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COLUMBIA MAINTENANCE MANUAL
Models: CL112
CL120
STI-409-2 (7/17)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

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  • Page 1 COLUMBIA MAINTENANCE MANUAL Models: CL112 CL120 STI-409-2 (7/17) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice.
  • Page 5 ™ EZWiring EZWiring makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro.
  • Page 6 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.
  • Page 7 Introduction Page Description For an example of a Columbia Maintenance Manual page, see Fig. Cooling 20−01 Coolant Replacement 20−02 Cooling Fan Inspection Columbia Maintenance Manual, December 2001 11/28/2001 f020127 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B.
  • Page 8 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 9: Table Of Contents

    General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals..........00–01 Initial Maintenance (IM) Operations.

  • Page 11: Determining Scheduled Maintenance Intervals

    Performing regular maintenance on your Freightliner mileage. will help ensure that your Freightliner delivers safe Service Schedule IV (long haul transport for Opti- reliable service and optimum performance for years mized Vehicle Configuration) is for vehicles that an- to come.
  • Page 12 General Information Service Schedule Table: 00–02 Maintenance Interval Service Schedule Maintenance Interval Operation Frequency Miles Hours Initial Maintenance (IM) first 1000 1600 Schedule I Maintenance 1 (M1) every 1000 1600 (Severe Service) vehicles that annually travel less Maintenance 2 (M2) every 5000 8000...
  • Page 13 General Information Vehicle Maintenance Schedule Tables: 00–03 1st through 30th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles IM and M1 1000 1600 10,000 16 000 2000 3200 20,000...
  • Page 14 General Information Vehicle Maintenance Schedule Tables: 00–03 31st through 60th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles 31st 31,000 49 600 3100 310,000 496 000 32nd 32,000 51 200...
  • Page 15 General Information Vehicle Maintenance Schedule Tables: 00–03 61st through 90th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles 61st 61,000 98 200 6100 610,000 982 000 62nd 62,000 99 800...
  • Page 16 General Information Vehicle Maintenance Schedule Tables: 00–03 91st through 100th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles 91st 91,000 146 500 9100 910,000 1 465 000 92nd 92,000 148 100...
  • Page 17 General Information Vehicle Maintenance Schedule Tables: 00–03 1st through 20th Maintenance for Service Schedules III and IV Service Schedules III and IV Service Maint. No. Maintenance Interval Date Miles M1 and M2 500,000 805 000 Table 6, 1st through 20th Maintenance for Service Schedules III and IV 21st through 40th Maintenance for Service Schedules III and IV Service Schedules III and IV Service...
  • Page 18 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.

  • Page 19: Initial Maintenance (Im) Operations

    General Information 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.

  • Page 20: Lubrication And Fluid Level Check

    General Information M1 Maintenance Interval Operations: 00–06 The M1 Maintenance Interval Operations tables list IMPORTANT: After performing all operations listed in all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly at the M1 maintenance interval. Maintenance opera- maintenance operations listed in the "Pretrip and tion numbers are reference numbers used to help Post-Trip Inspections and Maintenance"...
  • Page 21 General Information M1 Maintenance Interval Operations: 00–06 Maintenance M1 Maintenance Interval Operations for Service Schedule IV Check Operation Number 33–11 Steer Axle Hub Cap Vent Plug Inspection 40–02 Tire Check 42–07 Meritor Camshaft Bracket Lubrication 42–10 Brake Inspection 49–01 Exhaust System Inspection (noise emission control) 72–01 Door Seal, Door Latch, and Door Hinge Lubrication 88–01...

  • Page 22: M2 Maintenance Interval Operations

    General Information M2 Maintenance Interval Operations: 00–07 The M2 Maintenance Interval Operations tables list you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M2 maintenance interval. Maintenance opera- M1 maintenance interval operations at the M2 main- tion numbers are reference numbers used to help tenance interval.
  • Page 23 General Information M2 Maintenance Interval Operations: 00–07 Maintenance M2 Maintenance Interval Operations for Service Schedules I, II, and III Check Operation Number 83–01 Air Conditioner Inspection † 83–02 Air Filter Replacement For Schedule II vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first. †...
  • Page 24 General Information M2 Maintenance Interval Operations: 00–07 Maintenance M2 Maintenance Interval Operations for Service Schedule IV Check Operation Number 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 60–01 Mirror Folding Check 83–01...

  • Page 25: M3 Maintenance Interval Operations

    General Information M3 Maintenance Interval Operations: 00–08 The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M3 maintenance interval. Maintenance opera- M1 and M2 maintenance interval operations at the tion numbers are reference numbers used to help M3 maintenance interval.

  • Page 26: Maintenance Operation Sets Table

    General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. Service Schedules Service Schedule Operation Description I, II, and III M2 M3 00–04 Lubrication and Fluid Level Check • • • • • • 01–01 Engine Support Fasteners Check (noise emission control) •...
  • Page 27 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. Service Schedules Service Schedule Operation Description I, II, and III M2 M3 § ™ 33–09 Kingpin Lubrication, Detroit Axles • • • • § 33–10 Tie Rod Lubrication, Detroit ™...
  • Page 28 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. Service Schedules Service Schedule Operation Description I, II, and III M2 M3 88–01 Hood Rear Support Lubrication • • • • • • • •...
  • Page 29 Maintenance Instructions sure that such parts are warranted by their manufac- 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)"...

  • Page 30: Verification Of Inspections Log

    General Information Verification of Inspections Log: 00–11 Verification of Inspections Log Verification of Inspections Log, Group 01 Verification of Inspections Log — Group 01 — Engine Mounts Date Mileage Item Cost Maintenance Facility Verification of Inspections Log, Group 20 Verification of Inspections Log — Group 20 — Fan Clutch Date Mileage Item...
  • Page 31 General Information Verification of Inspections Log: 00–11 Verification of Inspections Log, Group 49 Verification of Inspections Log — Group 49 — Exhaust System Components Date Mileage Item Cost Maintenance Facility 00/21 Columbia Maintenance Manual, July 2017...
  • Page 33 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspection............01–02 Engine Support Fasteners Check .

  • Page 35: Engine Drive Belt Inspection

    Engine 01–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 36 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 ally caused by foreign objects in the pulley, or by 8. Inspect all pulleys for foreign objects, oil, or prying or forcing the belt during removal or instal- grease in the grooves.

  • Page 37: Pacbrake Inspection And Lubrication

    Engine Drive Belt Tensions Engine Component Belt Tension: lbf (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 Spring-Tension Type brake housing may trap water in the valve shaft bore causing corrosion, resulting in an improp- On belts equipped with a spring tensioner, belt ten- erly functioning or non-functioning brake.
  • Page 39 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement ......... . 09–01 Columbia Maintenance Manual, November 2014...
  • Page 41 Air Intake 09–01 Air Cleaner Element Inspection and Replacement Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet. Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash- mounted restriction gauge.
  • Page 43 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .

  • Page 45: Safety Precautions

    Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 47 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Safety Precautions .
  • Page 49 Alternators and Starters 15–00 Safety Precautions or poly-V belt have automatic belt tensioners and do not require belt tension inspection. Safety Precautions in this section apply to all 4. Check that all electrical connections at the alter- nator and starter are clean. Clean and tighten all procedures within this group.
  • Page 51 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Check (Noise Emission Control) ..........20–03 Pressure Relief Cap Check.
  • Page 53 Engine Cooling/Radiator 20–00 Safety Precautions 20–02 Radiator Pressure- Flushing and Coolant Safety Precautions in this section apply to all Change procedures within this group. NOTE: For additional instructions on cleaning DANGER and flushing the engine cooling system, see the applicable engine manufacturer’s maintenance When working on the vehicle, shut down the en- and operation manual.
  • Page 54 Engine Cooling/Radiator 06/08/95 f500244 1. Low-Coolant-Level Sensor 2. SAE Cap (for coolant overflow pressure relief only) 3. Fill Cap Fig. 1, Surge Tank 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.
  • Page 55 Engine Cooling/Radiator pressure. During vehicle operation and shut- When installing Breeze Constant-Torque hose clamps, the clamps must be tightened to the cor- down, the screw tip may adjust according to rect torque. The screw tip of the clamp must ex- temperature and pressure changes.
  • Page 56 Engine Cooling/Radiator 7. Connect the battery cables. Start the engine, and WARNING charge the air system to 120 psi (827 kPa). Shut down the engine. Separate the halves of the fan If the engine starts during this procedure, the fan solenoid connector.
  • Page 57 Engine Cooling/Radiator 03/30/95 f200194a 1. Mounting Bracket 9. Rear Hub Bearing 17. Face Seal 2. Rear Sheave Bearing 10. Bearing Spacer 18. Small O-Ring 3. Inner and Outer Bearing 11. Splined Hub 19. Air Chamber Spacers 12. Forward Hub Bearing 20.
  • Page 58 Engine Cooling/Radiator 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. WARNING Make sure the batteries are disconnected before checking the fan clutch.
  • Page 59 Engine Cooling/Radiator If the fan clutch does not operate correctly, see 11.3 If either the hub or sheave bearings are Group 20 of the Columbia® Workshop Manual worn, replace them, using a Horton Drive- for troubleshooting and repair procedures. Master Super Kit. 8.
  • Page 61 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Cross-Shaft Lubrication..........25–02 Eaton Fuller Clutch Release Bearing Lubrication .
  • Page 63 Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 64 Clutch 25–02 Clutch Release Cross- 25–03 Sleeve Assembly Bronze Shaft Lubrication Bushing Lubrication The clutch release cross-shaft is equipped with two Vehicles equipped with the sealed clutch release grease fittings in the transmission clutch housing. bearing require lubrication of the bronze bushing lo- Fig.
  • Page 65 Clutch 4. Wipe off excess grease, and apply it to both the yoke finger and sleeve bushing contact points. Fig. 5. Install the clutch inspection plate, then remove the chocks. 25/3 Columbia Maintenance Manual, September 2015...
  • Page 67 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement ..... . . 26–03 Manual and Automated Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic Lubricant) .
  • Page 69 Transmission 26–00 Safety Precautions 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 Safety Precautions in this section apply to all poles and divert the magnetic field.
  • Page 70 Transmission transmission lubricant capacities and Table 3 Eaton Fuller Transmission Lubricant Capacities Meritor transmission lubricant capacities. † Transmission Model Refill Capacity: qt (L) For more information and a complete listing of 7-Speed T Series Eaton approved lubricants, refer to the Eaton All Models 18.0 (17.0) website, www.roadranger.com.
  • Page 71 Transmission 8. Clean the fill plug, then install it in the transmis- proved lubricants, refer to the ZF Meritor web- sion. Tighten the plug as follows: site, www.zf.com. • 25 to 35 lbf·ft (34 to 48 N·m) for Eaton 5. Clean the fill plug, then install it. Tighten the plug Fuller transmissions with 3/4-inch pipe as follows: threads.
  • Page 72 Transmission 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.
  • Page 73 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection ............. . 31–01 Fifth Wheel Lubrication.

  • Page 75: Fifth Wheel Inspection

    Frame and Frame Components 31–00 Safety Precautions 6. Check the jaw and stationary jaw for mushroom- ing, and check that the serrations at the jaw and wedge are in good condition. Safety Precautions in this section apply to all 7. Test the secondary safety lock latch for ease of procedures within this group.
  • Page 76 Frame and Frame Components 12/02/2010 f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. 1. Wedge Stop Rod Nut 11. Bolt, Secondary Safety Lock 19. Bumper 2. Flat Washer, 5/8" 12. Flat Washer 20. Timer Spring 3. Wedge Stop Rod Spring 13.
  • Page 77 Frame and Frame Components Holland FWS1 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 fifth wheel plate for cracks. Check for sharp edges on top; the chamfer should be 1/8 to 1/4 inch (3 to 6 mm).
  • Page 78 Frame and Frame Components 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.
  • Page 79 Frame and Frame Components 09/01/2009 f311101 04/11/2011 f310475 Fig. 8, Bracket Pin Bolt Locking Tabs A. Extended Top Plate Lift Height 5. Check the fifth wheel for bent, worn, or broken 1. Fifth Wheel Top Plate parts. Replace as needed. 2.
  • Page 80 Frame and Frame Components 09/02/2009 f311100 1. Jam Nut 3. Grease Zerk 2. Adjustment Bolt Fig. 10, Jost Fifth Wheel Inspect the locking plungers for full en- gagement. Check the locking mechanism for proper operation. If the plungers will not release, check the 09/01/2009 f311099 air cylinder or plunger adjustment.

  • Page 81: Fifth Wheel Lubrication

    Frame and Frame Components 10. Replace cracked, worn, or damaged parts with cedure. Rock the top plate back and forth sev- new parts. Replace all loose mounting bolts with eral times to spread the grease over the bearing 5/8–11 SAE grade 8 bolts, grade C locknuts, and surface.

  • Page 82: Frame Fastener Torque Check

    Frame and Frame Components 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. 12/03/2010 f311135 1.
  • Page 83 Frame and Frame Components 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.

  • Page 84: Premier 690 Coupling Inspection

    Frame and Frame Components into the trailer connector. Once inside the connector, 1 year after installation date: the chloride-based chemicals corrode the brass ter- • Regardless of service duty, replace the 294 bolt minals and create bridging between positive and with a new one.
  • Page 85 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspection .

  • Page 87: Safety Precautions

    Suspension • a side to side crack extending beyond 3/4 of the 32–00 Safety Precautions length of the spring; • a top to bottom crack extending beyond 3/4 of Safety Precautions in this section apply to all the length of the spring; procedures within this group.
  • Page 88 Rear Suspension Check sons: • if there are gaps between the rubber bush- Freightliner Spring Suspension ing and the pin or outer steel sleeve; • if either bushing end contacts a torque arm WARNING pin mounting bolt;...
  • Page 89 Columbia® Workshop Manual for instructions. Inspect the crossmember(s) and gussets for wear, cracks, and other damage. If any of these conditions Freightliner AirLiner Suspension exist, replace the damaged parts. See Group 32 of the Columbia® Workshop Manual for instructions. WARNING...
  • Page 90 Suspension Only if necessary, tighten the valve housing bolts 45 lbf·in (500 N·cm). Any damage to the valve housing will void the warranty. • 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.
  • Page 91 Suspension f320432 09/27/95 A. Non-Wear Area B. Wear Area 1. Walking Beam 08/16/96 f320453 Fig. 8, Walking Beam End Wear Thickness A. Measure height here. 1. Left Forwardmost Axle Stop or the restrictor can is missing, replace the re- strictor can. Fig.
  • Page 92 Single Axle where lubricant may have hardened. Remove the safety stands. 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...
  • Page 93 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.
  • Page 95 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–04 Basic Inspection, Meritor Unitized Wheel Ends .
  • Page 97 Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.

  • Page 98: All-Axle Alignment Check

    (see Fig. 4) and adjust the scale end so that the equipment manufacturer. Freightliner dealers must pointers line up with the scribe lines. See Fig. have proof of this calibration history.

  • Page 99: Basic Inspection, Meritor Unitized Wheel Ends

    Front Axle 11/21/95 f330129 A. Grease Exit 1. Grease Fitting Fig. 6, Dana Spicer Knuckle Pin Lubrication 33–06 Tie Rod Lubrication, Dana Spicer Axles 10/05/2016 f400100a For any Dana Spicer axle that requires lubrication of the tie-rod ends, wipe the grease fittings clean, then Fig.

  • Page 100: End-Play Check, Meritor Unitized Wheel Ends

    Front Axle 3. Rotate the tire and hub assembly. They should 4. Remove the tire and wheel assembly. rotate smoothly and without noise. Grasp the NOTE: It is normal for small amounts of grease brake chamber while rotating the hub to detect to be visible around the inner and outer wheel any hub vibration.

  • Page 101: Kingpin Lubrication, Detroit

    Front Axle NOTE: If you cannot tighten the hub cap to If the hub rotates smoothly and without noise, go to the next step. the correct torque value, or if it makes a popping sound while being tightened, re- 18. Bend an opposing tab of the tabbed washer over place it with a new one.
  • Page 102 Front Axle 06/12/2012 f330273 NOTE: No grease should emit from the tie-rod boot. If grease emits from the tie-rod boot, the boot is dam- aged. 1. Grease Fitting 2. Boot Fig. 9, Tie Rod Grease Fitting and Boot, Detroit Axles 06/07/2012 f330272 Upper View, LH Side...
  • Page 103 Front Axle clean before checking the oil. Do not use a pres- sure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water. 1. Park the vehicle on a level surface, shut down the engine and set the parking brakes.
  • Page 105 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather and Axle Lubricant Level Inspection......... . 35–02 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (Synthetic Lubricant) .
  • Page 107 Rear Axle 35–00 Safety Precautions 2. Clean the fill plug and the area around it. In the axle housing rear cover, remove the plug from the oil fill hole. See Fig. Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires.
  • Page 108 Rear Axle Detroit Drive Axle Lubricants CAUTION IMPORTANT: Lubricant used in Detroit rear axles must Be careful when draining the axle oil. It may be meet Mercedes-Benz specification 235.20 (mineral) or very hot, and could cause personal injury if it con- 235.8 (synthetic).
  • Page 109 Rear Axle NOTE: There may be about one pint (0.5 L) of Meritor® lubricant remaining in the filter. Be careful not to IMPORTANT: On Meritor axles, the oil change spill it when removing the filter. interval for Schedule III and IV vehicles is ex- 4.
  • Page 110 Rear Axle Meritor Drive Axle Recommended Lubricant Recommended Lubricant SAE Ambient Temperature Meritor Specification Lubricant Type Viscosity Grade –40°F (–40°C) and Up 75W–90 0–76–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 3, Meritor Drive Axle Recommended Lubricant Meritor Drive Axle Lubricant Capacities Axle Model...
  • Page 111 Rear Axle 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).
  • Page 112 Rear Axle NOTE: Some Dana Spicer axles have a After the first oil is changed, inspect the drain plug each time for large quantities small tapped and plugged hole near and of metal particles. below the housing oil fill hole. This smaller hole is for a lubricant temperature indicator After cleaning, install the drain plug(s) only, and should not be used as a fill or level...
  • Page 113 Rear Axle IMPORTANT: When the ambient temperature is 2. If the vehicle has just been driven, allow a few minutes for the lubricant to settle. above 0°F (–18°C), use SAE 10 heavy-duty en- gine oil, API service classification SD (sulfated IMPORTANT: On Detroit axles, the oil change ash content must not exceed 1.85%).
  • Page 114 Rear Axle 1. Park the vehicle on level ground, set the parking 6. On non-drive axles using oil-lubricated wheel brakes, and chock the tires. bearings, check the oil level at the wheels, and add oil if low. Use the same lubricant recom- IMPORTANT: Oil level must be checked at each mended for the drive axle.
  • Page 115 Rear Axle This cold-weather mixture can be safely used 4. Check that the lubricant is level with the bottom of the fill hole, or with the top of the standpipe up to 32°F (0°C). opening. See Fig. 2. If low, check for oil leaks, Commercially available automatic transmission and correct as needed.
  • Page 117 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut Check.
  • Page 119 Wheels and Tires 40–01 Wheel Nut Check 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 IMPORTANT: After a wheel has been installed, procedure for all wheel nuts, using the tightening se- the wheel nut torque must be rechecked after quence shown in...
  • Page 121 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection ..............41–01 Driveline Lubrication.
  • Page 123 Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 124 Driveline 10/06/2016 f410067b 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.
  • Page 125 Driveline 10/06/2016 f410012a Attempt to move the sleeve-yoke and splined shaft back and forth. Fig. 4, Slip Joint Spline Wear Checking any evidence that balance weights are missing, remove the driveshaft and have it balanced. 9. For driveshafts with slip joints, check to be sure 10/07/2016 f410050a the yoke plug is not loose or missing.
  • Page 126 Driveline 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. 6. Check the purged grease. If it appears rusty, gritty, or burned, replace the U-joint.
  • Page 127 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection ........... . . 42–01 Air Dryer Desiccant Replacement .

  • Page 129: Air Brake System Valve Inspection

    Brakes 42–00 Safety Precautions 4. Disconnect the harness connector from the heater and thermostat assembly. Safety Precautions in this section apply to all 5. Loosen the capscrew securing the upper mount- ing bracket strap. procedures within this group. 6. Remove the two capscrews that secure the air DANGER dryer to the lower mounting bracket.
  • Page 130 Brakes 08/09/95 f421383 1. 5/16" x 4-1/2" Upper Mounting 9. Desiccant Cartridge 18. Purge Valve Bracket Capscrew 10. O-Ring 19. 1/4" Tapping Screw 2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3. 5/16" Lockwasher 12. Lower Mounting Bracket 21.
  • Page 131 Brakes WARNING Do not attempt to disassemble the desiccant car- tridge assembly. Parts for the assembly are not available and the cartridge contains a 150 lb spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury.
  • Page 132 Brakes IMPORTANT: Only use the silicone grease sup- 12.3 Fan the service brakes to reduce system air pressure to governor cut-in. Note that plied with Bendix replacement kits. the system once again builds to full pres- 5. Screw the desiccant cartridge onto the body, by sure and is followed by a purge at the hand, until the seal makes contact with the body.

  • Page 133: Air Dryer Inspection

    Brakes • 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 weeks of operation may be needed to fully dry the system.

  • Page 134: Alcohol Evaporator Cleaning And Inspection

    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.

  • Page 135: Meritor Camshaft Bracket Lubrication

    Brakes 10/07/2016 f420011a A. Grease Exit 1. Brake Chamber 3. Non-Pressure-Relief 2. Slack Adjuster Grease Fitting Fig. 6, Camshaft Bracket Lubrication Automatic slack adjusters that have a grease fitting 02/01/2001 f421649a must be lubricated periodically to ensure proper brake operation. 1.

  • Page 136: Meritor Slack Adjuster Lubrication

    Brakes 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 42–10 before lubri- cating the slack adjusters.
  • Page 137 Brakes 5. Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses (the 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.
  • Page 138 Brakes Group 42 of the Columbia® Workshop Manual 3. Check to see if the colored over-stroke band on for repair procedures. each brake chamber pushrod is exposed. If a band shows, the stroke is too long. Check Brake Component Inspection the foundation brake components for wear or damage, and repair as needed.
  • Page 139 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size 1-3/8 (35) Standard Stroke 1-3/4 (44) Haldex 2-1/2-Inch Extended Stroke 2 (51) 3-Inch Extended Stroke 2-1/2 (64) Standard Stroke 2 (51) Long Stroke 2-1/2 (64) Less than 1-1/2 (38) Standard Stroke Less than 1-3/4 (44)
  • Page 141 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Bellows Replacement, Rack and Pinion Steering Gear ........46–07 Drag Link Inspection.

  • Page 143: Safety Precautions

    Steering 46–00 Safety Precautions 46–02 Power Steering Fluid and Filter Changing Safety Precautions in this section apply to all procedures within this group. WARNING DANGER Fill only with approved clean fluid. Failure to use the proper fluid could cause seal deterioration and When working on the vehicle, shut down the en- leaks.

  • Page 144: Power Steering Fluid Level Inspection

    Steering 46–04 Power Steering Gear 7. Clean the reservoir cover and gasket. Inspect the O-ring and the cover for cracks, deformities, or Lubrication damage. Replace the gasket seal or cover as needed. Sheppard Steering Gears 8. Install the reservoir cover along with the spring and the top plate.

  • Page 145: Rack And Pinion Steering Gear Inspection

    Steering 46–06 Rack and Pinion Steering Gear Inspection WARNING 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.
  • Page 146 Steering 07/24/2009 f462151 1. Steering Tie Rod Arm 10. Input Shaft Seal Cover 17. I-shaft Slip Joint 2. Power Steering Fluid Lines 11. I-shaft Upper Yoke 18. Transfer Lines 3. Large Bellows Clamp 12. I-shaft Lower Yoke Boot Clamp 19. Rack and Pinion Gear 4.
  • Page 147 Steering 10. Check the tube fittings on the hard transfer lines housing with brake cleaner to remove all remain- of the gear, see Fig. 4, Item 15. If there is leak- ing dirt and debris. age from either of the fittings, replace the steer- IMPORTANT: Only apply grease to the rack ing gear.
  • Page 148 Steering NOTICE Fully opening an Oetiker clamp may cause perma- nent damage and render it ineffective. 14.1 Rotate the ears of the large Oetiker clamp forward on the bellows to avoid pinching the clamp in the next step. 14.2 Ensure the large Oetiker clamp is prop- erly seated in the clamp groove on the bellows.
  • Page 149 Steering ear width is 0.08 to 0.16 in (2 to 4 mm). Fig. 9 Fig. 07/24/2009 f580473 Fig. 8, Oetiker Clamp Tool, P/N 14100037 or 14100082 08/25/2009 f462172 A. Crimp the clamp ears until the ear width is 0.08 to 0.16 inch (2 to 4 mm).
  • Page 150 Steering turning angles and to prevent possible contact with components. 20.9 Tighten the stop-bolt jam nuts 80 to 120 lbf·ft (108 to 163 N·m). NOTICE Maximum wheel cut is not to exceed 46 degrees. Excessive wheel cut may damage the inner tie rod.
  • Page 151 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Filter Replacement ............. 47–01 Fuel Separator Sight Bowl Cleaning and Element Replacement.

  • Page 153: Safety Precautions

    Fuel 47–00 Safety Precautions 5. Lightly lubricate the threads on the sight bowl with oil, then thread the sight bowl into the bot- tom of the fuel separator. Safety Precautions in this section apply to all 6. Hand-tighten until the gasket is in full contact procedures within this group.
  • Page 154 Fuel 08/25/95 f470146 1. Vacuum Breaker/Drain 6. Heater Assembly Valve 7. Gasket 2. Reducer Bushing 8. Sight Bowl Heater 3. Mounting Brackets 4. O-Ring (when 9. Sight Bowl Assembly equipped with heater) 10. Vacuum Breaker/Drain 5. Stainless Steel Valve V-Clamp (when equipped with heater) Fig.
  • Page 155 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement............49–02 Exhaust System Inspection (Noise Emission Control).

  • Page 157: Safety Precautions

    Fig. 2), for cracking, dam- creased. Replace parts that show leakage, wear, or age, and dry rot. Replace as needed. damage, with genuine Freightliner parts. Pre-EPA07 Exhaust System Inspecting 1. On all vehicles, check the condition of the muffler body and the top stack. Check the inlet/outlet tubes for leakage, dents, and corrosion, and check for holes in the muffler.
  • Page 158 Exhaust sealclamps. If necessary, install a new wide-band Definitions of ATS Components exhaust clamp. Refer to the following list of definitions of ATS com- EPA07 Exhaust System ponents. • After-Treatment System (ATS)—the entire ex- Inspecting haust system from the turbocharger to the ex- haust stack or tail pipe.
  • Page 159 Exhaust 10/20/2006 f490283 A. Inspect this area of the canister for dents. 1. Marmon Fitting at Inlet from Turbocharger 6. Sensor Housing 2. DOC Temperature Sensor 7. DPF Outlet Temperature Sensor 3. ATD Mounting Band 8. Exhaust Outlet Marmon Fitting 4.
  • Page 160 Exhaust 4. If present, check the condition of the insulation 5. On the workbench, remove the CGI bellows from material around the exhaust pipe between the the exhaust piping. Do not damage the piping. turbocharger and the ATD. NOTE: The following step, and its substeps, is 5.
  • Page 161 Exhaust 02/24/2011 f490456 1. 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. 6, CAT EPA07 Exhaust Installation with CGI Bellows 01/29/2010 f490415 02/23/2011...
  • Page 162 Exhaust 02/23/2011 f490458 A. At least 7/16 inch (10 mm) 1. Forward CGI Pipe 3. Aft CGI Pipe 2. CGI Bellows Fig. 9, CGI Bellows Installation 02/08/2010 f490417 1. CGI Bellows 4. Graphite Gasket 2. Slip Clamp 5. Forward CGI Pipe 3.
  • Page 163 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Mirror Folding Check ............. . . 60–01 Columbia Maintenance Manual, December 2011...
  • Page 165 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 the fold-away feature of the mirror.
  • Page 167 Doors Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Seal, Door Latch, Door Hinge, and Door Check Lubrication....... 72–01 Columbia Maintenance Manual, December 2011...
  • Page 169 Doors 72–01 Door Seal, Door Latch, addition, some lubricants may not be compatible with the hinge bushings. Door Hinge, and Door Check Lubrication Door Hinges on Vehicles Built Before 8/1/2005 NOTE: Light penetrating oils, such as WD–40, should not be used because they wash out ben- On vehicles built before 8/1/2005, the door hinge eficial factory-installed grease, and they evapo- center pin is flush with the top of the top loop of the...
  • Page 170 Doors f720613 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...
  • Page 171 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection............83–01 Air Filter Replacement .
  • Page 173 Heater and Air Conditioner 83–00 Safety Precautions ment, see Group 83 of the Columbia® Work- shop Manual. Safety Precautions in this section apply to all On a Climate Control A/C compressor, place a feeler gauge between the air conditioner com- procedures within this group.
  • Page 174 The cab recirculation air filter must be replaced every six months, regardless of mileage, to permit proper IMPORTANT: When replacing the air filter, use operation of the HVAC system. only a Freightliner-approved air filter. 83/2 Columbia Maintenance Manual, September 2015...
  • Page 175 filter installed. CAUTION IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. If the sleeper air filter is not replaced every six 1. Park the vehicle on a level surface. Apply the months, damage to the heater and air conditioner parking brakes and chock the rear tires.
  • Page 177 Hood, Grille, and Cab Fenders Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication............88–01 Columbia Maintenance Manual, December 2011...
  • Page 179 Hood, Grille, and Cab Fenders 88–01 Hood Rear Support Lubrication 1. 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.

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