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COLUMBIA MAINTENANCE MANUAL Models

1. Maint No Maintenance Service Service Schedule 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 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 14
2. Fig 9 CGI Bellows Installation 14 Slide the end of the forward CGI pipe into the bellows and properly align the pipe 15 Secure the forward CGI pipe to the engine and any CGI pipe support brackets 16 Using the yellow marks center the bellows be tween the exhaust pipes Verify that the pipe is inserted at least 7 16 inch 10 mm past the face of the flange See Fig 9 Ref A 17 Install the slip clamps on the bellows Tighten the slip clamps 11 Ibf ft 15 Nm 18 Start the engine and check for exhaust leaks Tighten any clamps as needed Columbia Maintenance Manual December 2011 49 5 49 1 2 3 4 5 LL 02 08 2010 1490417 1 CGI Bellows 4 Graphite Gasket 2 Slip Clamp 5 Forward CGI Pipe 3 Retaining Ring Fig 10 Forward Facing Slip Clamp Installation Exhaust 49 6 Columbia Maintenance Manual December 2011 Cab 60 Index Alphabetical Title of Maintenance Operation MOP MOP Number Mitror Folding Se RR cutis igen a NE 200 LESS CORTE 60 01 Columbia Maintenance Manual December 2011 Cab 60 01 Mirror Folding Check For vehicles with folding main mirrors make sure that the mirrors fold freely on the pivot points Pivot each mirror fully forward and backward two times to break loose any debris that may affect th
3. 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 E Lubricants or Off Highway Dana Spicer and Meritor i i Equipment or f cias 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 1 Fig 5 Two Speed Axle Shift Unit Reducti ET Ee DER IT 43 20 3 2 Thoroughly wash the axle shift parts and housing Quantities listed are approximate Fill axle until lubricant is level with bot cover and allow them to air dry tom of fill hole with vehicle on level groun
4. 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 EE IS M2 Maintenance Interval Operations for Service Schedules I Il and III 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
5. 000000 02 eeee Exhaust System Inspection Noise Emission Control 49 Index Alphabetical MOP Number Columbia Maintenance Manual December 2011 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 EPAO7 Exhaust System Inspecting 1 On all vehicles check the condition of the muffler body and the top stack Check the inlet outlet 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 o
6. 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 check 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 vehicl
7. 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 00 16 Columbia Maintenance Manual December 2011 General Information 00 Maintenance Operation Sets Table 00 09 Maintenance Operation Sets for Groups 00 through 83 ns Operation Description bd ek a Service oe 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
8. 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 If the 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 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 Ea
9. 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 J X 7 D N m J Y 4 NOTE The optional transmission fluid filter is a 7 Y remote mount spin on type and is located be E A 2 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 Trans
10. Work shop Manual for replacement instructions Columbia Maintenance Manual February 2010 32 1 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 replace the suspension crossmember or gussets if they are cracked worn or otherwise
11. 20 01 Coolant Replacement 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 OPE eee o EE General Information EE AR IEEE Engine 9 crit EE TE Rs Air Intake 18 cc PIC AA Air Compressor ARME EE N TA Alternators and Starters 20 EE ir ed ater at EE Engine Cooling Radiator CERT Clutch 2D ks endo cet DEE BES E E Transmission EE EE xem Frame and Frame Components EE ET EE OF Suspension QI Ek oe rue aide Front Axle GO EE dant ds OR EE N a Rear Axle AD ES RE KORE ME IM anes Satine Wheels and Tires AN TD Ge Mae BE ag ah Driveline SEE ERA EE HOE MEE EN Brakes EE A RE e eens Steering EE OE EE EE N dos Fuel EN RE EN Fe EF Exhaust OE ER GE EE DE A deaths ae Cab TE SERS BEE MAER OER ee EE er Doors PA AE TE OE AK Heater and Air Conditioner OB ida Rub Hood Grille and Cab Fenders 1 4 Columbia Maintenance Manual February 2010 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Determining Scheduled Maintenance Intervals 000 SS Es EE ee ER eee 00 01 Initial Maintenance
12. 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 December 2011 General Information 00 Vehicle Maintenance Schedule Tables 00 03 1st through 30th Maintenance for Service Schedules and II 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 100 000 160 000 11th M1 11 000 17 600 1100 110 000 176 000 12th M1 12 000 19 200 1200 120 000 192 000 13th M1 13 000 20 800 1
13. 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 24 Columbia Maintenance Manual December 2011 General Information 00 Torque Specifications Tables 00 13 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 Y ad N Ss N TOP N F P N uds a E Te f230010 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
14. 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 December 2011 00 25 Engine Title of Maintenance Operation MOP Engine Drive Belt Inspection lt lt lt Engine Support Fasteners Check o ooooooooo oo Pacbrake Inspection and Lubrication 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 fasten
15. Clamp 5 Slip Clamp 8 Center Pipe 2 Inlet Pipe 6 CGI Bellows 9 Clamp 3 U Clamp 7 Center Pipe Support Brace 10 Outlet Pipe 4 Forward Pipe Support Brace Fig 5 CAT EPA07 Exhaust Installation with CGI Bellows 4 f present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD Columbia Maintenance Manual December 2011 49 3 49 49 02 CAT CGI Bellows Replacement On vehicles with CAT EPAO7 compliant engines re place the CGI bellows at the M3 maintenance inter val to prevent a later failure NOTICE A leak in the CGI piping including the bellows will allow unfiltered air and contaminants into the engine intake and can cause serious engine damage 1 Park the vehicle set the parking brake chock the wheels 2 Open the hood 3 Remove the right side inner fender splash shield as needed 4 Remove the CGI piping between the engine and aftertreatment device ATD See Fig 6 5 On the workbench remove the CGI bellows from the exhaust piping Do not damage the piping Exhaust will align the pipes so that the bellows can be installed correctly 6 Install the CGI piping without CGI bellows and align piping 6 1 Attach the aft CGI pipe to the ATD 6 2 Attach the forward CGI pipe to the en gine NOTICE When the CGI pipes and bellows are installed there should be approximately 3 4 inch 19 mm clearance from the main bellows C
16. 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 each pole Magnets will rapidly lose their effectiveness as collected material bridges the gap between the two poles 5 3 Ea
17. Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Fiter Heplaee melle d ado euge dh dt aue anh de qi dbi S HEES bones 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 EER EE Pied t kere ien y er RRR eee eee 47 03 Columbia Maintenance Manual March 2000 F uel 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 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
18. 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 e 3 hd 05 27 93 5 f320023a A 1 8 3 mm Clearance 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar Fig 5 Top View of the Equalizer ditions exist replace the damaged bracket
19. S e Diesel Particulate Filter DPF a filter that col ge s z lects and holds particulate matter soot and d ash j e 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 Turbocharger 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 na OOND Fig 4 Typical After Treatment Device 49 2 Columbia Maintenance Manual December 2011 Exhaust the required torque If leakage persists install a new clamp 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 NOTICE A leak in the CGI piping including the bellows will al
20. 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 engine 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
21. 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 46 04 Power Steering Gear Lubrication Sheppard Sheppard power steering gears manufactured with out grease fittings are maintenance free lf 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 1460296a 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 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
22. 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 December 2011 General Information 00 Vehicle Maintenance Schedule Tables 00 03 1st through 20th Maintenance for Service Schedules lll 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 II and IV 21st through 40th Maintenance for Service Schedules lll 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 1 490 000 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 Maintenanc
23. 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 8 18 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 03 10 2011 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 SEUN ES DER net DEW RD OND eens AAA Pacem gb Doe 33 04 Basic Inspection Meritor Unitized Wheel Ends llli 33 07 End Play Check Meritor Unitized Wheel Ends lilii 33 08 Knuckle Pin Lubrication Dana Spicer Axles ia dua ah da aam RR reor a cea RR da ea 33 05 Knuckle Pin Lubrication Meritor Axles SEE 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 sa ue ek ata doe ge an a E ex e a Ere ex soe axe ge ae 33 06 Tie Rod Lubrication Meritor Axles SE SE Se SE has 33 03 Columbia Maintenance Manual October 2004 Front Axl
24. 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake System valve Inspeccion A Saw Rees He 42 01 Alr Dryer AA uate maa coheed ER EE a tha eee beam dee 42 03 Alcohol Evaporator Cleaning and Inspection ii EE EE Se ee ee eee 42 04 Bendix AD 9 Air Dryer Desiccant Replacement 0 2000 eee eee 42 02 Bendix AD IS Air Dryer Desiccant Replacement 000000 eee 42 09 Bendix E 6 Foot Control Valve Inspection and Lubrication llli 42 10 Brako INSPSCHON 252 dur Modem a NES ERAS Gu Gene ORGS e AA Hi IE 42 11 Dana Spicer Camshaft Bracket Lubrication liliis 42 05 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication liliis 42 06 Meritor Camshaft Bracket LUDNCallOnis s s deos db oe DER EES Dg Ee SR RE DER ds 42 07 Meritor Slack Adjuster Lubrication liliis 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 563 000 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
25. 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 Diive ie MSp ses Regine eae 3 uer E hd DS A Steere A n ER ere 41 01 Diveline EW OMCAUOM aos RED ENS EAS AAA we Sh Bde coat a dome eee 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 Ah CAUTION Due to the extreme load occurring at high speed rotation a loose or broken capscrew at any point in the driveline will weaken the driveline connec tion which could eventually result in serious ve hicle damage Do not over tighten bearing cap capscrews o
26. LLC Daimler Trucks North America LLC is a Daimler company Daimler Trucks North America LLC Service Systems and Documentation POC SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Daimler Trucks North America L via ServicePro 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
27. 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 60 01 Mirror Folding Check 83 01 Air Conditioner Inspection 00 12 Columbia Maintenance Manual December 2011 General Information 00 M2 Maintenance Interval Operations 00 07 Maintenance Operation Number M2 Maintenance Interval Operations for Service Schedules I Il and III Check 83 02 Air Filter Replacement Replace the HVAC filters every 6 months regardless of mileage Table 12 M2 Maintenance Interval Operations for Service Schedules I Il and III o Eed 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 Power Steering Fluid Level Inspection e Power Steering Gear Lubrication e Drag Link Lubrication 00 06 Perform All M1 Operat
28. 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 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 29 05 27 93 f250081a Fig 1 Release Bearing Grease Fitting b ES 08 10 2009 1 Sleeve Bushing Contact Point 2 Yoke Finger Contact Points 1250444 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 sea
29. 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 filter 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 facin
30. Schedule Il usage are opera tion primarily in cities and densely populated areas local transport with infrequent freeway travel or high percentage of stop and go travel Service Schedule III long haul transport is for ve hicles that annually travel more than 60 000 miles 100 000 kilometers with minimal city or stop and go operation Examples of Schedule III usage are re gional delivery that is mostly freeway miles interstate transport or any road operation with high annual mileage 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 lb capacity with synthetic lubricant Front suspension with maintenance free rubber bushings for 12 000 lb 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 air dryer mounted on the right hand frame rail located directly behind the front bumper with heater and a Bendix a
31. 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 88 01 Hood Rear Support Lubrication Table 8 Maintenance Operation 00 04 Lubrication and Fluid Level Check for Service Schedules 1 Il Ill and IV 00 8 Columbia Maintenance Manual December 2011 General Information 00 Initial Maintenance IM Operations 00 05 The Initial Maintenance table lists all maintenance tenance operations to be performed All operations operations that are to be performed at the initial listed in the table along with the operations listed in maintenance IM interval Maintenance operation the applicable M1 maintenance interval table must numbers are reference numbers used to help you be performed to complete the initial maintenance find detailed instructions in this manual on the main IM Maintenance m Operation Number Initial Maintenance IM Operations for Service Schedules Il IIl and IV Check 00 06 Perform all M1 Operations 31 03 Frame Fastener Torque Check 31 05 Premier 690 Coupling Inspect
32. 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 FALLS f A J ll YN 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 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 Size Torque Ibf ft N m Stage 1 Hand Tighten Stage 2 60 81 Stage 3
33. 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 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 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
34. 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 dryer on the lower mounting bracket Install the two previously marked cap screws four washers and two new Nylok nuts Torque the two remaining capscrews 270 to 385 Columbia Maintenance Manual January 2008 42 1 42 Brakes
35. 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 e aside 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 MEA oy EN y C 08 14 2008 3821135 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 absorber is damaged or leaking replace it with a new one See Group 32 of the Columbia
36. 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 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 tigh
37. 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 Inspect the weld seams between the torque arm tube and the shorter bushing tubes If there are cracks replace the torque arm Do not weld the torque arm for any reason 5 Inspect the rubber bushing ends See Fig 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 32 of the Columbia Workshop Manual for instructions E 2 05 27 93 A
38. 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 z HL MY 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 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
39. 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 with bottom of fill hole with vehicle in normal operating position Table 3 Eaton Fuller Transmission Lubricant Capacities e 44 bf 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 CAUTION
40. 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 Capscrew 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
41. 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 Loctite 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 This smaller hole is for a lubricant Rear Axle temperature indicator only and should not be used as a fill or level hole 3
42. fully apply Check for im proper operation or adjustment of the automatic slack adjuster See Group 42 of the Columbia Workshop Manual for inspection and trouble shooting procedures 5 Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine 6 Check all of the foundation brake components for damage wear and loose or missing parts Re pair as needed See Group 42 of the Columbia Workshop Manual for repair procedures 42 8 Columbia Maintenance Manual January 2008 Brakes 42 Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 9 1 3 8 35 12 16 Standard Stroke 20 1 3 4 44 24 30 2 51 16 20 2 51 24 2 1 2 inch rated Long Stroke stroke 24 3 inch rated stroke 2 1 2 64 30 12 1 3 8 35 16 Standard Stroke 20 1 3 4 44 24 Haldex 2 1 2 Inch Extended Stroke 24 2 51 3 Inch Extended Stroke 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke 30 2 1 2 64 9 Less than 1 1 2 38 12 Standard Stroke 16 Less than 1 3 4 44 Meritor 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Columbia Maintenance Manual January 2008 42 9 42 Brakes Brake Chamber Stroke Specifications Chamber r Max Applied Stroke inch mm Manufacturer Type Sizet 1
43. glycol base antifreeze will freeze at approximately 0 F 18 C 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 Radiator 20 03 Fan Clutch Check Noise Emission Control Horton Advantage 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 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 conn
44. 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 E f Contains 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 Max
45. 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 dial 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
46. of how to operate and care for the vehicle and its components Each manual contains a chapter that covers pretrip and post trip inspections and daily weekly and monthly maintenance of vehicle components Driver s operators manuals do not contain detailed repair or service information Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid Parts technical bulletins provide information on parts These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures parts documentation can be accessed using the following applications on the ServicePro provides Web based access to the most up to date versions of the publications listed above In addition the Service Solutions feature provides di agnostic assistance with Symptoms Search by connecting to a large knowledge base gathered from technicians and s
47. 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 noise go to the next step Bend an opposing tab of the tabbed washer over a flat of the outer locknut Install the whee
48. 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 December 2011 00 19 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 ltem Cost Maintenance Facility Verification of Inspections Log Group 20 Verification of Inspections Log Group 20 Fan Clutch Date Mileage Item Cost Maintenance Facility 00 20 Columbia Maintenance Manual December 2011 General Information Verification of Inspections Log Group 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 December 2011 00 21 00 General Information Metric U S Customary Conversion Tables 00 12 ME SEE Us E To Get Metric Balls ede ii To Get U S Custom
49. 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 Ah 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 operated 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 Remo
50. 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 splines 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
51. 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 durability Scheduled intervals are in the maintenance tables in 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
52. 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 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 47 1 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 Title of Maintenance Operation MOP CAT CGI Bellows Replacement
53. 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 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
54. 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 Sh alt LUbfiGaHOR ss se aee seem ES BEER DE DR dh BE RR RD BE dr x need Sas 25 02 Eaton Fuller Clutch Release Bearing Lubrication ER EE EE ee 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 vehicle 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
55. 0 Input Shaft Seal Cover 17 Shaft Slip Joint 2 Power Steering Fluid Lines 11 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 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 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
56. 1 600 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 December 2011 00 5 00 Vehicle Maintenance Schedule Tables 00 03 General Information 91st through 100th Maintenance for Service Schedules and Il Maint No Maintenance Service Service Schedule 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 II 1st through 20th Maintenance for Service Schedules II and IV Maint No Maintenance Interval a pe dd ate Miles km 1 IM and M1 25 000 40 000 2 M1 50 000 80 000 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
57. 10 149 90 122 146 198 5 8 11 128 173 136 184 110 149 180 244 5 8 18 145 197 154 209 130 176 204 277 3 4 10 226 306 241 327 200 271 320 434 3 4 16 253 343 269 365 220 298 357 484 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 December 2011 00 23 00 Torque Specifications Tables 00 13 General Information Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged Thread Grade 5 or B Grade 8 or 8 2 Grade 8 or C Grade 8 or 8 2 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 econ oom su Exe em 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
58. 11 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 December 2011 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 apply the parking brakes and chock the tires 2 Check the appearance of the air conditioner compressor pulley assembly If the friction sur face of the pulley shows signs of excessive grooving due to belt slippage replace both the pulley and the drive plate 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 Grou
59. 20 93 f420012a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or plug NAON no 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 with silicone grease a 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 Ja
60. 3 24 Face Seal Small O Ring Air Chamber Socket Head Capscrew Stud Bolt Lockwasher Hexnut Piston Assembly Fig 6 Horton Advantage Fan Cl 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 performed 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 Radiator 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 WARNING If the engine starts during this procedure the fan coul
61. 300 130 000 208 000 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 December 2011 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 33 000 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 36
62. 6 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 III 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 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
63. 6 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 eli uc 22 To Get degrees Fahrenheit F 32 1 8 degrees Celcius C 1 8 32 degrees Fahrenheit F Table 17 Temperature Conversion 00 22 Columbia Maintenance Manual December 2011 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 1230002 1230003 1230004 1230005 1230006 1230007 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 7 16 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2 20 72 98 77 104 65 88 102 138 9 16 12 92 125 98 133 80 108 130 176 9 16 18 103 140 1
64. 6L 20L 2 51 Dana Spicer Long Stroke 24L 24LS 2 1 2 64 30LS Long stroke design is indicated by a tag or embossing on the brake chamber t Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers t If type 36 chamber is used slack length should be less than 6 inches Table 1 Brake Chamber Stroke Specifications 42 10 Columbia Maintenance Manual January 2008 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Link Inspec OE ss eo ocn tives aude ED DE ES A PAAR que bed wb pde 46 01 Drag Emi BUDIESUO x53 ear chin cots cote d AN ER a EN dedidit AR A 46 05 Power Steering Fluid Level Inspection EE EE EE EE Ee ee 46 03 Power Steering Fluid and Filter Changing ooooooooccn nh 46 02 Power Steering Gear Lubrication is s curga ia iiai a a i aaa ae a EG rn 46 04 Rack and Pinion Steering Inspectlon a suena cc e redo mm DR EE RD Recreo s aa 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 a
65. 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 E 2 3 06 07 94 f350062a 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 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 After 300 000 miles 500 000 km oil level must be checked at each M1 interval on Freightliner axles 2
66. 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 rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level gr
67. Dana Spicer and Haldex 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 29 C and higher use Texaco Multifak EP 2 or Mobil Grease No 77 For operating temperatures between 20 F 29 C and 40 F 40 C use Lubriplate Aero grease 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 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 The
68. Descriptions and specifications in this manual were in effect at the time of printing Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerTrucks com for more informa tion 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 2011 Daimler Trucks North America LLC All rights reserved No part of this publication in whole or in part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Daimler Trucks North America
69. Dryer Desiccant Replacement x 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 Element Replacement 47 03 Fuel Tank Band Nut Tightening 49 01 Exhaust System Inspection noise emission control 49 02 CAT CGI Bellows Replacement 60 01 Mirror Folding Check 72 01 Door Seal Door Latch and Door Hinge Lubrication 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement Columbia Maintenance Manual December 2011 00 17 00 Maintenance Operation Sets Table 00 09 General Information Maintenance Operation Sets for Groups 00 through 83 Maint Service Schedules Service Schedule No Operation Description 1 II and Ill IV IM M1 M2 M3 IM M1 M2 M3 88 01 Hood Rear Support Lubrication No specific lubrication interval See MOP 01 03for more information t Inspect Meritor Unitized Wheel Ends at 200 000 miles 321 869 km and then e
70. FREIGHTLINER Run Smart COLUMBIA MAINTENANCE MANUAL Models CL112 CL120 STI 409 2 12 11 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle A proper maintenance program also helps to minimize downtime and to safeguard warranties This mainte nance 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 mainte nance 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
71. IM Operations s ceras J DS A RE cd RR OE RE AR RR RE RE ge 00 05 Lubrication and FluidiLevel Check wi is RARR ERA RE DS a 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 ii EE EE ER ee GE Ge nn 00 08 Maintenance Operation sets Table 2a am der ded ria de a ai a ade 00 09 Metric U S Customary Conversion Tables 2 SE SE SS EG nee ee 00 12 Noise Emission Controls Maintenance 0 000000 eee 00 10 Service schedule Table 5i suse cod dipsa dob dar dr de 00 02 Torque Specifications Tables ss 22008 HERE RR RE DERE bon gic DE HORE gees eaage lanes RE I anes 00 13 Vehicle Maintenance Schedule Tables 0 000 ccc eh 00 03 Vernicalon ol Inspeeioiis Lod ss Ese a O AA a 00 11 Columbia Maintenance Manual December 2011 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 intervals for your vehicle you must first determine the type of ser vice or conditions the vehicle will be operating i
72. If the vehicle moves the parking brakes are not operating correctly and must be repaired Brakes before the vehicle is returned to service See Group 42 of the Columbia Workshop Manual for repair procedures Brake Component Inspection 1 Park the vehicle on a level surface set the park ing brake and chock the tires Once the tires are chocked release the parking brake Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak ing system may lead to brake failure resulting in property damage personal injury or death 2 With the engine off and 100 psi 689 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 550 to 620 kPa brake applica tion 3 Check to see if the colored over stroke band on each brake chamber pushrod is exposed If a band shows the stroke is too long Check the foundation brake components for wear or damage and repair as needed See Group 42 of the Columbia Workshop Manualfor inspection troubleshooting and repair procedures 4 Measure the applied chamber stroke See Table 1 for the proper stroke for the type of chamber being used If the stroke is too short the brakes may drag or will not
73. M3 Maintenance Interval Operations 00 08 you find detailed instructions in this manual on the maintenance operations to be performed Perform all M1 and M2 maintenance interval operations at the tion numbers are reference numbers used to help M3 maintenance interval SEE ie M3 Maintenance Interval Operations for Service Schedules I Il Ill and IV Check 00 06 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 49 02 CAT CGI Bellows Replacement Table 14 M3 Maintenance Interval Operations for Service Schedules I Il Ill and IV Columbia Maintenance Manual December 2011 00 15 00 General Information Maintenance Operation Sets Table 00 09 Maintenance Operation Sets for Groups 00 through 83 SEE Operation Description em Service eer IM M1 M2 M3 IM M1 M2 M3 00 04 Lubrication and F
74. 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 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 1
75. ary 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 cm 0 06102 cubic inches in cubic inches in 0 01639 liters L 61 024 cubic inches in fluid ounces fl oz 29 54 milliliters mL 0 03381 fluid ounces fl oz pints pt 0 47318 liters L 2 1134 pints pt quarts qt 0 94635 liters L 1 0567 quarts qt gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic feet ft cubic feet ft3 0 02832 cubic meters m3 35 315 cubic feet ft3 Weight Force ounces av oz 28 35 grams g 0 03527 ounces av oz pounds av Ib 0 454 kilograms kg 2 205 pounds av Ib U S tons t 907 18 kilograms kg 0 001102 U S tons t U S tons t 0 90718 metric tons t 1 1023 U S tons t Torque Work Force inch pounds Ibf in 11 298 Newton centimeters N cm 0 08851 inch pounds Ibf in foot pounds Ibf ft 1 3558 Newton meters N m 0 737
76. ce 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 28 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 slo
77. ch 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 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 1
78. ck Adjuster Lubrication e Door Seal Door Latch and Door Hinge Lubrication e Hood Rear Support Lubrication 13 01 Bendix Air Compressor Inspection 20 03 Fan Clutch Check noise emission control 31 01 Fifth Wheel Inspection 31 05 Premier 690 Coupling 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 I Il and Ill Guereton amba 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 31 05 Premier 690 Coupling Inspection 42 11 Brake Inspection 49 01 Exhaust System Inspection noise emission control 72 01 Door Seal Door Latch and Door Hinge Lubrication 00 10 Columbia Maintenance Manual December 2011 General Information 00 M1 Maintenance Interval Operations 00 06 Maintenance Operation Number 88 01 Hood Rear Support Lubrication Table 11 M1 Maintenance Interval Operations for Service Schedule IV M1 Maintenance Interval Operations for Service Schedule IV Check Columbia Maintenance Manual December 2011 00 11 00 General Information M2 Maintenance Interval Operations 00 07
79. d 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 used for all temperatures do not mix it with kerosene To prevent component damage do not mix engine oil and automatic transmission
80. d 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 lt 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 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
81. d 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 10 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 int
82. d 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 EPAO7 compliant engines the coolant capacity varies depending on the engine and accessory installation After servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on the surge tank 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 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 1 anhydrous sodium
83. 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 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 in
84. e 33 01 Knuckle Pin Lubrication Meritor Axles 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 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease until new grease is seen at the bushing grease seal opposite the fittings The grease seal will accept grease 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 for adequate clamping See Fig 2 Replace the components if this cannot be done For in structions refer to Group 33 of the Columbia Wo
85. e fold away feature of the mirror 60 Columbia Maintenance Manual December 2011 60 1 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 December 2011 Doors 72 01 Door Seal Door Latch Door Hinge and Door Check Lubrication NOTE Light penetrating oils such as WD 40 should not be used because they wash out ben eficial factory installed grease and they evapo rate Door Seals Lightly coat the door seals with a lubricant that s safe for rubber Door Latches Wipe old grease and dirt from all door latch assem blies then apply liberal amounts of an approved grease to each moving joint see Table 1 Use an appropriate applicator that will not leave material behind Door Hinges The door hinges on 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 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 Door Hinges o
86. e for Service Schedules III and IV Columbia Maintenance Manual December 2011 00 7 00 General Information Lubrication and Fluid Level Check 00 04 Maintenance Operation 00 04 Lubrication and Fluid Maintenance operation numbers given in the table Level Check Operation Table 8 summarizes all op are reference numbers used to help you find detailed erations that must be performed to complete the Lu instructions in the manual on the lubrication or fluid brication and Fluid Level Check operation 00 04 check called for as an M1 maintenance interval for Service Schedule Il and III vehicles and as an M2 mainte nance interval for Service Schedule IV vehicles 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 Knuckle Pin Lubrication Meritor Axles 33 03 Tie Rod Lubrication Meritor Axles 33 05 Knuckle Pin Lubrication Dana Spicer Axles 33 06
87. e 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 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 April 2005 Transmission 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant 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 tiv
88. e 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 11 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 MOP 31 02 for lubrication instruc tions 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 6 Columbia Maintenance Manual December 2011 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 1 Tilt the top plate forward the front of the fifth wheel is down and apply grease to each bearing area through the zerk fittings located on each side of the top plate just to the front of the bracket pins Continue to apply grease until it is coming out of the back of the bearing It may be necessary to
89. e 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 degrees in one day Small amounts of water can accumulate in the air brake system due to condensation Under these conditions the presence of moisture is normal and should not be con sidered an indication of poor air dryer per formance Inspect the air
90. e 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 1011008 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 radiator 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
91. ections 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 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 827 kPa Shut 20 08 08 94 Ss 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 ps
92. er 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 Hood Grille and Cab Fenders 88 Index Alphabetical Title of Maintenance Operation MOP MOP Number Hood Rear Support LUDNCAION 22 265 002 cnet Race ER bad bU dat Geass Dodoma es teehee nee 88 01 Columbia Maintenance Manual December 2011 Hood Grille and Cab Fenders 88 01 Hood Rear Support Lubrication Apply the parking brakes and chock the tires 2 Open the hood 3 Clean both the hood and cab mounted hood rear support components with a soapy water so lution 4 Cover all contact surfaces of the hood rear sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Grease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Shell Retinax LC Grease Texaco Starplex 2 Table 1 Approved Suppliers of Multi Purpose Lithium Grease 88 Columbia Maintenance Manual December 2011 88 1
93. eriodically 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 inH4 O on a vehicle with an MBE engine or 25 inH20 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 higher than the previous recording reset the air restriction indicator If the value is lower than the previous recording in spect the air cleaner and air cleaner element of cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air restriction indicator Method 2 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 inH5O on a vehic
94. ers see Fig 1 Ref 4 for tightness Tighten the 3 4 inch fasteners 215 to 265 Ibf ft 292 to 359 Nm Check the front engine support fasteners for tight ness Tighten the 5 8 inch fasteners 125 Ibf ft 170 Nm 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 described 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 glaz
95. ervice personnel Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data PartsPro is an electronic parts catalog system showing the specified vehicle s build record EZWiring makes Freightliner Sterling Western Star Thomas Built Buses and Freightliner Custom Chassis Corporation products wiring drawings and floating pin lists available online for viewing and printing EZWiring can also be ac cessed from within PartsPro 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
96. es 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 For a transmission equipped with a transmission fluid filter s replace the fluid filter s 5 1 Place a drain pan under the transmission fluid filter 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
97. f corrections are needed refer to Group 33 of the Columbia Workshop Manual tor 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 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 stearate grease or NLGI Grade 2 896 12 hydroxy lithium stearate grease into the tie rod ends until all used grease is forced out and fre
98. finite 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 1421384 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 cap 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
99. g 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 Ifa 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
100. h 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 000005 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Eubricarib acuto tke ath dead tame ean OY ohh te eink one onde da 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 intervals of shrill noises when the vehicle oper ates at low speed or when the vehicle makes sharp turns Use a limited slip f
101. he Premier web site at Columbia Maintenance Manual December 2011 31 9 31 www premier mfg comfor complete safety op eration and maintenance instructions A WARNING If at any time the 690 coupling is bound up jack knifed the 294 bolt MUST be replaced immedi ately Do not use the coupling until the bolt has been replaced In addition carefully inspect the 690 coupling drawbar drawbar eye front end as sembly and tail board for damage Failure to do so may result in trailer separation from the truck while in use resulting in serious personal injury or property damage The time in service of the 294 bolt located in the 690 coupling must be monitored and maintenance per formed as follows See Fig 14 For a new or replaced 294 bolt e Record the date of installation 6 months after installation date e Remove the 294 bolt Using dye penetrate or magnetic particle testing along the length of the bolt inspect for fractures e If the 294 bolt has no damage install it and continue to use for another 6 months e f the 294 bolt is fractured DO NOT USE Con tact Premier Mfg Co 1 year after installation date e Regardless of service duty replace the 294 bolt with a new one 07 13 2010 f310313a 1 Linch Pin 3 Pintle Hook 2 Handle 4 294 Bolt Fig 14 Premier 690 Trailer Coupling Frame and Frame Components 31 10 Columbia Maintenance Manual December 2011 Suspensi
102. 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 Radiator 200326 02 28 96 Fig 3 T Bolt Type Hose Clamp 08 15 94 1200286 A The screw tip must extend about 1 4 inch 6 mm B Belleville washers must collapse almost flat 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 adjuste
103. i 827 kPa and with the fan solenoid connector halves separated check the fan clutch for audible air leaks using a suitable listening device 9 Ifa 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 Maintenance 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 2
104. ife 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 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 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 Col
105. imum Coolant Protection in F C at Various Antifreeze ConcentrationS Cooling ETHYLENE GLYCOL BASE ANTIFREEZE REQUIRED System gallons liters Capacit gal L 2 8 3 11 aas 5 19 6 23 7 26 8 30 9 34 38 42 145 10 38 16 9 4 216 12 C24 34 37 62 52 t 11 42 18 C8 8 13 6 C21 23 31 47 44 62 52 1 12 45 19 7 10 212 0 218 15 C26 34 37 57 49 13 49 21 6 13 211 3 16 9 C23 25 31 45 243 62 52yt 14 53 15 9 6 14 5 C19 18 C28 34 37 54 48 15 57 16 9 8 13 0 18 12 24 26 32 43 42 a 16 61 17 C8 10 12 2 17 8 22 19 C28 34 237 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 0o18 10 23 21 29 d ws at 19 72 20 7 15 9 93 27 7 C22 16 227 T gt Wc 20 76 16 9 10612 sie 3t19 12 C24 50 Can Cay 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
106. 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 change remove and clean the magnetic strainer if equipped See Fig 4 4 1 Remove the magnetic strainer from the power divider co
107. ing 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 undercord ribs causing the belt to lose its gripping power 6 Check the drive belts for cracks See Fig 2 Ref F Small irregular cracks are usually 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 pla
108. ion 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 l Il Ill and IV Columbia Maintenance Manual December 2011 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 Maintenance Operation Number M1 Maintenance Interval Operations for Service Schedules I Il and III 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 Gunite Sla
109. ions 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 Play 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 Columbia Maintenance Manual December 2011 00 13 00 General Information M2 Maintenance Interval Operations 00 07 cna ed ei M2 Maintenance Interval Operations for Service Schedule IV Check 60 01 Mirror Folding 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 00 14 Columbia Maintenance Manual December 2011 General Information The M3 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M3 maintenance interval Maintenance opera 00
110. ions 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 4h 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 11 21 95 O 1830746 1 Moisture Indicator 02 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
111. ir 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 December 2011 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 25 000 40 000 Optimized Vehicle Configuration E vehicles that annually travel over Maintenance 2 M2 every 100 000 161 000
112. itle of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check s sasaaa ease 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 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
113. ket shoe rubber pads see Group 31 of the Columbia Workshop Manual for replacement instructions 04 11 2011 y 1310475 A Extended Top Plate Lift Height Fifth Wheel Top Plate Fifth Wheel Frame Mount Frame Rail Lifting Point Static Top Plate Height gu oc Fig 7 Measuring Fifth Wheel Top Plate Lift NOTE Do not measure plate lift immediately after a trailer has been uncoupled from the fifth 31 4 Columbia Maintenance Manual December 2011 Frame and Frame Components 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 brackets for cracks or other damage 9 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 10 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions Jost 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 the mounting for missing or damaged fas teners and broken components Re
114. l 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 e 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 you cannot tighten the hub cap to the correct torque value or if it makes a popping sound while being tightened re place it wit
115. le 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 DEE ke id an ds 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 hoses 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 T
116. led 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 29 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 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 th
117. low unfiltered air and contaminants into the engine intake and can cause serious engine dam age NOTE Because the CGI bellows is covered with a metal mesh it is difficult to see cracks or damage that may cause a leak 3 On vehicles with CAT engines inspect the CGI bellows and piping for evidence of damage or leakage See Fig 5 If the bellows is damaged or leaking replace it See 49 02 for the replace ment procedure 10 49 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten 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 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 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 it to malfunction Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed 02 24 2011 i H 3 10 1 1490456 1
118. lphabetical Title of Maintenance Operation MOP MOP Number Wheel Nut XSITBOK sia raras DEERE ad Reece b A Le Shore Wes 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 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 35 N 6 5 1106 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 Ibf 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
119. luid 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 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 A Synthetic Lubricant 26 02 Transmission Fluid Level Inspection 26 03 Manual Transmission Air Filter Regulator Check Cleaning or i Replacement 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 03 Frame Fastener Torque Check 31 04 Trailer Electrical Connector Lubrication 31 05 Premier 690 Coupling Inspection 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
120. ly 1 4 inch 6 mm clearance by turning the wedge stop rod located on the right side of the top plate Fontaine 11 Replace cracked worn or damaged parts with 1 Disconnect the tractor from the trailer For in new parts Replace all loose mounting bolts with structions see the Columbia Driver s Manual 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 3 Check for cracks in the fifth wheel assembly 12 After inspecting the fifth wheel lubricate all mov mounting brackets and mounting parts 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 MOP 31 02 for lubrication instruc Thoroughly steam clean the fifth wheel 4 Ensure that both bracket pins are in place and secured by retainer pins and cotter pins See Fig 1 5 For fifth wheels equipped with bracket liners d rock the fifth wheel If it does not rock freely re move the top plate and inspect the bracket lin Holland FWS1 ers Replace liners that are broken or less than 1 0 125 inch 3 mm thick at the top of the liners For the liner replacement procedure see the Fontaine website www fifthwheel com Disconnect the tractor from the trailer For in structions see the Columbia Driver s Manual Thoroughly steam clean the fifth wheel 6 Check the jaw and stationary jaw for m
121. mechanism several times to test Repeat if nec essary See Fig 10 If the fifth wheel is equipped with a sliding mechanism inspect and adjust it as follows 9 1 Check the bracket for any cracks or miss ing and damaged parts 9 2 Inspect the locking plungers for full en gagement 9 3 Check the locking mechanism for proper operation If the plungers will not release check the air cylinder or plunger adjustment If the plungers are loose check the plunger adjustment and the plunger springs for proper compression Replace if needed 9 4 The outboard slider assembly requires no adjustment If the plungers are loose in spect and replace locking mechanism parts as needed Columbia Maintenance Manual December 2011 31 5 31 Frame and Frame Components rommoom 09 01 2009 f311099 Checking for fore aft play Rotating tester in lock Engage hook Pull push handle fore aft Check for movement of kingpin in lock Disengage hook Push pull handle inboard outboard Rotate lock tester Fig 9 Jost Fifth Wheel Adjustment 9 5 The inboard slider is adjustable for frame width and plunger engagement For ad justment refer to the fifth wheel installa tion instructions 09 02 2009 f311100 1 Jam Nut 3 Grease Zerk 2 Adjustment Bolt Fig 10 Jost Fifth Wheel 10 Replace cracked worn or damaged parts with new parts Replace all loos
122. mission 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 EE Fuller Synthetic transmission lubricant approved by All 50W Eaton Meritor Transmissions MobilTrans SHC 50 FreedomLine RN 2952 E 5 All 50W Synthetic engine oil All other meeting Meritor spec Meritor 0 81 orMIL L 2104p l 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 approximate 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
123. n 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 II short haul transport applies to vehicles that annually travel less than 60 000 miles 100 000 kilometers and operate under normal con ditions Examples of
124. n 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 72 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 every six months Wipe old grease and dirt from the hinge then force an ap proved grease into the hinge components see Table 1 Use an appropriate applicator that will not leave material behind Wipe off any excess grease Door Checks Wipe old grease and dirt from door checks Lubricate each moving joint of the door checks at installation and every six months thereafter with an approved grease see Table 1 Use an appropriate applicator that will not leave material behind Approved Grease T NLGI Application Lubricant Grade Door Latches ConocoPhillips Triton 460 1 5 Door Checks ConocoPhillips Megaplex XD3 2 Table 1 Approved Grease Columbia Maintenance Manual December 20
125. nd 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 end 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 an
126. nents secured with conventional bolts and nuts are to be checked at Initial Mainte nance IM See Fig 13 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 NOTICE Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage 31 8 Columbia Maintenance Manual December 2011 Frame and Frame Components E i E 4 Gr 2 5 SK 3 6 ca 5 9 Bes 10 SZ 3 11 13 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 13 Rear Engine Mount Assembly pre EPA07 engines NOTE Engine supports on vehicles built f
127. ng parts in the fifth wheel 4 Apply grease to the top plate Spread grease all over the mating surface of the top plate Be sure the grease pockets built into the top plates are full of grease Holland FWS1 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 Holland FW35 1 Using a water resistant lithium base grease grease the top plate 2 Using a light oil such as SAE 10W or 20W motor oil lubricate the cam track and pivot See Fig 11 3 Grease the yoke tips locks and the release handle and spring see Fig 12 Grease the mounting bracket supports through the grease fittings A low temp grade grease rated for 30 F 34 C or lower such as Cato Oil and Grease 5213 Craftsman Chemical Co LTF 2 Mystic LP 200 or equivalent is recommended Castloc Il and Simplex Series Use a chassis or multipurpose grease to lubricate the two grease fittings located on either side of the fifth wheel top plate Lubricate the two grease fittings lo cated in the grease grooves on the fifth wheel top plate Lubricate the two grease fittings located below the top plate mounting pins Lubricate the lock mechanism Once the fifth wheel s moving parts are lubricated apply a heavy coat of grease to the top plate either through the grease fittings located on the underside of the top plate or by direct application On slide m
128. ng 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 a 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 1330014a Fig 4 Trammel Bar Positioning 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Columbia Workshop Manual I
129. nuary 2008 42 7 42 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 11 Brake Inspection IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check A CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold the vehicle per sonal injury or property damage may result 1 With the engine running and air pressure at cut out pressure set the parking brake 2 Put the vehicle in the lowest gear and gently at tempt to move it forward The vehicle should not move
130. o 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 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
131. ompo 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 Suspension Lubrication Front Suspension Wipe all dirt away from the grea
132. on Title of Maintenance Operation MOP SUSPENSION Inspection sies SP EERS NR BE HERE MEDE HER Suspension Lubrication saecu RR IR ER RE EE N ee Suspension U Bolt Torque Check o o o oooo o 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 material For additional information refer to the CVSA Out of Service OOS Criteria for
133. ontact between the bellows could result in an exhaust leak which in this case may allow ingestion of contaminants into the engine causing engine damage 6 3 Use a straightedge to align the pipes so that the pipe ends that attach to the bel lows are parallel and concentric NOTICE When shortening the CGI pipe s it is critical to leave a minimum of 1 inch 25 4 mm of straight 02 24 2011 4 Forward Pipe Support Brace 1 Clamp 5 Slip Clamp 2 Inlet Pipe 6 CGI Bellows 3 U Clamp 7 Center Pipe Support Brace 10 1 1490456 8 Center Pipe 9 Clamp 10 Outlet Pipe Fig 6 CAT EPAO07 Exhaust Installation with CGI Bellows NOTE The following step and its substeps is to be done without the bellows installed This pipe on the end of each CGI pipe to allow for pipe insertion and clamp clearance Failure to do this could result in an exhaust leak which in this case 49 4 Columbia Maintenance Manual December 2011 Exhaust may allow ingestion of contaminants into the en gine causing engine damage 7 Once the pipes are aligned measure the pipe gap between the CGI pipes and record the dis tance See Fig 7 Ref A The existing pipe gap is designed at 10 inches 254 mm A 10 75 inches 273 mm pipe gap is required for the replacement CGI bellows and clamps This requires one or both of the CGI pipes
134. op Rod 14 Bushing Secondary Safety 22 5 Grease Fitting Lock 23 6 Bracket Pin 15 Hex Locknut 24 7 Bracket Retainer Pin 16 Pull Handle 25 8 Cotter Pin 3 16 x 1 17 Bolt Bumper 26 9 Bumper Spring 18 Bushing 27 10 Handle Spring f311134 Bumper Timer Spring Timer Operating Handle Bolt Operating Handle Bushing Operating Handle Hair Pin Cotter Wedge Step Jaw Fig 1 Fontaine Fifth Wheel 31 2 Columbia Maintenance Manual December 2011 Frame and Frame Components 10 29 2007 311052 1 Lubricant Grooves 2 Safety Latch 3 Release Handle 4 Mount Fig 2 Holland FWS1 Fifth Wheel 3 x Nx TREE 01 13 2011 310470 1 Release Handle 2 Lever Bar Fig 3 Lever Bar and Release Handle Alignment 7 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 brackets for cracks or other damage 8 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 9 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions 31 Holland FW35 1 Disconnect the tractor from the trailer Fo
135. ound 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 1350002a 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 39 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 it is unclogged and free from corrosion See Fig 7 If the breather is plugged or damaged clean or replace it as needed 7 Remove the chocks from the tires Two Speed Axles With Shift Unit Dana Spicer and Meritor A CAUTION Failure to kee
136. ount applications lubricate the slider lock pockets and the slider bracket Columbia Maintenance Manual December 2011 31 7 31 12 03 2010 311136 Use a light oil such as SAE 10W or 20W motor oil to lubricate the cam track and pivot 1 Cam Plate Fig 11 Holland FW35 Fifth Wheel Oil Lubrication 12 03 2010 1 Release Handle and 3 Yoke Tip Spring 4 Locks 2 Grease Fitting 311135 Fig 12 Holland FW35 Fifth Wheel Grease Lubrication Frame and Frame Components Jost Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel see MOP 31 01 Apply a light oil to all mov ing parts For sliding fifth wheels spray diesel fuel on the slide path of the base plate NOTICE Do not use a power grease gun The pressure will damage the lube line If the fifth wheel is not equipped with low lube plates apply a lithium based grease with extreme pressure EP additive to the trailer contact surface of the fifth wheel NOTE If the fifth wheel is equipped with low lube plates the top plate only requires lubrication at the new product break in stage The low lube plates re quire no further lubrication 31 03 Frame Fastener Torque Check Frame brackets and components secured with Huck bolt fasteners do not require a torque check how ever they should be inspected for damage Frame brackets and compo
137. p 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 if it is damaged 6 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on 83 08 25 94 1830641 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 instruct
138. p 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 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 the fill plug finger tight in the rear axle shift 35 8 Columbia Maintenance Manual July 2005 Wheels and Tires 40 Index A
139. place or re pair as needed 4 Inspect the bracket pin bolts Make sure the lock ing tabs are properly securing the bolts in place See Fig 8 09 01 2009 1311101 Fig 8 Bracket Pin Bolt Locking Tabs 5 Check the fifth wheel for bent worn or broken parts Replace as needed 6 Ifthe fifth wheel is equipped with low lube plates check the plates and replace if damaged or worn down to the securing bolts It is normal for out 31 side edges of the plate to pucker slightly this does not affect performance Check the fifth wheel adjustment Using a lock tester lock and unlock the fifth wheel several times Make sure that the locking mechanism works properly The lock is properly adjusted if the wheel locks and unlocks easily each time and the lock tester rotates freely The lock is too loose if you feel fore aft play when pulling and pushing on the lock tester handle See Fig 9 Ref A The lock is too tight if the lock tester does not rotate freely in the lock See Fig 9 Ref B If the lock is improperly adjusted correct as fol lows If the lock is too tight loosen the jam nut turn the adjustment bolt clockwise one full turn then reset the jam nut Lock and unlock the mecha nism several times to test Repeat if necessary See Fig 10 If the lock is too loose loosen the jam nut turn the adjustment bolt counterclockwise one full turn then reset the jam nut Lock and unlock the
140. r sharp edges on top the chamfer should be 1 8 to 1 4 inch 3 to 6 mm 4 When the wheel is locked the safety latch must swing free and fall freely into position See Fig 10 26 2010 f310353b 3 Lock Control Handle 4 Mount 1 Lubricant Grooves 2 Safety Latch Fig 5 Simplex Series Fifth Wheel 5 The lever bar and operating handle must be in proper alignment See Fig 6 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 Check all cotter pins for cracking or damage Re place any cotter pin that shows any signs of damage 7 Level the fifth wheel plate to a horizontal posi tion Measure the height from a stationary mounting point see Fig 7 Ref 3 such as the 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 gt Frame and Frame Components 04 11 2011 1 Operating Handle 310470 2 Lever Bar Fig 6 Lever Bar and Operating Handle Alignment wear or rubber deterioration install new stan dard or oversized brac
141. r in structions see the Columbia Driver s Manual 2 Thoroughly steam clean all fifth wheel compo nents before inspection 3 Check for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Check the fastener torques on the fifth wheel assembly and fifth wheel mounting Tighten bolts and nuts as needed Replace missing or dam aged bolts 5 Inspect the fifth wheel for bent worn damaged and missing parts replace them as needed with genuine Holland parts 6 Using a Holland Kingpin Lock Tester Holland tool number TF TLN 5001 available through the PDCs as HLD TFTLN5001 check the operation of the locking mechanism by opening and closing the locks See Fig 4 7 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions L ave 4 04 11 2011 B 1310887 A The nut and washer should be snug against the fifth wheel B The locks should be completely closed around the kingpin Fig 4 Holland Fifth Wheel Properly Closed Columbia Maintenance Manual December 2011 31 3 31 Castloc Il and Simplex Series 1 Disconnect the tractor from the trailer For in structions see the Columbia Driver s Manual Thoroughly steam clean the fifth wheel Check the fifth wheel plate for cracks Check fo
142. r 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 f410155a 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 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
143. raise the rear of the fifth wheel with a pry bar to open up the pocket slightly and allow the grease to flow through A substantial amount of grease may be required initially to fill the reservoir Tilt the fifth wheel ramps down the rear of the fifth wheel is down and repeat the greasing pro cedure Rock the top plate back and forth sev eral times to spread the grease over the bearing surface 2 Inspect the trailer kingpin plate and top surface of the fifth wheel to make sure each is properly greased A liberal coating of grease should be applied to the complete surfaces of both the trailer kingpin plate and the top surface of the fifth wheel NOTE Do not use a lube plate high density polyethylene on top of the fifth wheel or on the kingpin instead of grease without prior approval by Fontaine Fifth Wheel The additional thick ness of this material can prevent the proper op eration of the fifth wheel and may cause a dan gerous condition NOTE Fontaine suggests the use of a Moly based lubricant such as Mobilgrease XHP 320 or equivalent when applying lubricant to the locking jaw and wedge 31 3 Lubricate the fifth wheel prior to opening and closing it Separate the jaw and wedge with a screwdriver and grease the full length of their mating surfaces Lubricate the top and bottom contact surfaces of the jaw and wedge Open and close the fifth wheel several times to further distribute the grease Lightly oil other movi
144. 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 f 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 have a small tapped and plugged hole near and below the housing oil fill hole This smaller hole is for a lubricant temperature
145. riction 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 axle oil filter Use a suitable filter strap wrench See Fig 1 Discard the old filter 05 27 93 f350119a
146. rkshop 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 and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Place safety stands under the axle 3 Usi
147. rom January 2007 do not require checking Check the fasteners at the following locations e Axle Stops e Deck Plates e Engine Trunnion Supports e Equalizer Brackets 31 Exhaust Brackets Fifth Wheel Legs Fifth Wheel Mountings e Frame Crossmembers and Gussets Front Frame Brackets Front Suspension Spring Brackets Fuel Tank Brackets Radius Rods e Rear Engine Supports e Rear Suspension Spring Brackets e Shock Absorbers e All Other Frame Fasteners Any component that shows signs of cracking or other damage must be repaired or replaced Refer to the Columbia Workshop Manual tor repair or replace ment information in the respective section for the component in question 31 04 Trailer Electrical Connector Lubrication In some cases failure of trailer cables occurs due to intrusion of chloride based road deicing chemicals into the trailer connector Once inside the connector the chloride based chemicals corrode the brass ter minals and create bridging between positive and ground terminals NOTE The use of soap is not recommended for cleaning the electrical connector as some soaps may increase the corrosion process 1 Wash out any existing grease dirt and corrosion on the trailer connectors with electrical contact cleaner spray 2 Grease the trailer connector with a lithium based dielectric grease 31 05 Premier 690 Coupling Inspection IMPORTANT Before servicing the Premier cou pling refer to t
148. 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 e Do not attempt to disassemble the Barksdale valve body or the control lever There are no serviceable parts in the valve and any disas sembly will void the warranty NOTICE When removing or loosening a Barksdale height control valve from a mounting bracket always hold the valve side mounting studs in place with an Allen wrench while loosening or tightening the nuts that attach the valve to the bracke
149. se 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 1420653a 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 replaced 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
150. se 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 the bushings and pins to allow the proper flow of lubricant around them 3
151. 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 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
152. sh 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 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
153. 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 Automatic 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
154. t 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 measure the dis tance from the bottom of the forwardmost left axle stop to the
155. t Coat the terminal connections with dielectric red enamel after cleaning Columbia Maintenance Manual October 2008 15 1 Engine Cooling Radiator Title of Maintenance Operation MOP Fan Clutch Check Noise Emission Control Pressure Relief Cap Check llli Radiator Pressure Flushing and Coolant Change 20 Index Alphabetical MOP Number Columbia Maintenance Manual January 2007 Engine Cooling Radiator 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 maintains pressure to within 10 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
156. th 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 December 2011 General Information 00 Vehicle Maintenance Schedule Tables 00 03 61st through 90th Maintenance for Service Schedules and II
157. 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 A WARNING 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 ina 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 sever
158. to be shortened ES 02 23 2011 1490457 A Measure the pipe gap 1 CGI Aft Pipe 2 CGI Forward Pipe Fig 7 Measuring the Pipe Gap typical 8 Using a yellow paint pen mark the pipes 1 5 inches 38 mm in from the end of each pipe These two marks will be used to center the bel lows between the two pipes 9 Once the pipes are correctly aligned and sepa rated at the correct distance secure the aft CGI pipe to the ATD and to any CGI pipe support brackets 10 Remove the forward CGI pipe from the truck 11 Slide the slip clamp with the retaining ring and graphite gasket ring on the aft CGI pipe See Fig 8 for proper installation 12 Slide the new bellows onto the aft CGI pipe as far as it will go See Fig 9 Ref A Measurement A should be at least 7 16 inch 10 mm past the face of the flange 13 Install the slip clamp with the retaining ring and graphite gasket ring onto the forward CGI pipe See Fig 10 for proper installation 49 1 ec i 5 T h N mE E IL 01 29 2010 1490415 1 Aft CGI Pipe 4 Slip Clamp 2 Retaining Ring 5 CGI Bellows 3 Graphite Gasket Fig 8 Aft Facing Slip Clamp Installation Ua T i HET 02 23 2011 1490458 A At least 7 16 inch 10 mm 1 Forward CGI Pipe 3 Aft CGI Pipe 2 CGI Bellows
159. ton 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 a 05 27 93 1260037a 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 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 l
160. 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 05 15 95 320410 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 of the vehicle and support the frame on jack stands to unload the suspension c
161. umbia Maintenance Manual April 2005 Frame and Frame Components 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number FNA Wheel Mpe so ES Snare OASE ii o Dr 31 01 ita veel bI STIR aran AR behest PISOS aed RUF Ron HUN te RE RA OOREEN se OR eae 31 02 Frame Fastener Torque Check 2 0i 2cccviceeive vie G edocs eee Ee aN hw ee RE Rha eee RE Yes eS 31 03 Premier 690 Coupling INSpection s uid GED hd EER A AAA om 31 05 Trailer Electrical Connector Lubrication 0 0 0 0 ce eee 31 04 Columbia Maintenance Manual December 2011 31 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 10 Check wedge adjustment chanic Improper or incomplete procedures could 10 1 result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage 10 2 Parts are under spring compression Wear safety goggles while servicing the fifth wheel Failure to do so can result in personal injury due to parts ejecting with force Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause serious injury Open the kingpin lock and vertically in sert a 2 inch 50 mm diameter shaft Release the lock by tripping the release latch at the bottom of the throat 10 3 Adjust the wedge stop at the end of the wedge to approximate
162. ushroom Check the fifth wheel plate for cracks Check for ing and check that the serrations at the jaw and wedge are in good condition sharp edges on top the chamfer should be 1 8 to 1 4 inch 3 to 6 mm 7 Test the secondary safety lock latch for ease of 4 When the wheel is locked the safety latch must operation la free and fall freely into position See Fig 8 Check for loose nuts or bolts on the fifth wheel and the mounting Set a torque wrench to the 5 The lever bar and release handle must be in maximum torque value for the bolt being proper alignment See Fig 3 Compare the lever checked and confirm that the torque is to speci bar and release handle alignment to a new or a fication Do not loosen the bolt to check the properly operating lever bar and release handle torque See Group 00 for bolt torque specifica Replace any bent or misaligned lever bar or re tions lease handle 6 Check all cotter pins for cracking or damage Re 9 Check all springs to see if they are securely fas tened and are not deformed place any cotter pin that shows any signs of damage Columbia Maintenance Manual December 2011 31 1 31 Frame a nd Frame Components 12 02 2010 2 NOTE 6000 Series shown 7000 Series fifth wheels use similar parts Wedge Stop Rod Nut 11 Bolt Secondary Safety Lock 19 2 Flat Washer 5 8 12 Flat Washer 20 3 Wedge Stop Rod Spring 13 Secondary Safety Lock 21 4 Wedge St
163. utlet 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 Inspecting 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 December 2011 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 id EO OWING ISE O CEUNIHONS G oo 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
164. ve the retainer that holds the recirculation 1 air filter in place See Fig 4 4 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 1831491 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 Sleeper 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 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 filt
165. ver A 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 UA 1 101 Pe 2 Power Divider 1350017a 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 35 4 Columbia Maintenance Manual July 2005 Rear Axle 35
166. very 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 18 Columbia Maintenance Manual December 2011 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 vehicle 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
167. wly 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 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 p

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