracket will not have a grease fitting These camshafts use a special NLGI grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance camshaft bushings are lubricated Columbia Maintenance Manual January 2008 42 5 42 Brakes 10 27 93 f420653a 1 7 16 Inch Adjusting 6 Clevis Nut 7 1 2 Inch Clevis Pin 2 Grease Fitting 8 1 4 Inch Clevis Pin 3 Boot 9 Grease Relief 4 Link Opening 5 Brake Chamber Piston 10 Slack Adjuster Spline Rod Fig 6 Gunite Automatic Slack Adjuster during the brake reline service interval For ser vice and lubrication instructions see Group 42 of the Columbia Workshop Manual For camshaft brackets with grease fittings use an NLGI Grade 1 or Grade 2 multipurpose chassis grease Lubricate the camshaft bushings through the grease fitting on the camshaft bracket or the spider until new grease flows from the inboard seal See Fig 4 4h WARNING If grease leaks out under the camhead the cam shaft bracket grease seal is worn or damaged See Group 42 in the Columbia Workshop Manual for grease seal replacement instructions If this seal is not repl
16. Joint Lubrication with a plastic or rawhide mallet on the side oppo site the dry seal while continuing to lubricate If grease still does not appear loosen the cap screws at the bearing with the dry seal to relieve seal tension Lubricate the U joint until new grease is seen at the seal then tighten the cap screws to the correct torque specifications If the bearing will not take grease replace the U joint Refer to Group 41 of the Columbia 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 Columbia Maintenance Manual March 2000 41 3 41 Slip Joint Spline Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines 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 joint Add multipurpose chassis grease lithium 12 hydroxy stearate NLGI Grade 1 or Grade 2 with EP additives until it appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger while continuing to apply gun pressure until new grease appears at the slip joint seal See Fig 5 This ensures complete lubrication of the sp
17. Knuckle Pin Lubrication Meritor Axles 33 03 Tie Rod Lubrication Meritor Axles 33 05 Knuckle Pin Lubrication Dana Spicer Axles 33 06 Tie Rod Lubrication Dana Spicer Axles 35 02 Axle Breather and Axle Lubricant Level Inspection 41 02 Driveline Lubrication 42 05 Dana Spicer Camshaft Bracket Lubrication 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Inspection 72 01 Door Seal Door Latch and Door Hinge Lubrication Table 8 Maintenance Operation 00 04 Lubrication and Fluid Level Check for Service Schedules Il Ill and IV 00 8 Columbia Maintenance Manual February 2010 General Information The Initial Maintenance table lists all maintenance operations that are to be performed at the initial maintenance IM interval Maintenance operation numbers are reference numbers used to help you 00 Initial Maintenance IM Operations 00 05 tenance operations to be performed All operations listed in the table along with the operations listed in the applicable M1 maintenance interval table must be performed to complete the initial maintenance find detailed instructions in this manual on the main IM rape Initial Maintenance IM Operations for Service Schedules Il IIl and IV Check 00 06 Perform all M1
18. Operations 31 03 Frame Fastener Torque Check 32 03 Suspension U Bolt Torque Check 33 04 All Axle Alignment Check 40 01 Wheel Nut Check 47 03 Fuel Tank Band Nut Tightening Table 9 Initial Maintenance IM Operations for Service Schedules Il Ill and IV Columbia Maintenance Manual February 2010 00 9 00 General Information M1 Maintenance Interval Operations 00 06 The M1 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M1 maintenance interval Maintenance opera IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and tion numbers are reference numbers used to help you find detailed instructions in this manual on the the Columbia Driver s Manual maintenance operations to be performed Post Trip Inspections and Maintenance chapter of o EE ap M1 Maintenance Interval Operations for Service Schedules Il and Ill Check 00 04 Lubrication and Fluid Level Check includes the following e Eaton Fuller Clutch Release Bearing Lubrication e Fifth Wheel Lubrication e Trailer Electrical Connector Lubrication e Suspension Lubrication e Knuckle Pin Lubrication Dana Spicer Axles e Tie Rod Lubrication Dana Spicer Axles e Driveline Lubrication e Dana Spicer Camshaft Bracket Lubrication e Dana Spicer Haldex and Gunit
19. Place a tension gauge at the belt s widest span and adjust the belt tension to specification See Group 01 for belt tension specifications Some engines are equipped with dual alternator belts always check both belts for correct tension Check that the tensioner operates smoothly with out binding Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension inspection 3 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections including the connections at the starter B terminal and ground terminal and where the alternator charg ing cable terminates 4 Inspect the battery cables for wear and replace them if they are damaged Clean the cable con nector terminals with a wire brush See Group 54 of the Columbia Workshop Manual for troubleshooting instructions and for adjustment repair or replacement instructions 4 1 Clean and tighten the battery ground cable terminal and clamps 15 4 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any cor rosion with a wire brush and wash with a weak solution of baking soda and water Flush with clean water and dry Paint the retainer assembly if needed to prevent rusting 4 3 Check that foreign objects such as stones bolts and nuts are removed from the battery box
20. Use of an equivalent antifreeze to those listed in the table is also acceptable Always check that the antifreeze meets Freight liner s specifications and is at the proper concen tration for protection in the vehicle operating area See Table 3 for antifreeze protection infor mation Freightliner specifies that antifreeze must be an ethylene glycol solution that meets GM 6038 M Engineering Standards or a ethylene gly col solution that has less than 0 196 anhydrous sodium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards If supplemental coolant additives are being used add the supplements to the coolant as neces sary See the coolant additive manufacturer s instructions for the correct amount of additive required Don t forget to consider the volume of the supplemental coolant additive being added to the system when determining the amount of coolant required to refill the system Engine Coolant Capacity pre EPA07 engines Capacity with 1000 Capacity with 1200 sq inch Radiator sq inch Radiator Engine CAT C10 C12 39 5 qt 37 4 L 40 6 qt 38 5 L CAT 53 2 qt 50 4 L 54 1 qt 51 5 L Cummins 39 0 qt 37 0 L 40 2 qt 38 1 L DDE S60 54 8 qt 51 9 L 56 0 qt 53 0 L Table 1 Engine Coolant Capacity pre EPA07 engines Columbia Maintenance Manual January 2007 20 3 20 Engine Cooling R adiator Manufacturer Antifreeze Type F Contains
21. axle oil filter Use a suitable filter strap wrench See Fig 1 Discard the old filter 05 27 93 f350119a Fig 1 Meritor Axle Oil Filter Removal NOTE There may be about one pint 0 5 L of lubricant remaining in the filter Be careful not to spill it when removing the filter 4 Using the recommended drive axle lubricant coat the face of the gasket on the new oil filter if one was removed Install the filter over the adapter and tighten the filter one full turn after the gasket contacts the base do not overtighten See Table 1 for recommended lubricants Columbia Maintenance Manual July 2005 35 1 35 Rear Axle Meritor Drive Axle Recommended Lubricant Recommended Lubricant Type Ambient Temperature Lubricant SAE Viscosity Grade Meritor Specification 40 F 40 C and Up 75W 90 O0 76 N Synthetic Gear Oil 40 F 40 C and Up 75W 140 0 76 M There is no upper limit on these outside temperatures but axle sump temperature must never exceed 250 F 121 C Table 1 Meritor Drive Axle Recommended Lubricant Clean the fill and drain plugs Change them if necessary 5 1 For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 2 Check the drain plug for metal particles every 100 000 miles 160 000 km Clean away the collected material deposited on e
22. 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 mea sured resistance should be infinite ohms If the heater thermostat does not operate as outlined replace it If it does operate as outlined install it then remove the chocks from the tires Columbia Maintenance Manual January 2008 42 3 42 06 04 96 f421384 1 End Cover Assembly 2 Heater Thermostat Terminals Fig 3 End Cover Terminals Location 42 04 Alcohol Evaporator Cleaning and Inspection Midland Maintenance is required during both the freeze sea son and the off season to keep the alcohol evapora tor in good working order Off Season During the off season drain the unit of alcohol At regular engine service intervals open the drain cock to remove moisture from the alcohol evaporator Be fore reactivating the evaporator for the next freeze season drain disassemble inspect and steam clean the unit of any sludge that may have accumu lated It is advisable to replace any rubber parts when assembling the alcohol evaporator Perform this service just before the freeze season Brakes Freeze Season Reactivation 1 Park the vehicle on a level surface and apply the parking brakes Shut down the engine Chock the tires 2 Remove the filler cap and check the c
23. chock the rear tires 2 Remove the clutch inspection plate NOTE Some clutch release bearings are equipped with a lubrication extension that ex tends outside of the clutch housing It is not necessary to remove the clutch inspection plate when the lubrication extension is used NOTE For lubrication of the release bearing Meritor recommends a lithium base high temperature grease that meets the NLGI grade three specification 3 Wipe any dirt from the grease fitting See Fig 1 Using a pressure type grease gun equipped with recommended grease lubricate the bearing until excess grease purges from the rear of the re lease bearing toward the transmission 4h CAUTION Do not over lubricate the clutch release bearing Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature failure Do not use chassis grease or multipurpose lubricants 4 Wipe off excess grease and apply it to both the yoke finger and sleeve bushing contact points See Fig 2 5 Install the clutch inspection plate then remove the chocks 25 2 Columbia Maintenance Manual April 2005 Transmission Title of Maintenance Operation MOP Manual Transmission Air Filter Regulator Check Cleaning or Replacement Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant Transmission Fluid Level Inspection 26 Index Alphabetical MOP Number Columbia Maintenance Manual Ap
24. contamination If fluid is present replace the element Inspect the air supply sys tem for the source of the fluid and service it as needed 3 Install the element in the filter regulator assem bly 4 Apply a light coat of silicone grease or an equivalent grease to the O rings in the end cap Install and tighten the end cap 10 to 15 Ibf ft 14 to 20 N m 5 Build air pressure in the system check for leaks and make any needed repairs 26 4 Columbia Maintenance Manual April 2005 Frame and Frame Components 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number FiA Wheel Es se is E ER dee EA 7 0175 DE LT 31 01 Pita heel HC STIR cd oig dox Aman Aa AR kha KANA ted tate AMI Ron RUE a DR RARE Rb CRT dad eae 31 02 Frame Fastener Torque Check EE EE EE EE ee 31 03 Trailer Electrical Connector Lubrication i s es care aou eR esa oe ERG dodo a eod bog cx e e adh 31 04 Columbia Maintenance Manual October 2008 Frame and Frame Components 31 01 Fifth Wheel Inspection All fifth wheel maintenance adjustment and re building must be done only by a qualified me chanic Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Parts are under spring compression Wear safety goggles while servicing the fifth wheel Failure to do so can result in personal injury due to parts ejecti
25. fluid is found to be leaking from within the bel lows replace the rack and pinion unit Check the input shaft for any leakage around the on center cap If there is evidence of leakage from inside the on center cap remove the on center cap and replace the input shaft seal See Group 46 of the Columbia Workshop Manual for instructions Check the steering system pressure and return lines and fittings for leaks and damaged lines or 10 hoses Repair or replace lines hoses and fit tings as necessary Check the tube fittings on the hard transfer lines of the gear see Fig 4 Item 15 If there is leak age from either of the fittings replace the rack and pinion unit IMPORTANT Tightening the tube fittings can cause tearing of the O ring seal and increased fluid leakage 46 4 Columbia Maintenance Manual February 2010 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Fiter Replacement capas d ado euge dh dt aue anh de qi dbi S HEES DEUR eed Ea E p EE Er GE 47 01 Fuel Separator Sight Bowl Cleaning and Element Replacement 0200 ccc eee eee 47 02 Fuel tank Band Nut Tightening osse eere Rem OR t kere ien y er HE BERUBG NILAGA 47 03 Columbia Maintenance Manual March 2000 Fuel 47 01 Fuel Filter Replacement Refer to the engine manufacturer s service manual for removal and installation procedures 47 02 Fuel Separator Sight Bowl Cleaning and Element
26. have a small tapped and plugged hole near and below the housing oil fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 5 1 With the vehicle on a level surface fill the axle through the oil fill hole Lubricant should be level with the bottom of the oil fill hole To check fluid level see Fig 2 5 2 Install and tighten the fill plug 41 Ibf ft 55 N m Dana Spicer IMPORTANT The use of friction modifiers is not approved in Dana drive axles 1 Park the vehicle on level ground set the parking brakes and chock the tires 2 Clean the fill plug and the area around it In the axle housing rear cover remove the plug from the oil fill hole or standpipe if installed in the oil fill hole See Fig 3 3 Place a drain pan under the rear axle drain plug See Fig 3 Drain the oil at normal operating temperature 150 F to 200 65 C to 93 C At Columbia Maintenance Manual July 2005 35 3 35 Rear Axle f350018a 2 Oil Drain Plug 05 27 93 1 Oil Fill Plug Fig 3 Axle Housing Drain and Fill Plugs this temperature the oil will run more freely and ensure that the axle is flushed NOTE Some tandem drive axles are equipped with a cylindrical magnetic strainer located below the lube pump on the front of the power divider cover All rear axles are fitted with mag netic drain and fill plugs 4 At each axle oil chan
27. hinges every six months Using an appropriate applicator force a moly impregnated NLGI grade 2 grease into the hinge components Wipe off any excess grease In general light penetrating oils such as WD 40 should not be used because they wash out beneficial factory installed grease and they evaporate Door Checks Lubricate door checks at installation and every six months thereafter with moly impregnated NLGI grade 2 grease Columbia Maintenance Manual October 2005 72 1 12 Doors 1720613 8 24 2005 A Hinge installed on or after 8 1 2005 with dimple in the top loop of the hinge bracket Do not lubricate B Hinge installed before 8 1 2005 Lubricate according to recommendations Fig 1 Door Hinge Identification 72 2 Columbia Maintenance Manual October 2005 83 Heater and Air Conditioner Title of Maintenance Operation MOP Air Conditioner Inspection 00000 eee eee Air Filter Replacement aces o d pei ACRES das Index Alphabetical MOP Number Columbia Maintenance Manual October 2002 Heater and Air Conditioner 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 ap
28. 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 des iccant cartridge NOTE A substantial torque up to 50 Ibf ft 68 N m may be necessary to remove the desic cant 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 A 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 desiccant 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 Ibf ft 68 N m 15 Place the housing over the desiccant cartridge and align the mounting holes with the end cover IMPORTANT Replace do not reuse the Nylok nuts on the air dryer cover 16 Install the 6 capscrews 12 washers and 6 new Nylok nuts Torque the capscrews in a star pat tern 270 to 385 Ibf in 3060 to 4340 N cm See Fig 2 17 Install the air drye
29. intervals for your vehicle you must first determine the type of ser vice 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 Il Ill or IV that applies to the intended use of the ve hicle 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 opera tions to be performed at that maintenance interval Use the maintenance operation reference numbers to find detailed instructions in the manual on each op eration Types of Service Service Schedule severe service applies to ve hicles that annually travel less than 6000 miles 10 000 kilometers or that operate under severe condi tions Examples of severe service Schedule usage include operation on extremely poor roads or where there is heavy dust accumulation constant exposure to extreme hot cold salt air or other extreme cli mates frequent short distance travel construction site operation city operation fire truck or farm operation Service Schedule Il short haul transport applies to vehicl
30. intervals of shrill noises when the vehicle oper ates at low speed or when the vehicle makes sharp turns Use a limited slip friction modifier to correct this slip stick condition Add 1 6 ounces 35 mL of additive for each pint 0 5 L of lube capacity For all GL 5 oils add one of the following limited slip friction modifiers e Lubrizol No 6178 Lubrizol Corporation e DSL 178 Guardsman Products e Equa Torque No 2411 Sta Lube Corporation e Equa Torque No 2414 Sta Lube Corporation IMPORTANT These friction modifiers generally deteriorate faster than conventional extreme pressure additives so the lubricant change schedule must be shortened when using these additives The traction equalizer additive and 35 recommended drive axle lubricant must be changed at the Maintenance 2 M2 interval instead of the Maintenance 3 M3 interval rec ommended in the Maintenance Operation Chart for axles that require only those lubricants rec ommended in Table 1 1 Park the vehicle on level ground set the parking brakes and chock the front tires 2 Remove the axle carrier fill plug Then remove the drain plug from the bottom of the housing Completely drain the lubricant while the unit is warm to allow the lubricant to drain faster On tandem drive axles it is also necessary to remove the plug at the bottom of the interaxle differential housing to drain that lubricant 3 If equipped with an oil pump remove the
31. leak is detected remove the fan blade In stall a new seal kit See Group 20 of the Columbia Workshop Manual for repair proce dures 10 Check the fan drive for discoloration or any other signs of slipping or overheating NOTE The fan clutch may slip if the air supply pressure is below 70 psi 483 kPa or if there is a leak inside the fan clutch Any leak must be remedied 11 Check the fan clutch bearings 11 1 Turn the fan in both directions and feel for worn hub bearings 11 2 If possible remove the drive belt and check for worn sheave bearings by turn ing the sheave in both directions 11 3 If either the hub or sheave bearings are worn replace them using a Horton Drive Master Super Kit For instructions and kit part number see Group 20 of the Columbia Workshop Manual 20 8 Columbia Maintenance Manual January 2007 Clutch 25 Index Alphabetical Title of Maintenance Operation MOP MOP Number Clutch Release Gross Shaft Eubfication 322 aee seem kx DE DR ER BE RR RD BE dr x need BAG 25 02 Eaton Fuller Clutch Release Bearing Lubrication liiis 25 01 Meritor Clutch Release Bearing Lubrication lille 25 04 Sleeve Assembly Bronze Bushing Lubrication lille 25 03 Columbia Maintenance Manual April 2005 Clutch 25 01 Eaton Fuller Clutch Release Bearing Lubrication The standard clutch release bearing is not sealed and requires lubrication If the vehi
32. movement or looseness is detected go to the next step 6 Check the wheel to hub mounting Make sure the wheel and tire assembly is mounted correctly and that all hardware is secure 7 Apply the service brakes to lock the hub and axle spindle together Check again for movement and looseness If movement is detected the king pin or king pin bushings are probably worn If applying the service brake eliminates the movement the problem is probably caused by incorrect wheel bearing end play Go to End Play Check Meritor Unitized Wheel Ends 33 08 End Play Check Meritor Unitized Wheel Ends 1 Park the vehicle on a level surface set the park ing brakes shut down the engine and chock the rear tires 2 Remove the hub cap 3 Raise the vehicle until the front tires clear the ground Support the vehicle with safety stands Never work under a vehicle that is supported only by a jack Jacks can slip causing the vehicle to fall This could result in serious injury or death Front Axle 4 Remove the tire and wheel assembly NOTE It is normal for small amounts of grease to be visible around the inner and outer wheel bearings 5 Remove the brake drum If needed back off the slack adjuster 6 Attach the magnetic base of a dial indicator to the end of the axle spindle 7 Touch the dial indicator stem to the surface of the hub making sure the stem is perpendicular to the surface of the hub 8 Set the d
33. pump does not labor when turning the wheel 12 Check for leaks in the power steering system and repair as needed Top off the power steering fluid level as needed Approved Power Steering Fluids Fluid Type Approved Fluid Automatic Transmission Dexron II Fluid Dexron III Shell Rotella T 30W Shell Rotella T SAE 30 Heavy Duty Engine Oil Chevron 10W 40 IMPORTANT Do not use Chevron Custom 10W 40 heavy duty engine oil on Mobil Super 10W 40 vehicles built from Texaco 10W 40 November 4 2002 Union 10W 40 Union 15W 40 Unocal Guardol 15W 40 Do not mix oil types Refer to the text in this group for a detailed warning statement Table 1 Approved Power Steering Fluids 46 03 Power Steering Fluid Level Inspection Apply the parking brakes and chock the tires 2 With the engine cool use a shop towel or a clean rag to clean the area around the power Steering reservoir fill cap Twist the cap counter clockwise to remove it Check the cold power steering fluid level The level should be between ADD COLD and FULL COLD with the engine off 3 Start the engine and run it at idle until it reaches operating temperature See Table 1 for recom mended power steering fluids Remove the dipstick and check that power steering fluid is between ADD HOT and FULL HOT If the fluid level is low add enough fluid to bring the level up to the FULL HOT mark on the dipstick Remove the chocks Steering
34. the bushings and pins to allow the proper flow of lubricant around them 3 Use a multipurpose chassis grease and lubricate the bronze ball indented bushings in the spring eyes at the grease fitting See Fig 10 Continue to lubricate until grease exits both ends of the bushing If the pin will not accept lubricant re move the pin and clean the lubrication channels where lubricant may have hardened Remove the safety stands 4 2 gt 3 V PIL ff f A J ll UN 7 L 2 4 1 09 15 95 1320424 1 Bronze Bushing 3 Grease Fitting 2 Lubrication Hole 4 Lubrication Groove Fig 10 Hendrickson RT2 and RTE2 Series Bushing Lubrication Neway No lubrication is required on Neway rear suspen sions Reyco No lubrication is required on Reyco rear suspen sions 32 03 Suspension U Bolt Torque Check 4h CAUTION Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 32 6 Columbia Maintenance Manual February 2010 Suspension 1 Park the vehicle on a flat surface and apply the parking brakes Chock the tires 2 Check the U bolt torque in a diagonal pattern Set a click type torque wrench to the highest torque value for the fastener being checked See Table 1 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks 3 Remove the chocks Spring Assembly U Bolt High Nut Torque Values Si
35. with bottom of fill hole with vehicle in normal operating position Table 3 Eaton Fuller Transmission Lubricant Capacities e 44 Ibf ft 60 N m for all ZF Meritor FreedomLine automated transmissions e 35 to 50 Ibf ft 48 to 67 N m for all other Meritor transmissions 9 Operate the vehicle to check for correct opera tion 26 2 Columbia Maintenance Manual April 2005 Transmission 26 02 Transmission Fluid Level Inspection 4h CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Overfilling will force fluid out of the case through the main shaft openings Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi tives friction modifiers extreme pressure gear fluids or multiviscosity lubricants With the transmission at operating temperature and the vehicle on a level surface check the fluid level in the transmission 1 Clean the area around the fill plug and remove it from the side of the gear case 2 Using your finger or a bent pipe cleaner see if the fluid is level with the fill opening See Fig 1 3 Ifthe fluid level is low check the transmission for leaks and correct as needed 4 f needed add the recommended fluid until it is level with the lower edge of the fill opening See Table 1 for approved transmission lubricants 5 Clean the fill
36. 0 11 Place the disconnected end of the steering gear to reservoir hose in the drain pan Raise the front of the vehicle with a floor jack and support it with jack stands Have someone turn the steering wheel to full lock left and right Capture the fluid flowing from the hose in the drain pan Add fluid to the reservoir as needed When clean power steering fluid flows from the hose remove the plug from the reservoir and reconnect the hose to the reservoir Remove the jack stands and lower the vehicle With the larger opening at the top install a new filter in the reservoir Clean the reservoir cover and gasket Inspect the O ring and the cover for cracks deformities or damage Replace the gasket seal or cover as needed Install the reservoir cover along with the spring and the top plate Make sure the center of the top plate fits into the opening at the top of the filter Place the clamp over the flanges of the cover and shell assembly then tighten 25 to 30 Ibf ft 35 to 40 N m Fill the power steering reservoir with approved power steering fluid to the FULL COLD mark See Table 1 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 level Add fluid as needed The system is Columbia Maintenance Manual February 2010 46 1 46 properly bled when the steering
37. 0 000 160 000 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 and II Columbia Maintenance Manual February 2010 00 3 00 General Information Vehicle Maintenance Schedule Tables 00 03 31st through 60th Maintenance for Service Schedules and II Maintenance Service Service Schedule I Service Schedule Il Maint No Interval Date Miles km Hours Miles km 31st M1 31 000 49 600 3100 310 000 496 000 32nd M1 32 000 51 200 3200 320 000 512 000 33rd M1 33 00
38. 0 52 800 3300 330 000 528 000 34th M1 34 000 54 400 3400 340 000 544 000 35th M1 and M2 35 000 56 000 3500 350 000 560 000 36th M1 36 000 57 600 3600 360 000 576 000 37th M1 37 000 59 200 3700 370 000 592 000 38th M1 38 000 60 800 3800 380 000 608 000 39th M1 39 000 62 400 3900 390 000 624 000 40th M1 and M2 40 000 64 000 4000 400 000 640 000 41st M1 41 000 65 600 4100 410 000 656 000 42nd M1 42 000 67 200 4200 420 000 672 000 43rd M1 43 000 68 800 4300 430 000 688 000 44th M1 44 000 70 400 4400 440 000 704 000 45th M1 M2 and M3 45 000 72 000 4500 450 000 720 000 46th M1 46 000 73 600 4600 460 000 736 000 47th M1 47 000 75 200 4700 470 000 752 000 48th M1 48 000 76 800 4800 480 000 768 000 49th M1 49 000 78 400 4900 490 000 784 000 50th M1 and M2 50 000 80 000 5000 500 000 800 000 51st M1 51 000 82 000 5100 510 000 820 000 52nd M1 52 000 83 700 5200 520 000 837 000 53rd M1 53 000 85 300 5300 530 000 853 000 54th M1 54 000 86 900 5400 540 000 869 000 55th M1 and M2 55 000 88 500 5500 550 000 885 000 56th M1 56 000 90 100 5600 560 000 901 000 57th M1 57 000 91 700 5700 570 000 917 000 58th M1 58 000 93 300 5800 580 000 933 000 59th M1 59 000 94 900 5900 590 000 949 000 60th M1 M2 and M3 60 000 96 500 6000 600 000 965 000 Table 3 31st through 60th Maintenance for Service Schedules and II 00 4 Columbia Maintenance Manual February 2010 General Information 00 Vehicle Maintenance Schedule Tables 00
39. 0 km or if the vehicle is equipped with another air dryer maintenance will have to be performed to the air brake valves See Group 42 of the Columbia Workshop Manual for procedures 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 1 Park the vehicle on a level surface and apply the parking brakes Shut down the engine Chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa A CAUTION The compressor discharge line may still contain residual air pressure 3 Identify tag and disconnect the three air lines from the end cover 4 Disconnect the harness connector from the heater and thermostat assembly 5 Loosen the capscrew that secures the upper mounting bracket strap 6 Remove the two capscrews that secure the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the capscrews to ease 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 6 capscrews 12 washers 6 Nylok nuts and the air dryer housing See Fig 1 Dis card the Nylok nuts Remove the end cover to housing O ring 9 Clamp the desiccant cartridge in a vise 42 A 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
40. 00 40 000 Optimized Vehicle Configuration E vehicles that annually travel over Maintenance 2 M2 every 100 000 161 000 60 000 miles 100 000 km Maintenance 3 M3 every 300 000 483 000 For Schedule severe service vehicles equipped with an hourmeter use maintenance intervals based on hours of operation rather than distance traveled t Use Schedule severe service maintenance intervals for vehicles that operate under severe conditions such as extremely poor roads heavy dust accumu lation extreme climate frequent short distance travel construction site operation city operation garbage truck or farm operation Table 1 Service Schedule 00 2 Columbia Maintenance Manual February 2010 General Information 00 Vehicle Maintenance Schedule Tables 00 03 1st through 30th Maintenance for Service Schedules and Il Maint No Maintenance Service Service Schedule I Service Schedule Il Interval Date 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 eth 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 10
41. 007 1230008 1230009 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 16 18 15 20 16 22 13 18 21 28 5 16 24 16 22 17 23 14 19 23 31 3 8 16 26 35 28 38 23 31 37 50 3 8 24 30 41 32 43 25 34 42 57 716 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2 20 72 98 77 104 65 88 102 138 9 16 12 92 125 98 133 80 108 130 176 9 16 18 103 140 110 149 90 122 146 198 5 8 11 128 173 136 184 110 149 180 244 5 818 145 197 154 209 130 176 204 277 3 410 226 306 241 327 200 271 320 434 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 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 18 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads Columbia Maintenance Manual February 2010 00 21 00 Torque Specifications Tables 00 13 General Information Torque Values for U S Customary Thread Fasteners With Dr
42. 2 of the Columbia9 Workshop Manual for instructions E 2 05 27 93 A Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer f320022a Fig 4 Side View of the Equalizer 7 With the vehicle unloaded attempt to move the equalizer side to side using a pry bar between the equalizer and frame rail Apply hand pressure only See Fig 5 If clearance between the equal izer assembly and any frame component or fas tener is less than 1 8 inch 3 mm replace the equalizer bushings See Group 32 of the Columbia Workshop Manual for instructions Freightliner AirLiner Suspension WARNING Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death Inspect the forward and rear spring brackets for wear cracks and other damage If any of these con 32 1 jy A Y A L 3 hd 05 27 93 5 f320023a A 1 8 8 mm Clearance 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar
43. 26 2002 FE 1831493 1 Air Filter Cover 2 Wire Retainer Fig 2 Receiver Drier not replaced every six months damage to the heater and air conditioner components could occur IMPORTANT When replacing the air filter use only a Freightliner approved air filter 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Lift the wire retainer on the air filter cover up and over the upper edge of the cover and pull the wire retainer down See Fig 3 3 Note the direction of the arrow on the air filter cover then remove the cover and the attached filter 4 Remove the air filter from the air filter cover Dis card the air filter 5 Attach a new air filter to the air filter cover Make sure the arrow on the filter is pointing in the same direction as the arrow on the cover Fig 3 HVAC Air Intake Plenum 6 Install the air filter and air filter cover in the HVAC air intake plenum 7 Pull the wire retainer up and over the upper edge of the air filter cover 8 Remove the chocks from the tires Cab Recirculation Air Filter Replacement Blend Air The cab recirculation air filter must be replaced every six months regardless of mileage to permit proper operation of the HVAC system 4h CAUTION If the recirculation air filter is not replaced every six months damage to the heater and air condi tioner components could occur The HVAC system should not be opera
44. 27 kPa Shut 20 08 08 94 COSS 1200290 1 System Sentry Fuse 4 Piston Friction Disc 2 Safeguard Hole 5 Air Chamber 3 Friction Facing Fig 5 Horton Advantage Fan Clutch down the engine Separate the halves of the fan solenoid connector The fan clutch should en gage If the fan does not operate correctly see Group 20 of the Columbia Workshop Manual for troubleshooting and repair procedures 8 With the air system charged to 120 psi 827 kPa and with the fan solenoid connector halves separated check the fan clutch for audible air leaks using a suitable listening device 9 If a leak is detected remove the fan blade Using a soapy water solution check the fan clutch at the following locations to find the source of the leak Install a new seal kit See Group 20 of the Columbia Workshop Manual for repair proce dures 9 1 Check for a leak at the bleed hole on the fan pilot Air leakage means the cartridge assembly Fig 6 Ref 16 or face seal Ref 17 is damaged 9 2 Check for air leaks between the air cham ber and the piston friction disc Air leak age means the large O ring Ref 14 is damaged 9 3 Check for air leaks around the safeguard hole on the piston friction disc Air leak age means the small O ring Ref 18 is damaged 9 4 Check for air leaking from the System Sentry fuse Leaking air means the clutch has gotten so hot the lead alloy in Columbia Maintenan
45. 4 4 After cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m 4 5 Coat the battery terminals with dielectric grease Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel after cleaning Columbia Maintenance Manual October 2008 15 1 Engine Cooling R adiator Title of Maintenance Operation MOP Fan Clutch Check Noise Emission Control Pressure Relief Cap Check 0 00 00 cece ee Radiator Pressure Flushing and Coolant Change 20 Index Alphabetical MOP Number Columbia Maintenance Manual January 2007 Engine Cooling R adiator 20 01 Pressure Relief Cap Check 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 seri ous personal injury 1 Remove the fill cap first to relieve the cooling system pressure then remove the SAE cap 2 Using a radiator cap tester check the pressure cap to see if it maintai
46. 5 4 Columbia Maintenance Manual July 2005 Rear Axle 35 Dana Spicer Drive Axle Recommended Lubricant the standpipe opening To check fluid level see Fig 2 Lubricant SAE Lubricant Type Condition Viscosity 6 2 Install and tighten the fill plug 40 to 60 Grade Ibf ft 54 to 81 Nm Dana Spicer Over the Road i j Roadranger Service 75W 90 Two Speed Axles With Shift Unit Synthetic Drive Axle a Lubricants or Off Highway Dana Spicer and Meritor i i Equipment or f 3 is ak cae Extra 80W 140 1 Remove the shift unit housing cover See Fig 5 MIL L 2105D Heavy Loads Drain and discard the old lubricant Discard the housing cover gasket Table 4 Dana Spicer Drive Axle Recommended Lubricant Dana Spicer Drive Axle Lubricant Capacities Capacity Axle Type Axle Model Pints liters Single Drive Axle Installation Single 23080S 23080D 40 18 9 Reduction 23105S 23105D 48 22 7 d Tandem Drive Axle Installation DD404 DD404 P 31 14 7 t Single E Reduction DS404 DS404 P 39 18 5 t DS461 P 43 20 3 t DT402 402 P 34 16 1 ipe EPES Pe 2 Speed dual Housing Cover Gaske EE i DT451 P 39 18 5 2 OilFill Plug DT461 P 43 20 3 t 3 Shift Unit Housing Cover Double DP451 P 34 16 1 T Fig 5 Two Speed Axle Shift Unit Reducti ET Ee DER IT 43 20 3 T 2 Thoroughly wash the axle shift parts and housing Quantities listed are approximat
47. 6 Tie Rod Lubrication Meritor Axles 0 00 SE SE Se SE has 33 03 Columbia Maintenance Manual October 2004 Front Axle 33 01 Knuckle Pin Lubrication Meritor Axles 4h CAUTION Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps When lubricating knuckle pin bushings do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease NLGI Grade 1 696 12 hydroxy lithium stearate grease or NLGI Grade 2 896 12 hydroxy lithium stearate grease until new grease is seen at the bushing grease seal opposite the fittings The grease seal will accept grease pres sure without damage and is designed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate gasket continue pumping until new grease is seen at the bushing seal opposite the grease fitting See Fig 1 09 06 96 1 A Grease Exit 1 Grease Fitting f320032a Fig 1 Meritor Knuckle Pin Lubrication 33 02 Tie Rod Inspection Inspect the tie rod ends as follows 1 Shake the cross tube A loose fit or movement between the tapered shaft of the ball and the 33 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 f
48. 8 12 2 Forward 29 3 13 9 RT 44 145 RT 44 145P Rear 25 1 11 9 Forward 39 1 18 5 RT 46 160 RT 46 160P Rear 34 4 16 3 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground t See Traction Equalizer Additives in the text Table 2 Meritor Drive Axle Lubricant Capacities 35 2 Columbia Maintenance Manual July 2005 Rear Axle 6 2 Install and tighten the fill plug 35 Ibf ft 47 N m 7 Whenever the interaxle differential housing has been drained add an additional 2 pints 0 9 L of the recommended lubricant directly into the inter axle differential housing 8 Remove the chocks then drive the vehicle un loaded for 1 or 2 miles 2 or 3 km at speeds not to exceed 25 mph 40 km h to thoroughly circulate lubricant throughout the carrier and housing assemblies Freightliner IMPORTANT On Freightliner axles the oil change interval for Schedule Ill and IV vehicles is extended to 500 000 miles 800 000 km for axles with weight ratings of 34 000 to 40 000 Ib 15 000 to 18 000 kg using synthetic lubricant Oil must be changed at least every four years and more often if the axle is exposed to high temperatures and steep grades 1 Park the vehicle on level ground set the parking brakes and chock the tires IMPORTANT Freightliner rear axles do not re quire the use of friction modifiers 2 Clean the fill plug
49. 8 4 Table 1 Drive Belt Tensions 01 2 Columbia Maintenance Manual January 2007 Engine 01 Spring Tension Type On belts equipped with a spring tensioner belt ten sion is automatically adjusted Check that the ten sioner is holding tension on the belt by inserting the end of a breaker bar in the 1 2 inch square hole on the forward face of the tensioner and rotating the tensioner away from the belt When the breaker bar is slowly released the tensioner should return to its original position The tensioner should rotate smoothly with no binding If not see Group 01 of the Columbia Workshop Manual for replacement in structions NOTE The following engines which appear in Table 1 are provided with automatic tensioners for the fan and alternator belts 01 03 Pacbrake Inspection and Lubrication With frequent use the Pacbrake Exhaust Brake will operate maintenance free If the vehicle is used in consistently or seasonally it will be necessary to per form preventative maintenance If the vehicle is ex posed to excess moisture or is used only for periodic or seasonal use perform the following steps 1 With the engine off use any oil free or non petroleum based high heat lubricant and spray or coat a sufficient amount on the restrictor valve shaft and the attaching locations at each end of the actuation cylinder 2 With your hands or a pair of pliers motion the valve several times to distribute
50. 81a Fig 1 Release Bearing Grease Fitting b ES 08 10 2009 1 Sleeve Bushing Contact Point 2 Yoke Finger Contact Points 250444 Fig 2 Grease the Contact Points See Fig 3 and Fig 4 Wipe any dirt from the grease fittings and lubricate with multipurpose chassis grease 25 03 Sleeve Assembly Bronze Bushing Lubrication Vehicles equipped with the sealed clutch release bearing require lubrication of the bronze bushing lo cated between the clutch bearing housing and the transmission input shaft Use a pressure type grease Columbia Maintenance Manual April 2005 25 1 25 10 19 93 1 Clutch Release Cross Shaft 2 Grease Fitting f250048a Fig 3 Cross Shaft Grease Fitting Left Side 05 27 93 f260146a Fig 4 Cross Shaft Grease Fitting Right Side gun equipped with high temperature grease only and lubricate until grease flows from the release bearing housing Depress the clutch pedal a couple of times before starting the engine 25 04 Meritor Clutch Release Bearing Lubrication The standard clutch release bearing is not sealed and requires lubrication If the vehicle is not equipped with an optional sealed clutch release bear ing with a grease fitting lubricate the bearing as follows Clutch 1 Park the vehicle on a level surface Apply the parking brakes and
51. 850 000 1 370 000 86th M1 86 000 138 400 8600 860 000 1 384 000 87th M1 87 000 140 000 8700 870 000 1 400 000 88th M1 88 000 141 600 8800 880 000 1 416 000 89th M1 89 000 143 200 8900 890 000 1 432 000 90th M1 M2 and M3 90 000 144 800 9000 900 000 1 448 000 Table 4 61st through 90th Maintenance for Service Schedules and II Columbia Maintenance Manual February 2010 00 5 00 General Information Vehicle Maintenance Schedule Tables 00 03 91st through 100th Maintenance for Service Schedules and Il Maint No Maintenance Service Service Schedule I Service Schedule Il Interval Date Miles km Hours Miles km 91st M1 91 000 146 500 9100 910 000 1 465 000 92nd M1 92 000 148 100 9200 920 000 1 481 000 93rd M1 93 000 150 000 9300 930 000 1 500 000 94th M1 94 000 151 300 9400 940 000 1 513 000 95th M1 and M2 95 000 153 000 9500 950 000 1 530 000 96th M1 96 000 155 000 9600 960 000 1 550 000 97th M1 97 000 156 100 9700 970 000 1 561 000 98th M1 98 000 157 700 9800 980 000 1 577 000 99th M1 99 000 159 300 9900 990 000 1 593 000 100th M1 and M2 100 000 160 900 10 000 1 000 000 1 609 000 Table 5 91st through 100th Maintenance for Service Schedules and Il 1st through 20th Maintenance for Service Schedules Ill and IV Maint No Maintenance Interval soi EE on IE dd ate Miles km 1 IM and M1 25 000 40 000 2 M1 50 000 80
52. 90 000 38 M1 950 000 1 529 000 39 M1 975 000 1 569 000 40 M1 and M2 1 000 000 1 609 000 Table 7 21st through 40th Maintenance for Service Schedules III and IV Columbia Maintenance Manual February 2010 00 7 00 Lubrication and Fluid Level Check 00 04 Maintenance Operation 00 04 Lubrication and Fluid Level Check Operation Table 8 summarizes all op erations that must be performed to complete the Lu brication and Fluid Level Check operation 00 04 called for as an M1 maintenance interval for Service Schedule I Il and Ill vehicles and as an M2 mainte nance interval for Service Schedule IV vehicles General Information Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check Maintenance Operation 00 04 Lubrication and Fluid Level Check for Service Schedules I Il Ill and IV Maint Service Service Operation Operation Description Schedules I Il Schedule IV Check Number and Ill at M1 at M2 25 01 Eaton Fuller Clutch Release Bearing Lubrication 25 02 Clutch Release Cross Shaft Lubrication 25 03 Sleeve Assembly Bronze Bushing Lubrication 26 02 Transmission Fluid Level Inspection 31 02 Fifth Wheel Lubrication 31 04 Trailer Electrical Connector Lubrication 32 02 Suspension Lubrication 33 01
53. Cap Check 20 02 Radiator Pressure Flushing and Coolant Change 20 03 Fan Clutch Check noise emission control 25 01 Eaton Fuller Clutch Release Bearing Lubrication 25 02 Clutch Release Cross Shaft Lubrication 25 03 Sleeve Assembly Bronze Bushing Lubrication 25 04 Meritor Clutch Release Bearing Lubrication 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning 7 Synthetic Lubricant 26 02 Transmission Fluid Level Inspection 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 03 Frame Fastener Torque Check 31 04 Trailer Electrical Connector Lubrication 32 01 Suspension Inspection 32 02 Suspension Lubrication 32 03 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication Meritor Axles 33 02 Tie Rod Inspection 33 03 Tie Rod Lubrication Meritor Axles 33 04 All Axle Alignment Check 33 05 Knuckle Pin Lubrication Dana Spicer Axles 33 06 Tie Rod Lubrication Dana Spicer Axles 33 07 Basic Inspection Meritor Unitized Wheel Endst 33 08 End Play Check Meritor Unitized Wheel Endst Columbia Maintenance Manual February 2010 00 15 00 General Information Maintenance Operation Sets T
54. 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 Columbia Workshop Manual for clutch lining replacement instructions 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 7 Connect the battery cables Start the engine Horton DriveMaster Fan Clutch NOTE If any part of the fan clutch needs to be repaired or replaced after performing the checks below see Group 20 of the Columbia Work shop Manual 1 Disconnect the batteries at the negative termi nals Drain all air from the air system If equipped with an air starter drain the air starter reservoir Make sure the batteries are disconnected before checking the fan clutch If the engine starts during this procedure the fan could engage which could result in serious personal injury 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filter if equipped 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment 3 2 Clean the filter element with cleaning sol vent 3 3 Using a clean lint free cloth wipe off any excess solvent 3 4 Reassemble the clutch valve solenoid air fil
55. FREIGHTLINER Run Smart COLUMBIA MAINTENANCE MANUAL Models CL112 CL120 STI 409 2 2 10P 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 Descri
56. Perform All M1 Operations 00 07 Perform All M2 Operations 09 01 Air Cleaner Element Inspection and Replacement 20 02 Radiator Pressure Flushing and Coolant Change 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning synthetic lubricant 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning synthetic lubricant 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 42 09 Bendix AD IS Air Dryer Desiccant Replacement 42 10 Bendix E 6 Foot Control Valve Inspection and Lubrication 46 02 Power Steering Fluid and Filter Change Table 14 M3 Maintenance Interval Operations for Service Schedules Il IIl and IV 00 14 Columbia Maintenance Manual February 2010 General Information 00 Maintenance Operation Sets Table 00 09 Maintenance Operation Sets for Groups 00 through 83 god Operation Description md ek al Service oe IM M1 M2 M3 IM M1 M2 M3 00 04 Lubrication and Fluid Level Check 01 01 Engine Support Fasteners Check noise emission control 01 02 Engine Drive Belt Inspection 01 03 Pacbrake Inspection and Lubrication 09 01 Air Cleaner Element Inspection and Replacement 13 01 Bendix Air Compressor Inspection 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief
57. Replacement ConMet Fuel Separator Sight Bowl Cleaning The only maintenance necessary on ConMet fuel separators is to clean the sight bowl if equipped See Fig 1 Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain the fuel separator 2 Unscrew the sight bowl from the fuel separator 3 Wipe the sight bowl clean using a soft cloth 4 Lubricate the gasket with a film of oil and rein stall it on the sight bowl If the gasket appears dry rotted or damaged replace the gasket 5 Lightly lubricate the threads on the sight bowl with oil then thread the sight bowl into the bot tom of the fuel separator 6 Hand tighten until the gasket is in full contact with the fuel separator then tighten an additional 1 4 to 1 3 turn 7 Check that the drain valve is tightened and closed 8 Prime the fuel separator 8 1 Remove the vacuum breaker fitting and fill the unit with diesel fuel 8 2 Install and close the vacuum breaker fit ting when the unit is full of fuel 47 2 3 3 4 5 6 7 8 9 10 08 25 95 1470146 1 Vacuum Breaker Drain 6 Heater Assembly Valve 7 Gasket
58. Shock Absorbers e All Other Frame Fasteners 31 6 Columbia Maintenance Manual October 2008 Suspension Title of Maintenance Operation MOP Suspension INSPECTION ss aaa dee BE cp ae MEDE HER Suspension Lubrication 44 csa aaa EE a ee ee ee Suspension U Bolt Torque Check a 32 Index Alphabetical MOP Number Columbia Maintenance Manual February 2010 Suspension 32 01 Suspension Inspection Front Suspension Check Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death Inspect the front spring assemblies for cracked bro ken or abnormally bent leaves If any of these condi tions exist replace the spring assembly See Group 32 of the Columbia Workshop Manual for instruc tions Composite Springs The Commercial Vehicle Safety Alliance CVSA de fines a crack that causes out of service conditions for composite spring assemblies as a separation in any axis which passes completely through the composite spring materia
59. able 00 09 Maintenance Operation Sets for Groups 00 through 83 EE Operation Description em em Service ee IM M1 M2 M3 IM M1 M2 M3 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning synthetic lubricant 35 02 Axle Breather and Axle Lubricant Level Inspection 40 01 Wheel Nut Check 41 01 Driveline Inspection 41 02 Driveline Lubrication 42 01 Air Brake System Valve Inspection 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 42 05 Dana Spicer Camshaft Bracket Lubrication 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 42 07 Meritor Camshaft Bracket Lubrication 42 08 Meritor Slack Adjuster Lubrication 42 09 Bendix AD IS Air Dryer Desiccant Replacement 42 10 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 11 Brake Inspection 46 01 Drag Link Inspection 46 02 Power Steering Fluid and Filter Change 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Steering Inspection 47 01 Fuel Filter Replacement 47 02 Fuel Separator Sight Bowl Cleaning and El
60. ace the suspension crossmember or gussets if they are cracked worn or otherwise damaged could result in damage to the vehicle chassis 3 Without detaching the torque arms attempt to move by hand each radius rod end up down in and out If there is any movement replace the torque arm If a torque arm needs to be re placed see Group 32 of the Columbia Work shop Manual for instructions 4 nspect 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 3 Re place the torque arm for any of the following rea sons e if there are gaps between the rubber bush ing and the pin or outer steel sleeve e if either bushing end contacts a torque arm pin mounting bolt e if there are cracks in the bushing e if part of the rubber bushing extends be yond the outer circumference of the outer bushing sleeve 05 27 93 f320021a Fig 3 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 32 2 Columbia Maintenance Manual February 2010 Suspension bracket apply hand pressure only See Fig 4 If movement at the center of the equalizer exceeds 1 8 inch 3 mm replace the equalizer bushings See Group 3
61. aced the brake linings could become contaminated with grease The stopping distance of the vehicle will be increased which could result in personal injury or property damage 42 08 Meritor Slack Adjuster Lubrication IMPORTANT Perform MOP 42 11 before lubri cating the slack adjusters NOTE If equipped with an extended maintenance Q Plus brake system the slack adjuster will not have a grease fitting These slack adjusters use a special NLGI grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance slack adjusters are lubricated dur ing the brake reline service interval For service and lubrication instructions see Group 42 of the Columbia Workshop Manual For slack adjusters with grease fittings and for oper ating temperatures above 40 F 40 C use a NLGI Grade 1 clay base grease or a NLGI Grade 1 or 2 lithium base grease For slack adjusters with grease fittings and for oper ating temperatures below 40 F 40 C and above 65 F 54 C use a NLGI Grade 2 synthetic oil clay base grease Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure relief capscrew or past the gear splines around the inboard snap ring See Fig 7 42 09 Bendix AD IS Air Dryer Desiccant Replacement 1 Park the vehicle on a level surface and apply the parking brakes Shut down the e
62. ach pole Magnets will rapidly lose their effectiveness as collected material bridges the gap between the two poles 5 3 Each time the oil is changed replace any magnetic drain plug that does not meet the minimum pickup capacity NOTE Meritor recommends plugs with ele ments having a minimum pickup capacity of 1 5 pounds 0 7 kg of low carbon steel 5 4 After cleaning install the drain plug s and tighten to 35 Ibf ft 47 Nm Fill the axle with recommended lubricant See Table 2 for drive axle lubricant capacities NOTE Some Meritor axles have a small tapped and plugged hole near and below the housing lubricant fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 6 1 With the vehicle on a level surface fill the axle through the oil fill hole Lubricant should be level with the bottom of the oil fill hole To check fluid level see Fig 2 08 17 2009 A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole f350061a Fig 2 Axle Lubricant Level Inspection Meritor Drive Axle Lubricant Capacities Axle Model Capacity pt L Single Drive Single Reductiont RS 21 160 39 5 18 7 RS 23 160 39 5 18 7 RS 23 161 37 2 17 6 RS 23 185 47 3 22 4 RS 25 160 37 2 17 6 Tandem Drive Single Reduction RT 40 145 RT 40 145A Forward 30 2 14 3 RT 40 145P Rear 25
63. air dryer mounted on the right hand frame rail located directly behind the front bumper with heater and a Bendix air com pressor e TRW TAS65 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 Columbia Maintenance Manual February 2010 00 1 00 Service Schedule Table 00 02 General Information Service Schedule Maintenance Interval Operation Maintenance Interval Frequency Miles km Hours Initial Maintenance IM first 1000 1600 50 Schedule I Severe Service Maintenance 1 M1 every 1000 1600 50 vehicles that annually travel less Maintenance 2 M2 every 5000 8000 500 than 6000 miles 10 000 km Maintenance 3 M3 every 15 000 24 000 1500 Initial Maintenance IM first 10 000 16 000 Schedule Ilt vehicles that annually travel less Maintenance 2 M2 every 50 000 80 000 than 60 000 miles 100 000 km Maintenance 3 M3 every 150 000 240 000 Initial Maintenance IM first 25 000 40 000 Schedule lt Long Haul Transport Maintenance 1 M1 every 25 000 40 000 vehicles that annually travel over Maintenance 2 M2 every 100 000 161 000 60 000 miles 100 000 km Maintenance 3 M3 every 300 000 483 000 Schedule IVt Initial Maintenance IM first 25 000 40 000 Long Haul Transport for Maintenance 1 M1 every 25 0
64. aired or replaced after performing the checks below see Group 20 of the Columbia Workshop Manual 1 Disconnect the batteries at the negative termi nals Drain all air from the air system If equipped with an air starter drain the air starter reservoir 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 filler and remove its element 3 2 Clean the filter element with cleaning sol vent 3 3 Reassemble the clutch valve solenoid air filter then install it 4 Check the fan for bent cracked or damaged blades Replace if damaged Check for adequate clearance between the fan and other compo nents 5 Check the fan belt for wear tension and align ment Correct as needed 6 Check for wear on the friction facing See Fig 5 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 Start the engine and charge the air system to 120 psi 8
65. all old grease and dirt from each U joint grease fitting See Fig 5 Ref 8 3 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 4 Tighten the bearing 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 damage If the seal is damaged replace the complete U joint 5 f grease does not appear at one seal use a pry ing tool to pry the U joint trunnion away from the non purging seal or tap the driveshaft or yoke 10 20 93 l f410050a A ONDA wh 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 Fig 5 Slip Joint and U
66. and the area around it In the axle housing rear cover remove the plug from the oil fill hole 3 Place a drain pan under the rear axle drain plug Drain the oil when it is warm At this tempera ture the oil will run more freely and ensure that the axle is flushed 4 Clean the fill and drain plugs Change them if necessary 4 1 For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 4 2 Clean away the collected material depos ited on each pole Magnets will rapidly lose their effectiveness as collected mate rial bridges the gap between the two poles 4 3 After the first oil is changed inspect the drain plug each time for large quantities of metal particles 35 4 4 After cleaning install the drain plug s and tighten to 41 Ibf ft 55 N m 5 Fill the axle with the recommended lubricant See Table 3 for recommended drive axle lubri cants and drive axle lubricant capacities Freightliner Rear Axle Approved Lubricant Type and Capacity Cil Capacity Quarts liters Lubricant Type Axle Hubs Hubs Full Dry 80W 90 Gear Oil a Forward 14 3 15 9 75W 90 Synthetic Tandem 13 5 15 0 Gear Oil 80W 90 Gear Oil Single amp Rear 10 6 12 2 75W 90 Synthetic Tandem 10 0 11 5 Gear Oil Table 3 Freightliner Rear Axle Approved Lubricant Type and Capacity NOTE Some Freightliner axles
67. ap tet raseal 3 Remove the capscrews and reservoir from the cover Remove the cover tetraseal 5 Drain the air tank and disconnect the line from the evaporator outlet Remove the check valve retainer spring and disc 6 Install the disc spring and check valve retainer and connect the line to the evaporator outlet Install the cover tetraseal 8 Install the reservoir on the cover and tighten the capscrews 9 Fill the reservoir with 40 ounces 1183 mL of methyl alcohol then install the filler cap 10 Remove the chocks from the tires 42 05 Dana Spicer Camshaft Bracket Lubrication IMPORTANT Perform MOP 42 11 before lubri cating the camshaft bracket Pump grease into the camshaft bracket until it ap pears at the slack adjuster end of the bracket See Fig 4 Use an NLGI Grade 1 or Grade 2 multipurpose chas sis grease If grease leaks out under the camhead the camshaft bracket grease seal is worn or dam aged replace it See Group 42 of the Columbia Workshop Manual for grease seal replacement instructions 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication IMPORTANT Perform MOP 42 11 before lubri cating the slack adjusters 42 4 Columbia Maintenance Manual January 2008 Brakes 42 05 28 93 A Grease Exit 1 Brake Chamber 2 Slack Adjuster f420011a 3 Non Pressure Relief Grease Fitting Fig 4 Camshaft Bracket Lubrication Automati
68. arate grease or NLGI Grade 2 896 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 07 Basic Inspection Meritor Unitized Wheel Ends 1 Park the vehicle on a level surface set the park ing brakes shut down the engine and chock the rear tires 2 Raise the vehicle until the front tires are clear of the ground Support the vehicle with safety stands Never work under a vehicle that is supported only by a jack Jacks can slip causing the vehicle to fall This could result in serious injury or death IMPORTANT A clicking sound while rotating the wheel end hub is normal and does not indicate a problem Columbia Maintenance Manual October 2004 33 3 33 3 Rotate the tire and hub assembly They should rotate smoothly and without noise Grasp the brake chamber while rotating the hub to detect any hub vibration If the hub rotates smoothly go to the next step If the tire and hub assembly do not rotate smoothly or you hear noise during rotation go to End Play Check Meritor Unitized Wheel Ends 4 Grasp the tire and hub assembly at the 3 o clock and 9 o clock positions Using about 50 pounds 23 kg of force check for vertical and horizontal movement 5 f no movement or looseness is detected raise the vehicle to remove the safety stands lower the vehicle and remove the chocks from the tires If any
69. ation 01 Index Alphabetical MOP Number Columbia Maintenance Manual January 2007 Engine 01 01 Engine Support Fasteners Check Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance Mounts should be inspected when the engine is re moved for service For vehicles manufactured prior to January 2007 perform the following check Check the rear engine support fasteners see Fig 1 Ref 4 for tightness Tighten the 3 4 inch fasteners 215 to 265 Ibf ft 292 to 359 N m Check the front engine support fasteners for tight ness Tighten the 5 8 inch fasteners 125 Ibf ft 170 N m NOTE At engine overhaul and whenever the engine has been removed inspect the lower and upper isolators Refs 1 and 6 and replace them if they are worn See Group 01 of the Columbia Workshop Manual for procedures 10 05 94 2200472 1 Lower Isolator Engine Support Washer 3 4 10 Capscrew 3 4 10 Hexnut Engine Mount Upper Isolator EET IS Fig 1 Engine Rear Mount 01 02 Engine Drive Belt Inspection Worn or loose drive belts may cause premature bearing failure or engine overheating Excessive ten 01 sion or too little tension on the belt may result in ex cessive and premature belt wear Poly V belts or serpentine belts are retained by a belt tensioner that requires no tension adjustment Replace the drive belt if any conditions de
70. bf ft N m 10 Hole and 8 Hole Hub Piloted Disc Wheel With Two Piece Flange Nuts Front and Rear Wheel Nut M22 x 1 5 All 450 500 610 678 Nuts on Double Threaded Wheel Studs M22 x 1 5 All 390 450 529 610 Double Threaded Wheel Stud Retainer Nut 3 4 16 All 175 200 235 270 10 Hole Stud Piloted Disc Wheel With Inner and Outer Nuts Front Wheel Nut 1 1 8 16 All 450 500 610 678 Rear Wheel Inner Nut 3 4 16 All 450 500 610 678 Rear Wheel Outer Nut 1 1 8 16 All 450 500 610 678 Torque values for hub piloted wheels are given for lubricated threads Lubricate threads with SAE 30W engine oil Do not apply thread lubricant to ball seats of the nuts and wheels Wipe it off if it is applied accidentally t Torque values for stud piloted wheels are given for clean dry threads Table 1 Disc Wheel Fastener Torques Columbia Maintenance Manual April 2005 40 1 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveiie INGPEGIO Nama Regine eae cet hd DS EER E Dw E up ra Steere Sees dau ere 41 01 Diveline EW OMCAUOM iS RED ANA EAS o are ded EO dU lu oder d Er ot o Bde coat a dome GO DOE 41 02 Columbia Maintenance Manual March 2000 Driveline 41 01 Driveline Inspection 41 1 Park the vehicle on a flat level surface apply the parking brakes and chock the tires 4h CAUTION Due to the extreme load occurring at high speed rota
71. c slack adjusters that have a grease fitting must be lubricated periodically to ensure proper brake operation Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death Dana Spicer and Haldex 4h CAUTION Do not use moly disulfide loaded grease or oil Both the life and reliability of the slack adjuster will be reduced if this type of grease is used Lubricate the automatic slack adjuster at the grease fitting See Fig 5 Use standard chassis lubricant for Haldex slack adjusters Dana Spicer Low Lube slack adjusters should be lubricated with SHC 460 syn thetic lubricant Gunite For operating temperatures of 20 F 29C 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 02 01 2001 1 Grease Fitting 1421649a 2 Slack Adjuster Fig 5 Dana Spicer Automatic Slack Adjuster Lubricate a Gunite automatic slack adjuster at the grease fitting until grease appears on the camshaft or flows from the grease relief See Fig 6 The newest Gunite automatic slack adjusters are produced without a grease relief During lubrication with a grease gun lubricant is forced through the drilled worm wheel onto the camshaft Lubricate the automatic slack adjuster at the grease fitting until grease appears on the camshaft See
72. ce Manual January 2007 20 5 20 Engine Cooling R adiator 03 30 95 CONDOS 1 Mounting Bracket 2 Rear Sheave Bearing 3 Inner and Outer Bearing Friction Facing Journal Spacer Socket Head Capscrew 24 9 Rear Hub Bearing 10 Bearing Spacer 11 Splined Hub Spacers 12 Forward Hub Bearing Forward Sheave Bearing 13 Piston Friction Disc Sheave 14 Large O Ring 15 Locknut 16 Cartridge Assembly f200194a 17 18 19 20 21 22 23 24 Face Seal Small O Ring Air Chamber Socket Head Capscrew Stud Bolt Lockwasher Hexnut Piston Assembly Fig 6 Horton Advantage Fan CI the fuse melted This released the clutch before the heat could damage the clutch bearings Before replacing the fuse find and repair the source of the heat 10 If equipped with an override toggle switch on the dash check fan clutch operation as follows utch Components 10 4 Set the toggle switch to ON the fan clutch should engage 10 5 Apply the foot brake and release the parking brakes 10 6 Set the toggle switch to AUTO or OFF air should exhaust and the fan clutch should 10 1 Connect the halves of the fan solenoid disengage Replace the switch if neces connector sary 10 2 Turn off the air conditioner 11 If the fan stays engaged at all times on a Detroit 10 3 Start the engine and charge the air sys ot cheek the circul breaker lahelod tem to 120 psi 827 kPa Tests must be g j perfor
73. charger DOC Temperature Sensor ATD Mounting Band DPF Intake Pressure Sensor DPF V Band Mounting Clamps Sensor Housing DPF Outlet Temperature Sensor Exhaust Outlet Marmon Fitting DPF Outlet Pressure Sensor NAGA OO ND Fig 4 Typical After Treatment Device 49 2 Columbia Maintenance Manual January 2007 Exhaust the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage See Item A of Fig 4 A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing i
74. cle is not equipped with an optional sealed clutch release bear ing lubricate the bearing as follows 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Remove the clutch inspection plate NOTE Some clutch release bearings are equipped with a lubrication extension that ex tends outside of the clutch housing It is not necessary to remove the clutch inspection plate when the lubrication extension is used NOTE For lubrication of the release bearing Eaton Fuller recommends a lithium base high temperature grease that meets the NLGI grade one or two specification 3 Wipe any dirt away from the grease fitting See Fig 1 Using a pressure type grease gun equipped with the recommended grease lubri cate the bearing until excess grease purges from the rear of the release bearing toward the transmission 4h CAUTION Do not over lubricate the clutch release bearing Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature failure Do not use chassis grease or multipurpose lubricants 4 Wipe off excess grease and apply to both the yoke finger and sleeve bushing contact points See Fig 2 5 Install the clutch inspection plate then remove the chocks 25 02 Clutch Release Cross Shaft Lubrication The clutch release cross shaft is equipped with two grease fittings in the transmission clutch housing 25 05 27 93 f2500
75. ded 7 Remove the chocks from the tires Two Speed Axles With Shift Unit Dana Spicer and Meritor A CAUTION Failure to keep lubricant at the specified level could cause damage to the axle shift unit 1 Clean the shift unit oil fill plug and the area sur rounding the plug See Fig 5 Turn the fill plug counterclockwise to remove it 2 Insert a finger or pipe cleaner into the fill plug hole and check the fluid level The lubricant should be level with the bottom of the fill hole If low add the recommended lubricant 4h CAUTION Before adding additional lubricant make sure of the type currently in the shift unit To prevent component damage do not mix engine oil with automatic transmission fluid IMPORTANT When the ambient temperature is above O F 18 C use SAE 10 heavy duty en gine oil API service classification SD sulfated ash content must not exceed 1 85 When the ambient temperature is below 0 F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classification 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 3 Coat the threads of the fill plug with a small amount of Loctite 242 or equivalent sealant Install
76. e Fill axle until lubricant is level with bot cover and allow them to air dry tom of fill hole with vehicle on level ground t Add 2 pints 1 L of additional lubricant to the power divider Table 5 Dana Spicer Drive Axle Lubricant Capacities NOTE Some Dana Spicer axles have a small tapped and plugged hole near and below the housing oil fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 6 1 With the vehicle on a level surface fill the axle through the oil fill hole or standpipe opening Lubricant should be level with the bottom of the oil fill hole or the top of 3 Install the housing cover and a new cover gas ket Tighten the housing cover capscrews 90 to 110 Ibf in 1020 to 1240 N cm then remove the oil fill plug from the cover IMPORTANT When the ambient temperature is above 0 F 18 C use SAE 10 heavy duty en gine oil API service classification SD sulfated ash content must not exceed 1 85 When the ambient temperature is below 0 F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Columbia Maintenance Manual July 2005 35 5 35 Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be
77. e and is located be 7 A 9 tween the transmission and the fluid cooler The H E j filter bracket is attached to the frame rail or KOLLA ok ELF some other near by location The filter is mounted in a vertical position and should be 05 27 99 eons filled with fluid before installation to assure the A Full B Low proper fluid level For optimum transmission per Fig 1 Checking Transmission Fluid Level Columbia Maintenance Manual April 2005 26 1 26 Transmission Approved Manual Transmission Lubricants Transmission x Temp SAE Model Lubricant Type Range Viscosity Eaton Fuller Transmissionst MobilTrans SHC 50 RN 2952 E 5 AR All Eaton f mE Fuller Synthetic transmission lubricant approved by All 50W Eaton Meritor Transmissions R MobilTrans SHC 50 FreedomLine RN 2952 E 5 All 50W Synthetic engine oil All other meeting Meritor spec Meritor 0 81 or MIL I 2104D 50W or 2104E Do not mix types or brands of fluid Multi weight and extreme pressure gear fluids are not recommended T Call 1 800 826 4357 for a complete list of Eaton approved lubricants Table 1 Approved Manual Transmission Lubricants Meritor Transmission Lubricant Capacities Transmission Model Refill Capacity qt L Meritor M MO Series M MO all 10 25 9 7 ZF Meritor FreedomLine All 12 Speed Models 11 6 11 0 All 16 Speed Models 12 5 11 8 Quantities listed are appro
78. e Slack Adjuster Lubrication e Door Seal Door Latch and Door Hinge Lubrication 13 01 Bendix Air Compressor Inspection 20 03 Fan Clutch Check noise emission control 31 01 Fifth Wheel Inspection 41 01 Driveline Inspection 42 11 Brake Inspection 49 01 Exhaust System Inspection noise emission control Table 10 M1 Maintenance Interval Operations for Service Schedules Il and Ill o Se Eed r M1 Maintenance Interval Operations for Service Schedule IV Check 13 01 Bendix Air Compressor Inspection 20 03 Fan Clutch Check noise emission control 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 04 Trailer Electrical Connector Lubrication 42 11 Brake Inspection 49 01 Exhaust System Inspection noise emission control 72 01 Door Seal Door Latch and Door Hinge Lubrication Table 11 M1 Maintenance Interval Operations for Service Schedule IV 00 10 Columbia Maintenance Manual February 2010 General Information 00 M2 Maintenance Interval Operations 00 07 The M2 Maintenance Interval Operations tables list you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed Perform all at the M2 maintenance interval Maintenance opera M1 maintenance interval operations at the M2 main tion numbers are reference numbers used to help tenance interval
79. eeper Air Filter Replacement Blend Air Replace the air filter in the sleeper HVAC unit every six months regardless of mileage The filter should not be cleaned 4h CAUTION If the sleeper air filter is not replaced every six months damage to the heater and air conditioner components could occur The HVAC system should not be operated without the recirculation air filter installed Fig 5 Sleeper HVAC Assembly Discard the air filter Place a new air filter in the sleeper HVAC as sembly The edge of the filter should be flush with the HVAC assembly Lower the bunk panel and mattress Remove the chocks from the tires Columbia Maintenance Manual October 2002 83 3
80. ement Replacement s 47 03 Fuel Tank Band Nut Tightening 49 01 Exhaust System Inspection noise emission control 72 01 Door Seal Door Latch and Door Hinge Lubrication 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement No specific lubrication interval See MOP 01 03 for more information t Inspect Meritor Unitized Wheel Ends at 200 000 miles 321 869 km and then every 50 000 miles 80 467 km t Check the end play at 200 000 miles 321 869 km and then every subsequent 200 000 miles 321 869 km Replace the HVAC filters every 6 months regardless of mileage Table 15 Maintenance Operation Sets for Groups 00 through 83 00 16 Columbia Maintenance Manual February 2010 General Information 00 Noise Emission Controls Maintenance 00 10 Noise Emission Control the purpose of noise control prior to its sale or Maintenance delivery to the ultimate purchaser or while it is in use 2 The use of the vehicle after such device or ele Federal Law Part 205 ment of design has been removed or rendered Transportation Equipment Noise ihoperaNve by any person Among those acts presumed to constitute tam pering are the acts listed below Emission Controls Part 205 Transportation Equipment Noise Emission A Removal of engine noise deadening panels Controls requires the vehicle manufacturer to fur nish with each new vehic
81. ench while loosening or tightening the nuts that attach the valve to the bracket Because the mounting studs are threaded into the valve body loosening the nuts without holding the studs can tighten the studs which can crush the valve body and damage the valve Conversely tightening the nuts without holding the studs can back the studs out causing a separation of the two halves of the valve body and possibly a leak 1 Park the vehicle on a level surface using a light application of the brakes Do not apply the park ing brakes Shift the transmission into neutral and build the secondary air pressure to at least 100 psi 690 kPa Shut down the engine 2 Mark the location of the front and rear tires on the floor and chock the tires on one axle only 3 Check the length of the overtravel lever between its pivot points See Fig 6 Ref A Suspension 3 1 If the vehicle is equipped with an adjust able leveling valve the length should be 8 inches 200 mm If the length is incor rect see Group 32 of the Columbia Workshop Manual for adjustment proce dures 3 2 If the vehicle is equipped with a fixed lev eling valve see Group 32 of the Columbia Workshop Manual for the overtravel lever length for the rear axle installed in your vehicle On single drive rear axle configurations measure the distance from the bottom of the left axle stop to the top of the U bolt pad On tandem dual drive rear axle configurations meas
82. eplacement 20 02 Cooling Fan Inspection Columbia Maintenance Manual December 2001 20 1 A A D E 11 28 2001 1020127 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 Columbia Maintenance Manual Page Columbia Maintenance Manual February 2010 Introduction Maintenance Manual Contents Group No Group Title O ee RM NR E E ER ET General Information EER MET RA ME IE ED EM Engine OE luas EE AE me DE adu uude idea OE Air Intake PE reggadebdaedpeqages3ed 3 PENA Air Compressor EE SEN OD HA Alternators and Starters AE OE a X Re dre E d Engine Cooling Radiator EED OAR EL AE EE RR AS Clutch OB P P Pr KG Transmission c MT Frame and Frame Components UE isa ded Reda Yd d S XE E Suspension Oo Stade PEP dui d de id Front Axle vt MMC Sa eet ah eae Rear Axle EB iut unique ET Brat Wheels and Tires M ck es ein NEA KA NANG kA dete ced ek Aiea Driveline M vec deo he dd dhyana Sof OT gay fae vm ane d Brakes Han dares iuda Durs ENE feles neta iod Steering CDM CT athe wee hak Goes aes aes Fuel LC head EE Kh ees Exhaust y Ao oh Lyk EE EE ER tink ates oh ec ON Doors D sued quies xs Heater and Air Conditioner I 4 Columbia Maintenance Manual February 2010 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Determinin
83. erate and care for the vehicle and its components Each manual contains a chapter that covers pretrip and post trip inspections and daily weekly and monthly maintenance of vehicle components Driver s operators manuals do not contain detailed repair or service information Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid Parts technical bulletins provide information on parts These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures parts documentation can be accessed using the following applications on the ServicePro provides Web based access to the most up to date versions of the publications listed above In addition the Service Solutions feature provides di agnostic assistance with Symptoms Search by connecting to a large knowledge base gathered from technicians and service person
84. ercord 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 signs of an old belt 7 Inspect the pulleys for excessive play or wobble Excessive play or wobble indicates a failure of the pulley bearing Check for belt squealing or squeaking Replace the bearings as necessary NOTE If it is difficult to distinguish the location of a supposed bearing noise place a stetho Columbia Maintenance Manual January 2007 01 1 01 Engine 11 21 94 f150010a A Glazing C Streaked Sidewalls E Uneven Ribs B Separating Layers D Tensile Break F Cracks Fig 2 Drive Belt Replacement Conditions scope on the component being checked not the 2 Install a belt tension gauge at the center of the pulley to isolate the area from outside interfer belt s longest free span Check belt tension See ence Table 1 for belt tension specifications 8 Inspect all pulleys for foreign objects oil or 3 If belt tension is not correct see Group 01 of the grease in the grooves Columbia Workshop Manual to adjust belt ten sion Belt Tension Inspection Threaded Adjustment Type 1 Apply the parking brakes and chock the tires Drive Belt Tensions Engine Component Belt Tension Ibf kg Cummins ISB ISC ISM Refrigerant Compressor 100 45 Fan and Alternator 29 5 27 9 Mercedes Benz MBE900 Refrigerant Compressor 30 0 2
85. es that annually travel less than 60 000 miles 100 000 kilometers and operate under normal con ditions Examples of Schedule Il usage are opera tion primarily in cities and densely populated areas local transport with infrequent freeway travel or high percentage of stop and go travel Service Schedule Ill long haul transport is for ve hicles that annually travel more than 60 000 miles 100 000 kilometers with minimal city or stop and go operation Examples of Schedule Ill 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 an nually 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 transmis sion Meritor FF 961 or FF 981 front axle 12 000 Ib capacity with synthetic lubricant Front suspension with maintenance free rubber bushings for 12 000 Ib capacity suspension Meritor RPL series or Dana Spicer SPL series driveline U joints Synthetic lubricant used in rear axle Equipped with any Freightliner AirLiner suspen sion 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
86. ets for cracks or other damage 9 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 10 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See Maintenance Operation 31 02 for lubrica tion instructions 31 02 Fifth Wheel Lubrication To maintain proper fifth wheel operation always lubri cate the fifth wheel after an inspection has been performed IMPORTANT Lubricate the fifth wheel e After power washing or steam cleaning 31 4 Columbia Maintenance Manual October 2008 Frame and Frame Components e f the vehicle operates in harsh conditions such as salt spray from road surfaces or in ex tremely dusty environments e After any service that requires removal of lubri cation from the fifth wheel head or components 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 to lubricate all moving parts on the fifth wheel When lubricating the top plate at the grease fittings for the bracket bearing area tilt the top plate forward and backward to evenly distribute the grease Using a pry tool separate t
87. f the X pattern 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 Columbia Maintenance Manual October 2008 31 1 31 Frame and Frame Components 2 3 4 vd N 25 a 2 21 23 26 24 1 09 18 95 1310476 3 16 x 1 Cotter Pin 11 1 4 20 x 3 8 Thread Cutting 19 1 2713 x 2 Bumper Pivot Bolt 2 Lower Bracket Retainer Pin Screw 20 Bumper 3 Grease Fitting 12 Step Jaw and Wedge 21 Flatwasher 4 Lower Bracket Pin 13 Jaw Spring 22 5 16 Bumper Pivot Bushing 5 Wedge Stop Rod 14 1 4 x 3 Cotter Pin 23 1 2 13 Locknut 6 Flatwasher 15 Timer 24 7 16 Handle Pivot Bushing 7 Wedge Stop Rod Spring 16 Wedge Spring 25 Operating Handle side release 8 Wedge Stop Rod Nut 17 Pull Handle only 9 Side Release Upper Assembly 18 Bumper Handle Spring 26 1 2 13 x 2 Handle Pivot Bolt 10 Leaf Spring Fig 1 Fontaine H5092 Series Fifth Wheel left side release shown 8 Inspect for fatigue or cracked welds Castloc Il and Simplex Series 9 Replace cracked worn or damaged parts with a new parts Replace all loose mounting bolts with LE S ihe ord n mig a ln 5 8 11 SAE grade 8 bolts grade C locknuts and ee EE OPS dina hardened washers Do not re use bolts nuts Thoroughly steam clean the fifth wheel and washers on fifth wheel mountings Check the fifth wheel plate for cracks Check for 10 After inspecti
88. f it is damaged 6 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on 83 08 25 94 830641 Fig 1 Drive Plate Clearance Inspection the hoses Replace damaged hoses For re placement instructions see Group 83 of the Columbia Workshop Manual Also check for loose fittings on all of the air conditioning compo nents 7 Check for a buildup of road debris on the con denser fins For cleaning instructions see Group 83 of the Columbia Workshop Manual Refrigerant Checking Check the color of the moisture indicator on the receiver drier See Fig 2 If the indicator is blue the refrigerant charge is dry If the indicator is not blue the system is contami nated with water If the system is contaminated the refrigerant must be recovered and the receiver drier must be replaced For instructions see Group 83 of the Columbia Workshop Manual 83 02 Air Filter Replacement Cab Fresh Air Filter Replacement Blend Air If the vehicle is equipped with a cab fresh air filter it must be replaced every six months regardless of mileage to permit proper operation of the HVAC system A CAUTION If equipped with a fresh air filter it should be re placed every six months If the fresh air filter is Columbia Maintenance Manual October 2002 83 1 83 Heater and Air Conditioner 7 12195 O 1830746 1 Moisture Indicator 02
89. f the vehicle and support the frame on jack stands to unload the suspension compo nents The vehicle is lifted high enough when the beam ends are off of the saddles 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 5 Manipulate the walking beam so that a microme ter vernier or dial caliper can be used to deter mine the wear area thickness on the bottom face See Fig 8 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 8 Ref B from the thickness at the non wear area see Fig 8 Ref A to determine the amount of wear If the beams show any wear greater than 0 062 inch 1 5 mm a Chalmers wear plate must be installed or the walking beam must be replaced 6 Rotate the restrictor cans 360 degrees and in spect the cans for cracks severe corrosion and distortion If any of these conditions are present or the restrictor can is missing replace the re strictor can 32 09 27 95 320432 A Non Wear Area B Wear Area 1 Walking Beam Fig 8 Walking Beam End Wear Thickness Replace all cracked or missing restrictor cans Failure to do so could lead to loss of vehicle con trol which could result in property damage seri ous personal injury or death 32 02 S
90. feet ft cubic feet ft3 0 02832 cubic meters m3 35 315 cubic feet ft3 Weight Force ounces av oz 28 35 grams g 0 03527 ounces av oz pounds av Ib 0 454 kilograms kg 2 205 pounds av Ib U S tons t 907 18 kilograms kg 0 001102 U S tons t U S tons t 0 90718 metric tons t 1 1023 U S tons t Torque Work Force inch pounds Ibf in 11 298 Newton centimeters N cm 0 08851 inch pounds Ibf in foot pounds Ibf ft 1 3558 Newton meters N m 0 7376 foot pounds Ibf ft Pressure Vacuum inches of mercury inHg 3 37685 kilo Pascals kPa 0 29613 inches of mercury inHg pounds per square inch psi 6 895 kilo Pascals kPa 0 14503 pounds per square inch psi Table 16 Metric U S Customary Conversion When You Know Subtract eae To Get irse uc 22 To Get degrees Fahrenheit F 32 1 8 degrees Celcius C 1 8 32 degrees Fahrenheit F Table 17 Temperature Conversion 00 20 Columbia Maintenance Manual February 2010 General Information 00 Torque Specifications Tables 00 13 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged Hcc Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 GradeB Grade 8 or Grade G Pitch Bolt B Nut 8 2 Bolt C Nut Bolt Nut 8 2 Bolt Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m f230002 f230003 f230004 f230005 1230006 1230
91. g Scheduled Maintenance Intervals 2 00 01 Initial Maintenance IM Operations s 2 ener KAG A RE cd RR OE RE AR RR RE RE ge 00 05 Lubrication and FluidiLevel Check 233 xa aaa rp ke lise ex m ded eee Y vex Py a edd dus 00 04 M1 Maintenance Interval Operations ii EER EE ER Ee ee 00 06 M2 Maintenance Interval Operations suasana aaaeeeaa 00 07 M3 Maintenance Interval Operations EE EE ER ee GE Ge ee nn 00 08 Maintenance Operation sets Table sies am der ded exer ade E ed race ex mundos DE dn ade 00 09 Metric U S Customary Conversion Tables llli 00 12 Noise Emission Controls Maintenance rn 00 10 Service Schedule Table 5i sapa aaa cod dipsa dob e duros LALAKAD Rus deen eee Si oe 00 02 Torque Specifications Tables s 22008 HERE RR RE DERE bon gic DE HORE gees eaage lanes RR RR I anes 00 13 Vehicle Maintenance Schedule Tables 0 000 ccc eh 00 03 NN ol Nnepecions a AA AA 00 11 Columbia Maintenance Manual February 2010 General Information 00 Determining Scheduled Maintenance Intervals 00 01 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 pro gram can result in inefficient operation and unsched uled down time To determine the correct maintenance
92. ge remove and clean the magnetic strainer if equipped See Fig 4 4 1 Remove the magnetic strainer from the power divider cover 4h WARNING Always wear eye protection when using com pressed air to clean parts as flying debris could cause permanent damage to unprotected eyes Do not point the air stream in the direction of other persons 4 2 Wash the strainer in solvent and blow it dry with compressed air to remove oil and metal particles 4 3 Install and tighten the magnetic strainer 40 to 60 Ibf ft 54 to 81 Nm 5 Clean the fill and drain plugs Change them if necessary 05 27 93 1 O Vel 1 10 Pe 2 Power Divider f350017a Magnetic Strainer Fig 4 Dana Spicer Tandem Drive Axle Magnetic Strainer 5 1 For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 2 Clean away the collected material depos ited on each pole Magnets will rapidly lose their effectiveness as collected mate rial bridges the gap between the two poles 5 3 After the first oil is changed inspect the drain plug each time for large quantities of metal particles 5 4 After cleaning install the drain plug s and tighten to 40 to 60 Ibf ft 54 to 81 N m Fill the axle with the recommended lubricant See Table 4 for recommended drive axle lubri cants and Table 5 for drive axle lubricant ca pacities 3
93. gear mounting bolts for security 6 Check that the outer tie rod castellated nuts are tight and the cotter pins are properly installed IMPORTANT Do not remove the rack and pin ion bellows unless they are damaged and must be replaced or there is evidence of a loose inner tie rod or there is hydraulic fluid leaking from the bellows 7 Check the rack tie rod bellows for holes or tears If any are found remove the bellows and check the rack for evidence of corrosion No corrosion is allowed If corrosion is found replace the rack and pinion unit If there is no corrosion replace the damaged bellows with a new one 8 Check the rack and pinion tie rod bellows for evi dence of leakage from the bellows If hydraulic Columbia Maintenance Manual February 2010 46 3 46 Steering 07 24 2009 1462151 1 Steering Tie Rod Arm 10 Input Shaft Seal Cover 17 Shaft Slip Joint 2 Power Steering Fluid Lines 11 I Shaft Upper Yoke 18 Transfer Lines 3 Large Bellows Clamp 12 Shaft Lower Yoke Boot Clamp 19 Rack and Pinion Gear 4 Bellows 13 Shaft Lower Yoke Boot 20 Pinch Bolt 5 Small Bellows Clamp 14 I Shaft Lower End Yoke 21 Tie Rod Clamp 6 Driver Side Outer Tie Rod 15 Transfer Line Tube Fittings 22 Tie Rod Clamp Nut 7 Tie Rod Jam Nut 16 Power Steering Fluid Line 23 Passenger Side Outer Tie Rod 8 Inner Tie Rod Flat Fittings 9 Inner Tie Rod Ball Joint Fig 4 Rack and Pinion Steering System
94. h a transmission fluid filter s replace the fluid filter s 5 1 Place a drain pan under the transmission fluid filter 4h CAUTION To prevent skin burns from hot transmission fluid wear protective gloves when removing the filter 5 2 Place a strap or chain wrench around the filter canister and rotate it in a counter clockwise motion to separate the filter from the mounting Carefully spin the filter off the mount and remove it from the ve hicle 5 3 Apply a light coat of transmission fluid to the O ring gasket on the new filter Fill the filter with specified transmission fluid and spin the filter onto the mount NOTE The filter fills slowly so be patient to ensure the proper fluid level has been set 5 4 Once the filter makes contact with the mount use a strap wrench to rotate the canister an additional 180 to 270 degrees to firmly tighten the filter Wipe the filter clean of any fluid after it is tightened 6 Add fluid until it is level with the lower edge of the fill opening See Fig 1 If the transmission has two fill openings add fluid to the level of both openings See Table 1 for approved trans mission lubricants See Table 2 for Meritor trans mission lubricant capacities and Table 3 for Eaton Fuller transmission lubricant capacities Install and tighten each drain plug 50 Ibf ft 68 JB X VA D N m J y 4 NOTE The optional transmission fluid filter is a 7 7 j 7 remote mount spin on typ
95. h silicone grease oO gt Fig 9 Brake Pedal and Valve Assembly 3 Remove the brake pedal pivot pin Remove the brake pedal Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses the Columbia Maintenance Manual January 2008 42 7 42 Brakes area from which the pivot pin was removed Re place it if necessary 6 Check the brake pedal rollers for signs of wear or cracks Replace it if necessary 7 If the rollers are replaced replace the roller pin install a new cotter pin bend it to 90 degrees and apply Torque Seal OPG F900 White to the cotter pin 8 Remove the plunger from the valve Using alco hol clean the existing grease from the plunger Check the plunger for signs of wear or cracks Replace it if necessary 9 Lubricate the plunger with barium grease BW 246671 10 Insert the plunger in the valve 11 Install the brake pedal with the pivot pin 12 Install a new roll pin and apply Torque Seal OPG F900 White to the roll pin 13 Install the brake valve assembly See Section 42 10 Subject 110 of the Columbia Workshop Manual for instructions 14 Test the brakes before returning the vehicle to service 42 8 Columbia Maintenance Manual January 2008 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Link Inspec OE ss eo ocn NE ino Downes Bde De ED ASUS PAAR que bed wb pde 46 01 Drag Link BUDIESUO
96. he jaw and wedge and lubricate the serrations using a brush to distribute the grease On slide mount applications lubricate the slide rail and tapered wedges for smooth operation Once the moving parts of the fifth wheel are lubri cated apply a liberal coating of grease to the top plate and the trailer kingpin plate Holland Lubricate all moving parts with a multipurpose chas sis grease Lubricate 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 di rect application On slide mount applications lubri cate the baseplate rails and the plungers for smooth operation Castloc II and Simplex Series Use a chassis or multipurpose grease to lubricate the two grease fittings located on either side of the fifth wheel top plate Lubricate the two grease fittings lo cated in the grease grooves on the fifth wheel top plate Lubricate the two grease fittings located below the top plate mounting pins Lubricate the lock mechanism 31 Once the fifth wheel s moving parts are lubricated apply a heavy coat of grease to the top plate either through the grease fittings located on the underside of the top plate or by direct application On slide mount applications lubricate the slider lock pockets and the slider bracket 31 03 Frame Fastener Torque Check Frame brackets and componen
97. heck the air brake system for leaks If any air 42 2 Columbia Maintenance Manual January 2008 Brakes 09 20 94 f420544a Fig 2 End Cover to Housing Torque Pattern 42 03 Air Dryer Inspection 1 Park the vehicle on a level surface and apply the parking brakes Shut down the engine Chock the tires 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 indi cates excessive moisture is present in the air system and the desiccant cartridge needs to be replaced See Group 42 of the Columbia Work shop Manual for troubleshooting procedures The following conditions could cause small amounts of moisture to be found in the air system e 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 un load in a normal fashion Check for air sys tem leaks The air dryer has been installed on a sys tem that had previously been operated without an air dryer This type of system will be saturated with moisture and several 42 weeks of operation may be needed to fully dry the system The temperature range in your area fluctu ates more than 30 degree
98. her than the previous recording reset the air restriction indicator If the value is lower than the previous recording in spect the air cleaner and air cleaner element of cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air restriction indicator Method 2 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 inH5O on a vehicle with a Detroit Diesel engine 22 inH5O on a vehicle with an MBE engine or 25 inH O on a vehicle with a Caterpillar or Cummins engine For replacement instructions see Group 09 of the Columbia Workshop Manual Reset the air restriction indicator Each time the air cleaner is replaced perform the procedures in MOP 13 01 If the maximum restriction is not reached inspect the air cleaner and air cleaner element for cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air re striction indicator 09 Columbia Maintenance Manual February 2004 09 1 Air Compressor 13 Index Alphabetical Title of Maintenance Operation MOP MOP Number Bendix Air Compressor IR1spectlol s uude odode anes Doe DAKS LILINIS SRL aL Deen ANNE 13 01 Columbia Maintenance Manual May 2002 Air Compressor 13 01 Bendix Air Compressor Inspection Inspect the air intake line oil supply and return lines and coolant supply and return h
99. his smaller hole is for a lubricant Rear Axle temperature indicator 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 4 Install and tighten the fill plug 35 Ibf ft 47 Nm IMPORTANT Always check the axle breather whenever checking lubricant level Check the breather more frequently under adverse operat ing conditions 5 Check the axle housing breather Make sure that it is open and unclogged See Fig 6 If the breather is plugged or damaged clean or re place it as needed gt Na 2 3 06 07 94 1350062a 1 Axle Housing 2 Carrier Oil Fill Plugs Breathers 3 Interaxle Differential Fig 6 Meritor Axle Housing Breathers 6 On non drive axles using oil lubricated wheel bearings check the oil level at the wheels and add oil if low Use the same lubricant recom mended for the drive axle NOTE When adding to or checking the oil level make certain the hub cap and plug are clean before removing the plug this will minimize the possibility of dirt and road grime entering the assembly 35 6 Columbia Maintenance Manual July 2005 Rear Axle Freightliner 4h CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock
100. ial indicator to zero Without rotating the hub grasp it at the 3 and 9 o clock positions and push it straight in Note the reading on the dial indicator Pull the hub straight out Note the reading on the dial indicator The difference between the two measurements is the end play 10 If the end play is less than 0 003 inch 0 08 mm go to the step for installing the hub cap If the end play is 0 003 inch 0 08 mm or greater go to the next step 11 Remove the outer locknut and tabbed washer from the axle spindle 12 Loosen but don t remove the inner locknut 13 While rotating the hub a minimum of five rota tions tighten the inner locknut 600 Ibf ft 813 N m 14 Install the tabbed washer and outer locknut Tighten 250 Ibf ft 339 N m 15 Repeat the procedure for checking end play 16 If end play is greater than 0 003 inch 0 08 mm but less than 0 006 inch 0 15 mm record it in the vehicle maintenance log Go to the next step If end play is 0 006 inch 0 15 mm or greater replace the entire wheel end assembly For in structions see Group 33 of the Columbia Workshop Manual 17 Check the rotation of the hub If it doesn t rotate smoothly and without noise replace the entire wheel end assembly For instructions see Group 33 of the Columbia Workshop Manual 33 4 Columbia Maintenance Manual October 2004 Front Axle 20 21 22 23 If the hub rotates smoothly and without no
101. imler Trucks North America LLC is a Daimler company Daimler Trucks North America LLC Service Systems and Documentation POC SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Daimler Trucks North America L via ServicePro9 formats Workshop Service Manual Maintenance Manual Driver s Operator s Manual Service Bulletins Parts Technical Bulletins Web based repair service and AccessFreightliner com website ServicePro PartsPro EZWiring LC distributes the following major service publications in paper and electronic Workshop service manuals contain service and repair information for all vehicle systems and components except for major components such as engines trans missions and rear axles Each workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation and specifications Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables fluid replacement procedures fluid capacities specifica tions and procedures for adjustments and for checking the tightness of fasten ers Maintenance manuals do not contain detailed repair or service information Driver s operators manuals contain information needed to enhance the driver s understanding of how to op
102. ise go to the next step Bend an opposing tab of the tabbed washer over a flat of the outer locknut Install the wheel and tire assembly Hand tighten the wheel nuts Raise the vehicle remove the jackstands then lower the vehicle Tighten the wheel nuts 500 Ibf ft 678 N m Install the hub cap If installing a metal hub cap go to the next step If installing a plastic hub cap do the following 22 1 Apply a continuous 1 8 inch 3 mm bead of RTV silicone sealant to the outside first thread of the hub cap Apply the sealant around the entire circumference IMPORTANT Use only the following RTV sealants on the hub cap Meritor part number 2297 Z 7098 e Three Bond e Loctite Ultra Grey Adhesive Sealant 18581 22 2 Install the hub cap by hand until it is seated NOTE Disregard the torque value em bossed on the hub cap 22 3 Using a torque wrench tighten the hub cap 75 Ibf ft 102 N m If you cannot tighten the hub cap to the correct torque value or if it makes a pop ping sound while being tightened replace it with a new one If installing a metal hub cap do the following 23 1 Using a wire brush clean the unitized wheel end inner threads and the hub cap external threads 23 2 Apply Loctite 17430 gasket sealant to the external hub cap threads 23 3 Install the hub cap by hand until it is seated 23 4 Using a torque wrench tighten the hub cap 350 Ibf ft 475 Nm 33 NOTE If yo
103. l For additional information refer to the CVSA Out of Service OOS Criteria for composite spring assem blies Section 9 Suspension Pages 44 to 45 Inspect the Liteflex spring for cracks that result in an out of service condition as follows see Fig 1 a side to side crack extending beyond 3 4 of the length of the spring e a top to bottom crack extending beyond 3 4 of the length of the spring e intersecting cracks of any length The Liteflex composite spring should also be re moved from service if splintering has occured to the point where noticeable vehicle ride height loss has occurred 32 b sd EN C 08 14 2008 1321135 A Side to side crack extending beyond 3 4 of the length of the spring B Top to bottom crack extending beyond 3 4 of the length of the spring C Intersecting cracks of any length Fig 1 Out of Service Conditions Composite Spring Shock Absorber Check Front and Rear Suspensions Make sure the shock absorber brackets are tight and the shock absorber is not striking or rubbing the frame or some other part of the chassis Striking or rubbing the frame is characterized by chafe marks on the shock absorber body and the frame rail See Fig 2 Check the rubber mounting bushings for cracks cuts swelling and dry rot Also check the bushings for missing pieces Replace the bushings as needed Inspect the shock absorber for oil leakage If the shock ab
104. lay Check Meritor Unitized Wheel Ends 40 01 Wheel Nut Check 41 01 Driveline Inspection 42 01 Air Brake System Valve Inspection 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 46 01 Drag Link Inspection 46 06 Rack and Pinion Steering Inspection 47 01 Fuel Filter Replacement 47 02 Fuel Separator Sight Bowl Cleaning and Element Replacement 00 12 Columbia Maintenance Manual February 2010 General Information 00 M2 Maintenance Interval Operations 00 07 gee i M2 Maintenance Interval Operations for Service Schedule IV Check 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement Replace the HVAC filters every 6 months regardless of mileage Table 13 M2 Maintenance Interval Operations for Service Schedule IV Columbia Maintenance Manual February 2010 00 13 00 General Information M3 Maintenance Interval Operations 00 08 The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed Perform all at the M3 maintenance interval Maintenance opera M1 and M2 maintenance interval operations at the tion numbers are reference numbers used to help M3 maintenance interval Maintenance Operation Number M3 Maintenance Interval Operations for Service Schedules I Il Ill and IV Check 00 06
105. le such written instructions B Removal of cab tunnel or hood noise for the proper maintenance use and repair of the deadening panels vehicle by the ultimate purchaser to provide reason able assurance of the elimination or minimization of noise emission control degradation throughout the life of the vehicle In compliance with the law the C Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica noise emission controls maintenance information in tions each applicable group of this manual in conjunction D Removal of or rendering inoperative the fan with the vehicle workshop manual provides these clutch including bypassing the control on instructions to owners any thermostatic fan drive to cause it to op erate continuously Recommendations for Replacement Parts Removal of the fan shroud Removal of or rendering inoperative ex Replacement parts used for maintenance or repair of haust components including exhaust pipe noise emission controls should be genuine Freight clamping liner parts If other than genuine Freightliner parts are used for replacement or repair of components G Removal of air intake components affecting noise emission control the owner should be sure that such parts are warranted by their manufac Maintenance Instructions turer to be equivalent to genuine Freightliner parts in performance and durabilit
106. lines Wipe the purged grease from the pressure relief hole and slip joint seal and any excess grease from the grease fitting Driveline 41 4 Columbia Maintenance Manual March 2000 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake System Valve Inspectlofic uuu cs abrite et DE DES e do HS xe Rees DIY NONE Sat dedi e 42 01 Ar Dryer laspeeli Ms si 4 ceca AE d eagerness PRC NN ib buono OE OG EES EE RE NANG 42 03 Alcohol Evaporator Cleaning and Inspection 0 000000 eee 42 04 Bendix AD 9 Air Dryer Desiccant Replacement l i 42 02 Bendix AD IS Air Dryer Desiccant Replacement lille eh 42 09 Bendix E 6 Foot Control Valve Inspection and Lubrication liliis 42 10 Dana Spicer Camshaft Bracket Lu brication s saa ana SE KERE DEE ED DERE EDE ween SE SE EDE owe 42 05 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication llli 42 06 Meritor Camshaft Bracket Lubrication 0 0 00 EE c ee 42 07 Mentor Slack Adjuster Eubticaltiofi is 2 2 dao m EED wks s Moo du owas NG Ee pda es ERR 42 08 Columbia Maintenance Manual January 2008 Brakes 42 01 Air Brake System Valve Inspection NOTE There is no scheduled air valve mainte nance on vehicles equipped with Bendix air valves and a Bendix air dryer if the air dryer desiccant is replaced at 350 000 miles 563 000 km If the desiccant is not changed at 350 000 miles 563 00
107. med with the engine temperature below 205 F 96 C for Caterpillar en gines and below 200 93 C for Cum mins and Detroit Diesel engines 20 6 Columbia Maintenance Manual January 2007 Engine Cooling R adiator Kysor K22RA Fan Clutch 1 Disconnect the batteries at the negative termi nals Drain all air from the air system If equipped with an air starter drain the air starter reservoir 4h WARNING 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 7 Ref A 3 2 1 4 5 6 at A gt 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 5 Air Cylinder 2 Retaining Plate 6 Fan 3 Fan Pulley 4 Air Inlet from solenoid valve Fig 7 Kysor K22RA Fan Clutch Lining Wear Check 3 Disconnect the line from the air inlet of the air cylinder Connect a shop air hose to the inlet 4 Apply a minimum of 100 psi 690 kPa air pres sure to the air cylinder the bearing housing will move backwards disengaging the clutch Again measure the distance from the back surface of 20 the retaining plate to the forward most edge of the fan belt pulley 5
108. n 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 seri ous personal injury N 3 Remove the surge tank cap Do not attempt to drain the cooling system until the coolant and engine are cool Draining the cooling system prior to the system cooling could cause severe personal injury due to scalding 4 Remove the drain plugs at the radiator side tank and at the lower radiator outlet pipe elbow See Fig 2 Allow the coolant to drain e 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 A CAUTION When flushing the radiator do not apply more than 15 psi 100 kPa air pressure Excessive pres sure can damage the radiator 6 Gradually apply air pressure to help dislodge sediment built up in the radiator core Do not apply more than 15 psi 100 kPa air pressure to the radiator Pressures exceeding 15 psi 100 kPa could damage the radiator core Engine Cooling R adiator 06 29 95 011008 NOTE Cummins engine shown 1 Coolant Drain Plug Fig 2 Coolant Drain Plug Location 8 Repeat the previous two steps until clean water flows from the radiato
109. nd If it is loose replace the drag link See Group 46 of the Columbia Workshop Manual for replacement instructions If there is 1 8 inch 3 mm movement or more do not drive the vehicle until the drag link is replaced 46 02 Power Steering Fluid and Filter Changing Fill only with approved clean fluid Failure to use the proper fluid could cause seal deterioration and leaks Fluid leaks could eventually cause loss of power steering assist This could lead to an acci dent resulting in personal injury or property dam age Wear eye protection when changing the fluid and filter 1 Apply the parking brakes and chock the rear tires 2 Place a drain pan under the power steering res ervoir and remove the steering gear to reservoir return hose at the reservoir Drain the power 3 46 steering fluid into the drain pan and dispose of the fluid properly Plug the return line fitting on the reservoir Loosen the clamp and remove the cover along with the filter spring and the filter top plate NOTE Always replace the power steering reser voir filter when changing the fluid 4 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 IMPORTANT Do not start the engine while draining the system 1
110. nd chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Place safety stands under the axle 3 Using spray paint or a piece of chalk mark the entire center rib of each front tire 4 Place a scribe or pointed instrument against the marked center rib of each tire and turn the tires The scribe must be held firmly in place so that a single straight line is scribed all the way around each front tire 5 Place a turn plate or turntable under both front tires Remove the safety stands and lower the vehicle Remove the lock pins from the gauges make sure the tires are exactly straight ahead NOTE If turn plates or turntables are not avail able lower the vehicle Remove the chocks from the rear tires and release the parking brakes Move the vehicle backward then for ward 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 3 Lock in place Check that the scale is set on zero Front Axle aq B gt 08 29 94 f330082a NOTE B minus A equals toe in Fig 3 Wheel Toe In overhead view 7 Place the trammel bar at the front of the tires see Fig 4 and adjust the scale end so that the pointers line up with the scribe lines See Fig 5 N 08 30 94 f330014a Fig 4 Trammel Bar P
111. nel Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data PartsPro is an electronic parts catalog system showing the specified vehicle s build record EZWiring makes Freightliner Sterling Western Star Thomas Built Buses and Freightliner Custom Chassis Corporation products wiring drawings and floating pin lists available online for viewing and printing EZWiring can also be ac cessed from within PartsPro Columbia Maintenance Manual February 201 0 I 1 Introduction Descriptions of Service Publications Warranty related service information available on the AccessFreightliner com website includes the following documentation Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles Field Service Campaigns Field service campaigns are concerned with non safety related service work or replacement of parts All field service campaigns are distributed to dealers cus tomers receive notices that apply to their vehicles 2 Columbia Maintenance Manual February 2010 Introduction Page Description For an example of a Columbia Maintenance Manual page see Fig 1 A B C Y Y Cooling 20 20 01 Coolant R
112. ng the fifth wheel lubricate all mov sharp edges on top the chamfer should be 1 8 ing parts with a chassis or multipurpose grease to 1 4 inch 3 to 6 mm See Maintenance Operation 31 02 for lubrica 4 When the wheel is locked the safety latch must tion instructions swing free and fall freely into position See Fig 3 31 2 Columbia Maintenance Manual October 2008 Frame and Frame Components 31 17 16 14 14 11 12 1 08 29 95 13 1310472 1 Locknut 3 4 16 7 Torsion Spring 13 Lock Pin 2 Washer 8 Roll Pin 14 Lock Jaw 3 Rubber Washer 9 Secondary Lock Right Hand 15 Washer 4 Lock Adjustment Tag 10 Cam Plate 16 Right Hand Release Handle 5 Yoke Shaft 11 Lock Guard 17 Left Hand Release Handle 6 Yoke Sub Assembly 12 Pin 18 Secondary Lock Left Hand Fig 2 Holland Fifth Wheel 5 The lever bar and operating handle must be in proper alignment See Fig 4 Compare the lever bar and operating handle alignment to a new or a properly operating lever bar and operating handle Replace any bent or misaligned lever bar or operating rod 6 Check all cotter pins for cracking or damage Re place any cotter pin that shows any signs of damage Level the fifth wheel plate to a horizontal posi tion Measure the height from a stationary mounting point see Fig 5 Ref 3 such as the Columbia Maintenance Manual October 2008 31 3 31 Frame and Frame Components
113. ng with force Fontaine 1 Disconnect the tractor from the trailer For in structions see Chapter 10 of the Columbia Driver s Manual Thoroughly steam clean the fifth wheel Look for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Check the jaw and stationary jaw for mushroom ing and check that the serrations at the jaw and wedge are in good condition 5 Test the safety lock latch for ease of operation NOTE The safety lock latch is located at the front of the fifth wheel on the top plate 6 Check for loose nuts or bolts on the fifth wheel and the mounting See Fig 1 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 See Group 00 for bolt torque specifications 7 Check all springs to see if they are securely fas tened and are not deformed WARNING Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause serious injury 8 Check wedge adjustment 8 1 Open the kingpin lock and vertically in sert a 2 inch 50 mm diameter shaft 31 8 2 Release the lock by tripping the release latch at the bottom of the throat 8 3 Adjust the wedge stop at the end of the wedge to approximately 1 4 inch 6 mm clearance by turning the wedge stop rod located on the right side of the top plate 9 Replace c
114. ngine Chock the tires 2 Drain the air reservoirs 3 Using a strap wrench or equivalent loosen the desiccant cartridge Spin the cartridge off by hand and discard it See Fig 8 42 6 Columbia Maintenance Manual January 2008 Brakes 10 20 93 f420012a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or plug IRON NG 42 IMPORTANT Only use the silicone grease sup plied with AlliedSignal replacement kits 5 Screw the desiccant cartridge onto the body by hand until the seal makes contact with the body Rotate the cartridge clockwise about one full turn Tighten the cartridge firmly 6 Remove the chocks from the tires 42 10 Bendix E 6 Foot Control Valve Inspection and Lubrication 1 Remove the brake valve from the vehicle See Section 42 10 Subject 110 of the Columbia Workshop Manual for instructions 2 Remove the roll pin from the brake pedal pivot pin See Fig 9 Fig 7 Meritor Automatic Slack Adjuster 04 16 98 1421910 1 Desiccant Cartridge 2 Cartridge Sealing Ring 3 Threaded Base Post 09 10 2004 1430405 1 E 6 Foot Control Valve 5 Roll Pin 2 Mounting Plate 6 Roller 3 Nut and Washer 7 Roller Pin 4 Pivot Pin 8 Pedal Fig 8 Desiccant Cartridge Replacement 4 On the new desiccant cartridge lubricate the sealing rings wit
115. ns pressure to within 1096 of the pressure rating marked on the cap If it doesn t replace the cap See Fig 1 Make sure that the replacement radiator cap is correctly rated for the cooling system of the vehicle 20 3 There is a second valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cools Inspect the vacuum relief valve to be sure it is not stuck 4 Make sure that the cap seals properly on the coolant filler neck seat and that the radiator cap gasket is not damaged On vehicles with screw on caps with O rings make sure that the O ring is not cracked or deteriorated Replace the cap if the gasket shows deterioration or dam age 20 02 Radiator Pressure Flushing and Coolant Change NOTE For additional instructions on cleaning and flushing the engine cooling system see the 06 08 95 1 Low Coolant Level Sensor 2 SAE Cap for coolant overflow pressure relief only 3 Fill Cap 1500244 Fig 1 Surge Tank Columbia Maintenance Manual January 2007 20 1 20 applicable engine manufacturer s maintenance and operation manual 1 Park the vehicle and apply the parking brakes Tilt the hood Place a suitable container under the elbow of the radiator outlet pipe and the radiator The con tainer should hold at least 60 quarts 59 liters of fluid 4h WARNING Do not remove or loose
116. or adequate clamping See Fig 2 Replace the components if this cannot be done For in structions refer to Group 33 of the Columbia Workshop Manual 02 27 2007 f820033a NOTE Shown without pinch bolt to provide clarity 1 Cross Tube Split Fig 2 Tie Rod End Adjustment 33 03 Tie Rod Lubrication Meritor Axles For any Meritor axle that requires lubrication of the tie rod ends wipe the grease fittings clean then pump multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease into the tie rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck Columbia Maintenance Manual October 2004 33 1 33 33 04 All Axle Alignment Check Drive Axle Alignment Checking Check the axle alignment parallelism and thrust angle measurements for the rear drive axles Use the applicable procedure and specifications in Group 35 of the Columbia Workshop Manual Toe In Inspection For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for the front wheels must rotate freely without friction and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufacturer Freightliner dealers must have proof of this calibration history 1 Apply the parking brakes a
117. oses for tight connec tions and general condition Tighten the connections and replace the lines and hoses as needed If the compressor intake air adapter is loose remove the adapter replace the adapter gaskets and securely install the adapter Check the cooling fins on the compressor crankcase Clean the fins if they are clogged with dirt or grease 13 Columbia Maintenance Manual May 2002 13 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check eee ee 15 01 Columbia Maintenance Manual October 2008 Alternators and Starters 15 01 Alternator Battery and Starter Connections Check WARNING Batteries generate explosive gas as a by product of their chemical process Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment Make sure the battery compartment has been completely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective clothing when working around batteries 1 Check the tightness of the alternator bracket fas teners tighten the fasteners as needed For torque values see Group 15 of the Columbia Workshop Manual 2 Check the belt tension of the alternator drive belt
118. ositioning 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Columbia Workshop Manual If corrections are needed refer to Group 33 of the Columbia Workshop Manual for instructions on adjusting the toe in 33 2 Columbia Maintenance Manual October 2004 Front Axle 33 08 30 94 f400100a Fig 5 Setting Trammel Bar Pointers 33 05 Knuckle Pin Lubrication Dana Spicer Axles 4h CAUTION Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps Park the vehicle on a level surface apply the parking brakes and chock the tires When lubricating upper and lower knuckle assemblies do not raise the front axle Wipe the fittings clean then apply multipurpose chassis grease NLGI Grade 1 696 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease until new grease is seen at the junctions of the axle beam and knuckles See Fig 6 Knuckle pins without grease fittings are permanently lubricated 1 _A E QW NOS NON 1 11 21 95 1330129 A Grease Exit 1 Grease Fitting Fig 6 Dana Spicer Knuckle Pin Lubrication 33 06 Tie Rod Lubrication Dana Spicer Axles For any Dana Spicer axle that requires lubrication of the tie rod ends wipe the grease fittings clean then pump multipurpose chassis grease NLGI Grade 1 696 12 hydroxy lithium ste
119. p 49 00 Verification of Inspections Log 00 11 Verification of Inspections Log Group 49 Exhaust System Components Date Mileage Item Cost Maintenance Facility Columbia Maintenance Manual February 2010 00 19 00 General Information Metric U S Customary Conversion Tables 00 12 ME iha Us E To Get Metric Balls ede ii To Get U S Customary Length inches in 25 4 millimeters mm 0 03937 inches in inches in 2 54 centimeters cm 0 3937 inches in feet ft 0 3048 meters m 3 281 feet ft yards yd 0 9144 meters m 1 094 yards yd miles mi 1 609 kilometers km 0 6215 miles mi Area square inches in 645 16 square millimeters mm 0 00155 square inches in square inches in 6 452 square centimeters cm 0 155 square inches in square feet ft 0 0929 square meters m 10 764 square feet ft Volume cubic inches in3 16387 0 cubic millimeter mm3 0 000061 cubic inches in cubic inches in 16 387 cubic centimeters cm3 0 06102 cubic inches in3 cubic inches in3 0 01639 liters L 61 024 cubic inches in3 fluid ounces fl oz 29 54 milliliters mL 0 03381 fluid ounces fl oz pints pt 0 47318 liters L 2 1134 pints pt quarts qt 0 94635 liters L 1 0567 quarts qt gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic
120. pecting IMPORTANT The Environmental Protection Agency s 2007 regulations require lower ex haust emissions thus requiring new exhaust system components See Fig 4 In particular the after treatment device ATD which is part of the after treatment system ATS requires special attention during regularly scheduled Columbia Maintenance Manual January 2007 49 1 49 Exhaust maintenance inspections If any discrepancies Definitions of ATS Components are discovered refer to the engine manufactur i EE FATS er s service literature for repair instructions Haba EO OWING ISE O CEUNIHONS G bala e After Treatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe e After Treatment Device ATD a muffler like canister that houses a DPF DOC and sensors E Diesel Particulate Filter DPF a filter that col ge s Zyl lects and holds particulate matter soot and d ash j Diesel Oxidation Catalyst DOC oxidizes hy SN drocarbons and reduces NOx e Sensors detect temperatures and pressures in N the ATS D Inspection 09 29 93 l 199063 1 Check for leakage at the clamp that attaches the Fig 3 Donaldson Sealclamp Wide Band Exhaust exhaust pipe to the turbocharger exhaust outlet i Clamp If leakage exists tighten the nut on the clamp to 10 20 2006 A 1490283 A Inspect this area of the canister for dents Marmon Fitting at Inlet from Turbo
121. plug then install it Tighten the plug as follows e 25 to 35 Ibf ft 34 to 48 N m for transmis sions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for transmis sions with 1 1 4 inch pipe threads e 44 Ibf ft 60 N m for all ZF Meritor FreedomLine automated transmissions e 35 to 50 Ibf ft 48 to 67 N m for all other Meritor transmissions 26 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement Eaton Fuller 1 Apply the parking brakes and chock the rear tires Drain the air reservoirs Drain the air supply if the air supply is not drained before the air filter regulator is serviced serious injury and component damage could re sult 2 Clean the outside of the air filter regulator with cleaning solvent See Fig 2 IBA 05 27 93 12600372 Fig 2 Air Filter Regulator Location Eaton Fuller transmission shown 3 Remove the end cap large O ring and filter ele ment from the filter housing See Fig 3 Remove the small O ring from the end cap Columbia Maintenance Manual April 2005 26 3 26 10 17 2001 1 Air Regulator 2 Housing 3 Large O Ring 4 Filter Element f260052a 5 Small O Ring 6 End Cap 7 Plug Fig 3 Eaton Fuller Transmission Air Filter Regulator Components NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep ing air pressure between 58 and
122. ply the parking brakes and chock the tires 2 Check the appearance of the air conditioner compressor pulley assembly If the friction sur face of the pulley shows signs of excessive grooving due to belt slippage replace both the pulley and the drive plate Inspect the refrigerant compressor drive belt for damage and check that the belt is set at the proper tension Also check the tightness of the compressor mounting fasten ers For instructions and torque values see Group 01 of the Columbia 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 For removal and installation procedures see Group 83 of the Columbia Workshop Manual 4 Ona Sanden A C compressor use a feeler gauge to check that the drive plate clutch clear ance is 0 016 to 0 030 inch 0 4 to 0 8 mm See Fig 1 If the drive plate clutch requires adjust ment see Group 83 of the Columbia Workshop Manual On a Climate Control A C compressor place a feeler gauge between the air conditioner com pressor clutch and the pulley to check the com pressor clutch clearance Drive plate to pulley clearance is 0 020 to 0 030 inch 0 6 to 0 8 mm If the clearance is not correct see Group 83 of the Columbia Workshop Manual 5 Inspect the compressor clutch coil wire Check that the connector is not damaged or loose Re place the wire i
123. ponent that shows signs of cracking or other damage must be repaired or replaced Refer to the 1 Columbia Workshop Manual for repair or replace E 4 ment information in the respective section for the 2 2 5 5 component in question pu a 31 04 Trailer Electrical 7 Connector Lubrication In some cases failure of trailer cables occurs due to 6 intrusion of chloride based road deicing chemicals into the trailer connector Once inside the connector the chloride based chemicals corrode the brass ter minals and create bridging between positive and amp 5 ground terminals Or 7 N8 NOTE The use of soap is not recommended for g D cleaning the electrical connector as some i d soaps may increase the corrosion process 1 Wash out any existing grease dirt and corrosion on the trailer connectors with electrical contact cleaner spray ag UX 2 Grease the trailer connector with a lithium based O 4 ING 13 dielectric grease 2 10 12 03 30 95 1220054 1 Capscrew 3 4 x 4 5 7 Rear Engine Mount Inch Grade 8 8 Nut 5 16 18 2 Washer 3 4 Inch 9 Capscrew 5 8 11 x 3 Engine Leg 2 5 Inch Grade 8 4 Capscrew 1 2 13 x 10 Washer 5 8 Inch 1 5 Inch Grade 8 11 Lower Isolator 5 Washer 1 2 Inch 12 Nut 3 4 10 6 Upper Isolator 13 Nut 5 8 11 Fig 6 Rear Engine Mount Assembly pre EPA07 engines e Front Suspension Spring Brackets Fuel Tank Brackets e Radius Rods e Rear Engine Supports e Rear Suspension Spring Brackets e
124. ptions 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 2001 2010 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 Da
125. r 9 Remove the radiator side tank drain plug and allow the radiator to drain Install and tighten the side tank drain plug and the radiator outlet pipe drain plug after the radiator has been drained Do not overtighten the plugs 10 Connect the hoses Your hose clamps can be either T bolt clamps see Fig 3 or Breeze Constant Torque clamps see Fig 4 When working with T bolt hose clamps tighten the clamps 55 Ibf in 620 N cm These clamps are now standard on hoses with an inside diam eter greater than 2 inches 51 mm When installing Breeze Constant Torque hose clamps the clamps must be tightened to the cor rect torque The screw tip of the clamp must ex tend about 1 4 inch 6 mm from the clamp hous ing and the Belleville washer stacks must be collapsed almost flat Use a torque wrench to install these clamps correctly The correct instal lation torque is as follows For Breeze Constant Torque clamps with a 5 16 inch tightening screw hex 55 Ibf in 620 N cm 7 Shut off the air at the pressure gun nozzle and For Breeze Constant Torque clamps with a 3 8 allow the radiator to refill with water inch tightening screw hex 90 Ibf in 1020 N cm 20 2 Columbia Maintenance Manual January 2007 Engine Cooling R adiator 1200326 02 28 96 Fig 3 T Bolt Type Hose Clamp 08 15 94 f200286 A The screw tip must extend about 1 4 inch 6 mm B Belleville washers must collapse almost flat
126. r 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 Columbia Maintenance Manual January 2008 42 1 42 Brakes 08 09 95 1421383 1 5 16 x 4 1 2 Inch Upper 9 Desiccant Cartridge 18 Purge Valve Mounting Bracket Capscrew 10 O Ring 19 1 4 Inch Tapping Screw 2 Upper Mounting Bracket Strap 11 Safety Valve 20 Purge Valve Housing 3 5 16 Inch Lockwasher 12 Lower Mounting Bracket 21 Heater and Thermostat 4 5 16 Inch Nylok Nut 13 3 8 Inch Capscrew long Housing 5 Upper Mounting Bracket 14 Check Valve Assembly 22 Return Spring 6 Housing 15 Purge Valve Assembly 23 Purge Piston 7 Nylok Nut 16 Purge Valve Bolt 24 3 8 Inch Capscrew 8 3 8 Inch Special Washer 17 Exhaust Diaphragm 25 End Cover Fig 1 AD 9 Air Dryer exploded view Ibf in 3060 to 4340 N cm Install the capscrew leaks are present see Group 42 of the two washers and a new Nylok nut in the upper Columbia Workshop Manual for diagnosis and mounting bracket strap Torque the upper mount repair information ing bracket strap capscrew 80 to 120 Ibf in 904 to 1356 N cm 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 20 Remove the chocks from the tires 19 Start the engine build the air pressure and c
127. racked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 10 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fill the grooves or depressions on the top plate See Maintenance Operation 31 02 for lubrication instructions Holland 1 Disconnect the tractor from the trailer For in structions see the Columbia Driver s Manual 2 Thoroughly steam clean the fifth wheel 3 Check for loose nuts or broken bolts on the fifth wheel assembly 4 Inspect for cracks or wear on the mounting bolts 5 Inspect for improper locking action and for cracks or wear on the jaw locking mechanism 6 Check the depth of the grease grooves If the depth of the grooves is 1 8 inch or less replace the fifth wheel top plate See Group 31 of the Columbia Workshop Manual 7 Check the condition of the X pattern cast into the underside of the fifth wheel top plate See Fig 2 The fifth wheel top plate must be removed to check the X pattern 7 1 Remove the roll pins from the bushing pins Remove the bushing pins from the slide mount Using a hoist lift the fifth wheel top plate off of the vehicle 7 2 Turn the fifth wheel top plate over with the locks open Check the condition o
128. rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock the tires 2 Ifthe vehicle has just been driven allow a few minutes for the lubricant to settle 3 Clean the oil fill plug and the area surrounding it See Fig 7 Remove the plug from the fill hole or standpipe if installed in the oil fill hole 06 07 94 f350002a 1 Axle Housing Breather 2 Fill Plug 3 Temperature Indicator Plug Fig 7 Dana Spicer Axle Housing Breather IMPORTANT A lubricant level close enough to be seen or touched is not sufficient It must be level with the bottom of the fill hole or the top of the standpipe opening 4 Check that the lubricant is level with the bottom of the fill hole or with the top of the standpipe opening See Fig 2 If low check for oil leaks and correct as needed 5 Install and tighten the fill plug 40 to 60 Ibf ft 54 to 81 N m IMPORTANT Always check the axle breather whenever checking lubricant level Check the Columbia Maintenance Manual July 2005 35 7 35 Rear Axle breather more frequently under adverse operat unit housing Using a wrench tighten it an addi ing conditions tional 1 1 2 turns 6 Check the axle housing breather Make sure that itis unclogged and free from corrosion See Fig 7 If the breather is plugged or damaged clean or replace it as nee
129. ril 2005 Transmission 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant A CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Overfilling will force fluid out of the case through the main shaft openings Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi tives friction modifiers extreme pressure gear fluids or multiviscosity lubricants NOTE Fluid change intervals are extended to 500 000 miles 800 000 km on any vehicles filled with synthetic transmission fluid 1 Drain the transmission when the fluid is warm If not already warm run the engine until the trans mission fluid reaches operating temperature Shift the transmission to neutral N and shut down the engine 2 Park the vehicle on level ground apply the park ing brakes and chock the rear tires Place a large drain pan under the transmission 3 Clean the area around the fill plug and remove it from the side of the gear case Remove each drain plug from the bottom of the case 4 Clean the fill and drain plugs For magnetic plugs use a piece of key stock or any other con venient steel slug to short the two magnetic poles and divert the magnetic field 26 formance change the filter each time that the fluid is changed 5 Fora transmission equipped wit
130. s 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 con sidered an indication of poor air dryer per formance Inspect the air dryer for external damage and check that the unit is tightly mounted on the frame If the air dryer mounting is loose See Group 42 of the Columbia Workshop Manual for mounting instructions Turn on the ignition switch but do not start the engine Disconnect the harness connector from the air dryer Connect a voltmeter to circuit 94 on the air dry er 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 and 32 C the heater thermostat measured resis tance will be infinite ohms If the measured resis tance is less than infinity replace the heater thermostat Remove the heater thermostat assembly and place it in a freezer for about five minutes to cool it below 40 F 5 C Remove the cold heater thermostat assembly and check resis tance
131. scribed in Visual Inspection are found V belts are installed as individual belts and as matched sets When replacing matched sets of belts always replace both belts at the same time Matched belts must be from the same manufacturer To inspect a belt gently twist it to view the belt side walls and bottom Inspect all belts for the following conditions then perform the Belt Tension Inspec tion 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 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 belts before replacing the drive belts Do not use belt dress ing on any belt 3 Check the belt for a jagged or streaked sidewall See Fig 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 usu ally caused by foreign objects in the pulley or by prying or forcing the belt during removal or instal lation 5 Check for uneven ribs on serpentine poly V belts See Fig 2 Ref E Foreign objects in the pulley will erode the und
132. sorber is damaged or leaking replace it with a new one See Group 32 of the Columbia Work shop Manual for replacement instructions Columbia Maintenance Manual February 2010 32 32 11 27 95 1320465 Fig 2 Direct Acting Shock Absorber front suspension shown Rear Suspension Check Freightliner Spring Suspension Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only visibly damaged parts is no as surance that the spring is safe Failure to replace a damaged spring assembly could cause an acci dent resulting in serious personal injury or prop erty damage Replace worn cracked or damaged spring brackets Failure to do so could result in bracket breakage possibly leading to loss of vehicle con trol and resulting in personal injury or property damage 1 Inspect the forward and rear spring brackets and equalizer brackets for wear cracks and other damage If any of these conditions exist replace the damaged bracket s See Group 32 of the Columbia Workshop Manual for instructions 2 Inspect the tandem axle frame crossmember and gussets for wear cracks and other damage If any of these conditions exist replace the dam aged parts See Group 32 of the Columbia Workshop Manual for instructions Suspension NOTICE Failure to repl
133. supplement additives Available as a Caterpillar Caterpillar Diesel Engine Antifreeze Coolant premixed solution Cummins Fleetguard Compleat Premix Premixed solution with supplement additives Detroit Diesel Detroit Diesel Power Cool Premixed solution with supplement additives Old World Industries Fleet Charge With supplement additives Table 2 Approved Antifreeze Maximum Coolant Protection in F C at Various Antifreeze ConcentrationS Cooling ETHYLENE GLYCOL BASE ANTIFREEZE REQUIRED System gallons liters Capacit SAUL 2 8 3 11 aas 5 19 6 23 7 26 8 30 9 34 38 42 145 10 38 16 9 4 16 12 C24 34 37 62 52 t 11 42 18 C8 8 13 6 C21 23 31 47 44 62 52 t 12 45 19 7 10 12 0 18 15 C26 34 37 57 C49 13 49 21 6 13 mm 3 C16 9 C23 25 81 45 43 62 52 t 14 53 15 9 6 14 5 C19 18 C28 34 37 54 48 15 57 16 9 8 13 0 718 12 24 26 32 43 42 a 16 61 17 C8 10 C12 2 17 8 22 19 C28 34 87 oe ei 17 64 18 C8 12 C11 5 15 4 20 14 26 27 33 wc uo 18 68 19 C7 14 10 714 06 48 10 23 21 29 d ws ai 19 72 20 7 1569 9 13 2617 7 22 16 27 T gt Wc 20 76 16 9 t0 12 sie 3t19 12 C24 CS Can Ca
134. t to malfunction 8 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF 9 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed 49 Columbia Maintenance Manual January 2007 49 3 Doors 12 Index Alphabetical Title of Maintenance Operation MOP MOP Number Door Seal Door Latch Door Hinge and Door Check Lubrication es EE ES EE Se ee ee 72 01 Columbia Maintenance Manual October 2005 Doors 72 01 Door Seal Door Latch Door Hinge and Door Check Lubrication Door Seals Lightly coat the door seals with a lubricant that is safe for rubber Door Latches Approved NLGI grade 2 greases or products for lu bricating door latches are Mobilgrease Moly 52 e Chemtool Alpha 2000 Unirex Moly H e Conoco Moly Poly e Conoco Tachna 2000 Apply liberal amounts of an approved NLGI grade 2 grease to each moving joint of all door latch assem blies Use an appropriate applicator that will not leave material behind Chemtool Alpha 2000 is the preferred product for this application because it has superior properties and it is white unlike the moly impregnated greases In general light penetrating oils such as WD 40 should not be used because they wash out beneficial factory installed grease and they evaporate Door Hinges The door hinges on
135. ted without the recirculation air filter installed IMPORTANT When replacing the air filter use only a Freightliner approved air filter 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Remove the heater and air conditioner cover and the upper dash cover For instructions see Sec tion 60 08 of the Columbia Workshop Manual 83 2 Columbia Maintenance Manual October 2002 Heater and Air Conditioner 3 Remove the retainer that holds the recirculation 1 air filter in place See Fig 4 1 83 Turn off the engine apply the brakes and chock the tires Access the sleeper HVAC assembly by raising the mattress and bunk panel to the locked posi tion If there is a baggage compartment the sleeper HVAC assembly may be accessed through the baggage door on the right side of the vehicle Slide the air filter out of the sleeper HVAC as sembly See Fig 5 02 26 2002 1 Retainer 2 Recirculation Air Filter 831491 02 26 2002 831492 Air Filter Fig 4 Cab Recirculation Air Filter 4 Remove and discard the recirculation air filter 4 5 Install a new recirculation air filter in the HVAC 5 assembly j 6 Install the retainer to hold the recirculation air filter in place 6 7 Install the heater and air conditioner cover and 7 the upper dash cover For instructions see Sec tion 60 08 of the Columbia Workshop Manual Sl
136. ter then install it on the vehicle Columbia Maintenance Manual January 2007 20 7 20 4 Check the fan for bent cracked or damaged blades Replace if damaged Check for adequate clearance between the fan and other compo nents 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing Replace the friction facing if it is worn to a 3 16 inch 4 8 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evi dence of oil or burn marks are found replace the friction facing 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and fan clutch from a distance Look for vibration fan blade contact fan clutch slippage and overall fan clutch operation If the fan clutch does not operate correctly see Group 20 of the Columbia Workshop Manual for troubleshooting and repair procedures 8 With the air system charged to 120 psi 827 kPa check the fan clutch for audible air leaks using a suitable listening device Check at the solenoid valve the air filter assem bly and the air hoses and fittings See Fig 8 Using a wet finger or a soapy water solution check for a leak in the same areas 05 30 2002 1200581 Fig 8 Checking for Air Leaks Horton DriveMaster Engine Cooling R adiator 9 If a
137. the fill plug finger tight in the rear axle shift 35 8 Columbia Maintenance Manual July 2005 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel Nut XSITBOK cavete pu RES DEERE DE SERE p ph Reece b EUR Le Shore NE 40 01 Columbia Maintenance Manual April 2005 Wheels and Tires 40 01 Wheel Nut Check IMPORTANT After a wheel has been installed the wheel nut torque must be rechecked after 50 to 100 miles 80 to 160 km of operation See Table 1 for disc wheel nut torque specifications and see Fig 1 for the wheel nut tightening se quence 4h CAUTION Insufficient wheel nut rim nut torque can cause wheel shimmy resulting in wheel damage stud breakage and extreme tire tread wear Excessive wheel nut torque can break studs damage threads and crack discs in the stud hole area Use the recommended torque values and follow the tightening sequence shown in Fig 1 40 When checking wheel nuts on a dual disc assembly remove one outer nut at a time tighten the inner nut then reinstall and tighten the outer nut Repeat this procedure for all wheel nuts using the tightening se quence shown in Fig 1 1 1 10 8 7 f 4 3 W N 6 5 O6 50X 4 A B 09 18 2001 1400164 A 8 Stud Disc Wheel B 10 Stud Disc Wheel Fig 1 Wheel Nut Tightening Sequence Disc Wheel Fastener Torques Description Nut Size Wheel Manufacturer Torque I
138. the lubricant down the shaft and the attaching locations NOTE Operation of the Pacbrake could be af fected by starting the engine and idling for short periods of time During a cold engine start up moisture occurs in the engine and the exhaust system that creates a corrosion hazard The brake housing may trap water in the valve shaft bore causing corrosion resulting in an improp erly functioning or non functioning brake If it is necessary to periodically start the engine attain normal operating temperatures before shutting down the engine Columbia Maintenance Manual January 2007 01 3 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement 00000 0c eect eee 09 01 Columbia Maintenance Manual February 2004 Air Intake 09 01 Air Cleaner Element Inspection and Replacement Method 1 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 inH5O on a vehicle with a Detroit Diesel engine 22 inH O on a vehicle with an MBE engine or 25 inH5O on a vehicle with a Caterpillar or Cummins engine For replacement instructions see Group 09 of the Columbia Workshop Manual Reset the air restriction indicator Each time the air cleaner is replaced perform the procedures in MOP 13 01 If the maximum restriction is not reached record the air restriction value If the value is hig
139. the tires IMPORTANT After 300 000 miles 500 000 km oil level must be checked at each M1 interval on Freightliner axles 2 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature NOTE Some Freightliner axles have a small tapped and plugged hole near and below the housing oil fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 3 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 4 Install and tighten the fill plug 41 Ibf ft 55 N m IMPORTANT Always check the axle breather whenever checking lubricant level Check the breather more frequently under adverse operat ing conditions 5 Check the axle housing breather Make sure that it is open and unclogged If the breather is plugged or damaged clean or replace it as needed 6 On non drive axles using oil lubricated wheel bearings check the oil level at the wheels and add oil if low Use the same lubricant recom mended for the drive axle NOTE When adding to or checking the oil level make certain the hub cap and plug are clean before removing the plug this will minimize the possibility of dirt and road grime entering the assembly 35 Dana Spicer CAUTION Failure to keep the
140. tion a loose or broken capscrew at any point in the driveline will weaken the driveline connec tion which could eventually result in serious ve hicle damage Do not over tighten bearing cap capscrews or yoke strap capscrews 2 For driveline universal joints with bearing caps tighten bearing cap capscrews 43 Ibf ft 49 Nm 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 12 09 97 1410182 04 13 98 1410155a 1 Self Locking 2 Adhesive Band Capscrew Fig 1 Meritor U Joint Fasteners for Bearing Caps 3 Check the driveline yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes 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 driveshaft and U joint from the yoke then check the drive component s shaft seal for leak age or other visible damage that may have been caused by the loose yoke Replace the seal if needed then tighten the yoke nut Refer to Group 41 of the Columbia 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
141. ts secured with Huck bolt fasteners do not require a torque check how ever they should be inspected for damage Frame brackets and components secured with conventional bolts and nuts are to be checked at Initial Mainte nance IM See Fig 6 for pre EPA2007 engine mounts Check the torque of frame fasteners to off set the effects of bedding in or seating When checking torque torque the nut not the bolt head whenever possible This will give a true torque read ing by eliminating bolt body friction When checking the torque of frame fasteners inspect the frame for cracks and other damage Set a click type torque wrench to the maximum torque of the fastener you are checking Apply pressure until the torque wrench clicks Do not loosen the bolt to check the torque See the applicable torque table in Group 00 for torque specifications 4h CAUTION Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage NOTE Engine supports on vehicles built from January 2007 do not require checking Check the fasteners at the following locations Axle Stops e Deck Plates e Engine Trunnion Supports Equalizer Brackets Exhaust Brackets Fifth Wheel Legs Fifth Wheel Mountings e Frame Crossmembers and Gussets Front Frame Brackets Columbia Maintenance Manual October 2008 31 5 31 Frame and Frame Components Any com
142. u cannot tighten the hub cap to the correct torque value or if it makes a popping sound while being tightened re place it with a new one 24 Remove the chocks from the tires Columbia Maintenance Manual October 2004 33 5 Rear Axle Title of Maintenance Operation MOP Axle Breather and Axle Lubricant Level Inspection Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Eubricarib acuto obe ath dead tame ean OY PAGA eink one onde dos 35 Index Alphabetical MOP Number Columbia Maintenance Manual July 2005 Rear Axle 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Lubricant 4h CAUTION Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage For all axles including tandem drive axles and two speed axles do the procedures under the heading All Axle Models For a two speed axle with a shift unit also change the shift unit lubricant See under the heading Two Speed Axles With Shift Unit All Axle Models Meritor IMPORTANT On Meritor axles the oil change interval for Schedule Ill and IV vehicles is ex tended to 500 000 miles 800 000 km for axles using synthetic lubricant with a pump and filter System On single drive axles so equipped the traction equal izer may slip or stick When this happens you will hear
143. ure the dis tance from the bottom of the forwardmost left axle stop to the top of the axle U bolt pad See Fig 7 Ref A The correct distance for single and dual drive rear axles is between 2 3 8 inches and 2 7 8 inches 60 to 73 mm A a 05 15 95 1320410 A Measure the length of the overtravel lever between these two points 1 V Shaped Mark 2 Adjustment Locknut 3 Overtravel Lever 4 Cotter Pin 5 Linkage Rod Fig 6 AirLiner Overtravel Lever and Linkage Rod Measurement 08 16 96 1320453 A Measure height here 1 Left Forwardmost Axle Stop Fig 7 AirLiner Axle Stop Measurement 32 4 Columbia Maintenance Manual February 2010 Suspension 5 If the axle stop measurement is not correct see Group 32 of the Columbia Workshop Manual for adjustment procedures 6 Apply the parking brakes and remove the chocks Chalmers Suspension 1 Chock the front tires place the transmission in neutral and release the parking brakes 2 Power wash the suspension or clean it with a hard bristle brush before performing a visual in spection 3 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 re placement 4 Lift the rear o
144. used for all temperatures do not mix it with kerosene To prevent component damage do not mix engine oil and automatic transmission fluid 4 Using the recommended lubricant fill the shift unit housing through the oil fill hole until the lubri cant is level with the bottom of the opening 5 Coat the threads of the fill plug with a small amount of Loctite9 242 or equivalent sealant Install the fill plug finger tight in the rear axle shift unit housing Using a wrench tighten it an addi tional 1 1 2 turns 35 02 Axle Breather and Axle Lubricant Level Inspection For all axles including tandem drive axles and two speed axles do the procedures under the heading All Axle Models For a two speed axle with a shift unit also change the shift unit lubricant See under the heading Two Speed Axles With Shift Unit All Axle Models Meritor 4h CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock the tires IMPORTANT Oil level must be checked at each M1 interval on Meritor axles 2 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature NOTE Some Meritor axles have a small tapped and plugged hole near and below the housing oil fill hole T
145. uspension Lubrication Front Suspension Wipe all dirt away from the grease fittings if equipped on the spring eye bushings Apply multi purpose chassis grease with a pressurized grease gun until old grease is forced out NOTE Service Schedule IV vehicles equipped with a 12 000 Ib 5452 kg front axle are fitted with maintenance free rubber bushings and do not require lubrication Columbia Maintenance Manual February 2010 32 5 32 Rear Suspension Chalmers No lubrication is required on the Chalmers rear suspension Freightliner Spring Single Axle No lubrication is required on Freightliner single axle rear suspensions Tandem Axle Lubricate the equalizer cap and tube assembly bush ings by applying multipurpose chassis grease at the grease fitting until old grease is forced out from the cap and tube assembly See Fig 9 05 27 93 320020a A Lubricate here 1 Cap and Tube Assembly Bushing Fig 9 Equalizer Assembly Lubrication Hendrickson The Hendrickson RS Series suspension does not require lubrication For Hendrickson RT2 and RTE2 Series lubricate the bronze ball indented bushings in the spring eye as follows 1 Park the vehicle on a level surface apply the parking brakes and chock the front tires 2 Raise the rear of the vehicle until the rear wheels are suspended in the air then support the ve hicle with safety stands This relieves the load on Suspension
146. vehicles built before and after 8 1 2005 have different lubrication requirements The hinges on vehicles built before 8 1 2005 should be lubricated while those on vehicles built on or after 8 1 2005 should not be lubricated 4h CAUTION Do not lubricate the door hinges on vehicles built on or after 8 1 2005 Lubrication of these hinges could adversely affect the performance of the bushings To determine if the door hinges need to be lubri cated first identify the hinge by checking the top loop of the hinge bracket See Fig 1 72 Door Hinges on Vehicles Built on or After 8 1 2005 On vehicles built on or after 8 1 2005 the door hinge center pin is recessed in the top loop of the hinge bracket There is a dimple in the top and bot tom loop of the hinge bracket See Ref A of Fig 1 Do not lubricate this type of hinge Lubrication could adversely affect the performance of the bushings In addition some lubricants may not be compatible with the hinge bushings Door Hinges on Vehicles Built Before 8 1 2005 On vehicles built before 8 1 2005 the door hinge center pin is flush with the top of the top loop of the hinge bracket There is no dimple in the top or bot tom loop of the hinge bracket See Ref B of Fig 1 Lubricate this type of hinge with approved NLGI grade 2 greases or products such as Mobilgrease Moly 52 e Chemtool Alpha 2000 Unirex Moly H Conoco Moly Poly Conoco Tachna 2000 Lubricate external
147. w 11 Dust Cap 16 Rear Axle 5 Bearing Cap Fig 3 Components of a Basic Driveline greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft Visually examine the driveshaft tubes for dents bends twists or other damage If any tube ap pears to be damaged refer to Group 41 of the Columbia Workshop Manual for repair and re placement instructions Examine the driveshaft for evidence of missing balance weights and for build up of foreign ma terial Remove any foreign material If there is any evidence that balance weights are missing remove the driveshaft and have it balanced 9 For driveshafts with slip joints check to be sure the yoke plug is not loose or missing See Fig 5 Ref 2 Repair or replace the yoke plug as needed If the yoke plug is missing the splined shaft may be hitting the plug and knocking it out contact your Regional Service Office for assis tance in determining the correct driveshaft length 41 2 Columbia Maintenance Manual March 2000 Driveline 2A UU NY 05 27 93 Y f410012a Attempt to move the sleeve yoke and splined shaft back and forth Fig 4 Slip Joint Spline Wear Checking 41 02 Driveline Lubrication Universal Joint Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines do not require periodic lubrication 1 Park the vehicle on a flat surface apply the park ing brakes and chock the tires 2 Wipe
148. x53 ear d chin cots cote d d aee LARA a EN dedidit EDU Ah b ncaa d ER Gd poet a d itu A 46 05 Power Steering Fluid Level Inspection liliis 46 03 Power Steering Fluid and Filter Changing nh 46 02 Power Steering Gear Lubrication is s curga ia iiai a a i aaa EE Ee iR a Ee ee ee rn 46 04 Rack and Pinion Steering Inspectlon a suena cc e redo mm RARE Recreo EE ER eas gems 46 06 Columbia Maintenance Manual February 2010 Steering 46 01 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 per sonal 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 Inspect the boot of the drag link at both the pitman arm and the steering arm end for cracks splits or other damage Replace the boot as needed See Group 46 of the Columbia 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 e
149. ximate Fill transmission until lubricant is level with bottom of fill hole with vehicle in normal operating position Table 2 Meritor Transmission Lubricant Capacities NOTE In all cases the correct fluid level is es tablished by checking at the fill opening 7 Operate the engine for five minutes after filling the transmission then check the fluid level again 8 Clean the fill plug then install it in the transmis sion Tighten the plug as follows e 25 to 35 Ibf ft 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads Eaton Fuller Transmission Lubricant Capacities Transmission Model Refill Capacity qt L 7 Speed T Series All Models 18 0 17 0 All 9 Speed Series All Models 13 5 12 8 All 10 Speed Manual except deep reduction FR and FRO Series 11 75 11 0 RT and RTX Series 13 0 12 3 RTLO Series 14 0 13 2 10 Speed Deep Reduction RTO 14908LL 14 0 13 2 RTO 16908LL 10 Speed Automated Lightning Top 2 all 13 5 12 8 10 Speed Autoshift AS2 all 13 0 12 3 13 Speed RTLO Series All Models 14 0 13 2 15 Speed RTO Series All Models 14 0 13 2 All 18 Speed Series RTLO Series 14 0 13 2 18 Speed Autoshift AS2 all Quantities listed are approximate Fill transmission until lubricant is level
150. y Scheduled intervals are in the maintenance tables in MAGA this group A Verification of Inspections Log Groups Freightliner Noise Emission 01 20 and 49 follows and should be filled in each time noise emission controls on the vehicle are main Controls Warranty tained or repaired Refer to the vehicle owner s warranty information book for warranty information concerning noise emis sion controls Tampering with Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for Columbia Maintenance Manual February 2010 00 17 00 Verification of Inspections Log 00 11 Verification of Inspections Log Verification of Inspections Log Group 01 General Information Verification of Inspections Log Group 01 Engine Mounts Date Mileage Item Cost Maintenance Facility Verification of Inspections Log Group 20 Verification of Inspections Log Group 20 Fan Clutch Date Mileage Item Cost Maintenance Facility 00 18 Columbia Maintenance Manual February 2010 General Information Verification of Inspections Log Grou
151. y Unlubricated Plain Unplated Threadst Regular Hex Flanged Thread Grade 5 or B Grade 8 or 8 2 Grade 8 or C Grade 8 or 8 2 a Grade 5 Bolt Nut Bolt Nut Bolt Grade G Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Br po pa eue al Wa 1 4 20 8 11 10 14 1 4 28 9 12 12 16 5 16 18 15 20 22 30 22 30 5 16 24 17 23 25 34 3 8 16 28 38 40 54 40 54 3 8 24 31 42 45 61 7 16 14 45 61 65 88 65 88 7 16 20 50 68 70 95 1 2 13 70 95 95 129 95 129 1 2 20 75 102 110 149 9 16 12 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 818 155 210 215 292 3 410 240 325 340 461 340 461 3 4 16 270 366 380 515 7 8 9 385 522 540 732 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 18 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 19 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads 00 22 Columbia Maintenance Manual February 2010 General Information 00 Torque Specifications Tables 00 13
152. y coat For cooling system capacities not shown the required amount of antifreeze can be calculated using the following Ethylene g C 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 t 60 ethylene glycol base antifreeze and 40 water by volume gives maximum coolant protection 62 F 52 C Exceeding 60 antifreeze diminishes coolant protection concentrated ethy ene glycol base antifreeze will freeze at approximately 0 F 18C Table 3 Maximum Coolant Protection in F C at Various Antifreeze Concentrations NOTE You can mix purple pink coolant pre charged with a borate nitrate based additive with the common green coolant although some color change will be apparent 14 Replace the surge tank cap s 15 Return the hood to the operating position 16 Start the engine and turn on the cab heater Allow the engine to warm up to normal operating lycol base antifreeze in a 25 temperature Check the radiator and hoses for leaks Repair as needed 17 Shut off the engine then check the coolant level in the surge tank Add coolant if the level isn t between MIN and MAX lines on the surge tank 20 4 Columbia Maintenance Manual January 2007 Engine Cooling R adiator 20 03 Fan Clutch Check Noise Emission Control Horton Advantage Fan Clutch NOTE If any part of the fan clutch needs to be rep
153. ze Torque Ibf ft N m Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 180 to 230 245 to 313 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 5 818 3 4 16 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 7 8 14 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 520 to 600 707 to 816 1 14 Tighten in a diagonal pattern as shown in Fig 11 Table 1 Spring Assembly U Bolt High Nut Torque Values 01 05 99 2 3 1320783 Fig 11 Tightening Pattern for U Bolt High Nuts 32 Columbia Maintenance Manual February 2010 32 7 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AFA Alignment Chek doo ess dead Anas bli on me uires RD OND Eod xis perpe Rog x dotes di dia i gb Doe 33 04 Basic Inspection Meritor Unitized Wheel Ends 2 anena nan iatea nenian aia 33 07 End Play Check Meritor Unitized Wheel Ends lilii 33 08 Knuckle Pin Lubrication Dana Spicer Axles ia dua ah ora xd Rn ego aam RR reor a cea RR aye ea 33 05 Knuckle Pin Lubrication Meritor Axles SEE SE SS Se Se Se RR Rs 33 01 Tie Rod InSpectiOri esse m RR Ron Rm kem doe esc dave e ken a e PP RC UR Remi ES 33 02 Tie Rod Lubrication Dana Spicer Axles ea ue ek ata doe ge an a E ex EE DE a Ere ex soe axe ge ae 33 0

Maintenance Manual - TransChicago Truck Group

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