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COLUMBIA MAINTENANCE MANUAL
Models: CL112
CL120
STI-409-2 (2/10P)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

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  • Page 1 COLUMBIA MAINTENANCE MANUAL Models: CL112 CL120 STI-409-2 (2/10P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 2 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.
  • Page 3 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 4 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 5 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 6 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 7: 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 8: 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 9 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 10 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 11 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 12 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 13 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 14 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 15 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 16: 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 17: 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 18: 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 19 General Information M2 Maintenance Interval Operations: 00–07 Maintenance M2 Maintenance Interval Operations for Service Schedules I, II, and III Check Operation Number 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, II, and III Maintenance M2 Maintenance Interval Operations for Service Schedule IV Check...
  • Page 20 General Information M2 Maintenance Interval Operations: 00–07 Maintenance M2 Maintenance Interval Operations for Service Schedule IV Check Operation Number 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 00/13 Columbia Maintenance Manual, February 2010...

  • Page 21: 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 22: 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 23 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 35–01 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning • • (synthetic lubricant) 35–02 Axle Breather and Axle Lubricant Level Inspection...

  • Page 24: Noise Emission Controls Maintenance

    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 25: 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 26 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 00/19 Columbia Maintenance Manual, February 2010...
  • Page 27 General Information Metric/U.S. Customary Conversion Tables: 00–12 When You Know U.S. Multiply When You Multiply To Get Metric To Get U.S. Customary Customary Know Metric 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...
  • Page 28 652 (884) — — Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † 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...
  • Page 29 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...
  • Page 30 M30 x 2 792 (1074) 1096 (1486) Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed).
  • Page 31 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspection............01–02 Engine Support Fasteners Check .
  • Page 32 Engine 01–01 Engine Support sion, or too little tension on the belt may result in ex- cessive and premature belt wear. Poly-V belts, or Fasteners Check serpentine belts, are retained by a belt tensioner that requires no tension adjustment. Replace the drive Front and rear engine supports for vehicles built from belt if any conditions described in "Visual Inspection"...
  • Page 33 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 belt’s longest free-span.
  • Page 34 Engine 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.
  • Page 35 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement ......... . 09–01 Columbia Maintenance Manual, February 2004...
  • Page 36 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 inH O on a vehicle with a Detroit Diesel engine, 22 inH O on a vehicle with an MBE engine, or 25 O on a vehicle with a Caterpillar or Cummins engine.
  • Page 37 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Bendix Air Compressor Inspection............13–01 Columbia Maintenance Manual, May 2002...
  • Page 38 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.
  • Page 39 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Columbia Maintenance Manual, October 2008...
  • Page 40 Alternators and Starters 15–01 Alternator, Battery, and Inspect the retainer assembly or battery hold-downs, and the battery box. Replace Starter Connections worn or damaged parts. Remove any cor- rosion with a wire brush, and wash with a Check weak solution of baking soda and water. Flush with clean water, and dry.
  • Page 41 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 42 Engine Cooling/Radiator 20–01 Pressure Relief Cap 3. There is a second valve in the radiator cap that opens under vacuum. This prevents the collapse Check 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.
  • Page 43 Engine Cooling/Radiator applicable engine manufacturer’s maintenance and operation manual. 1. Park the vehicle and apply the parking brakes. Tilt the hood. 2. 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.
  • Page 44 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 02/28/96 f200326 antifreeze when refilling the cooling system.
  • Page 45 Engine Cooling/Radiator Manufacturer Antifreeze Type 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 ™...
  • Page 46 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 .
  • Page 47 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 48 Engine Cooling/Radiator Kysor K22RA Fan Clutch the retaining plate to the forward-most edge of the fan belt pulley. 1. Disconnect the batteries at the negative termi- 5. Compare the two measurements; if the difference nals. Drain all air from the air system. If between the two measurements exceeds 0.150 equipped with an air starter, drain the air starter inches (3.8 mm), the clutch lining is worn and...
  • Page 49 Engine Cooling/Radiator 4. Check the fan for bent, cracked, or damaged 9. If a leak is detected, remove the fan blade. In- blades. Replace if damaged. Check for adequate stall a new seal kit. See Group 20 of the Columbia ®...
  • Page 50 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Cross-Shaft Lubrication..........25–02 Eaton Fuller Clutch Release Bearing Lubrication .
  • Page 51 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.
  • Page 52 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.
  • Page 53 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement ..... . . 26–03 Manual Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic Lubricant) .
  • Page 54 Transmission 26–01 Manual Transmission formance, change the filter each time that the fluid is changed. Fluid Change, and 5. For a transmission equipped with a transmission Magnetic Plug Cleaning fluid filter(s), replace the fluid filter(s). (Synthetic Lubricant) Place a drain pan under the transmission fluid filter.
  • Page 55 Transmission Approved Manual Transmission Lubricants Eaton Fuller Transmission Lubricant Capacities Transmission Temp. Transmission Model Refill Capacity: qt (L) Lubricant Type Model Range Viscosity 7-Speed T Series † Eaton Fuller Transmissions All Models 18.0 (17.0) MobilTrans SHC 50 All 9-Speed Series (RN 2952 E-5) All Eaton All Models...
  • Page 56 Transmission 26–02 Transmission Fluid 26–03 Manual Transmission Air Level Inspection Filter/Regulator Check, Cleaning, or CAUTION Replacement Operating a transmission with the fluid level Eaton Fuller higher or lower than recommended can result in transmission damage. Do not overfill the transmis- 1.
  • Page 57 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.
  • Page 58 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection ............. . 31–01 Fifth Wheel Lubrication.

  • Page 59: Fifth Wheel Inspection

    Frame and Frame Components 31–01 Fifth Wheel Inspection Release the lock by tripping the release latch at the bottom of the throat. Adjust the wedge stop at the end of the WARNING wedge to approximately 1/4-inch (6-mm) clearance by turning the wedge stop rod All fifth wheel maintenance, adjustment, and re- located on the right side of the top plate.
  • Page 60 Frame and Frame Components 09/18/95 f310476 1. 3/16" x 1" Cotter Pin 11. 1/4–20 x 3/8" Thread-Cutting 19. 1/2–13 x 2" Bumper Pivot Bolt 2. Lower Bracket Retainer Pin Screw 20. Bumper 3. Grease Fitting 12. Step Jaw and Wedge 21.
  • Page 61 Frame and Frame Components 08/29/95 f310472 1. Locknut, 3/4–16 7. Torsion Spring 13. Lock Pin 2. Washer 8. Roll Pin 14. Lock Jaw 3. Rubber Washer 9. Secondary Lock, Right-Hand 15. Washer 4. Lock Adjustment Tag 10. Cam Plate 16. Right-Hand Release Handle 5.

  • Page 62: Fifth Wheel Lubrication

    Frame and Frame Components 11/28/95 f310353b 08/31/95 f310475 1. Lubricant Grooves 3. Lock Control Handle A. Extended Top Plate Lift Height 2. Safety Latch 4. Mount 1. Fifth Wheel Top Plate 2. Fifth Wheel Frame Mount Fig. 3, Simplex Series Fifth Wheel 3.

  • Page 63: Frame Fastener Torque Check

    Frame and Frame Components • If the vehicle operates in harsh conditions such Once the fifth wheel’s moving parts are lubricated, as salt spray from road surfaces, or in ex- apply a heavy coat of grease to the top plate, either tremely dusty environments.

  • Page 64: Trailer Electrical Connector Lubrication

    Frame and Frame Components Any component that shows signs of cracking or other damage must be repaired or replaced. Refer to the Columbia ® Workshop Manual for 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...
  • Page 65 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Suspension Inspection ............. . 32–01 Suspension Lubrication.
  • Page 66 Suspension 32–01 Suspension Inspection Front Suspension Check 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.
  • Page 67 5. Inspect the rubber bushing ends. See Fig. 3. Re- place the torque arm for any of the following rea- Freightliner Spring Suspension sons: • if there are gaps between the rubber bush- WARNING ing and the pin or outer steel sleeve;...
  • Page 68 Inspect the crossmember(s) and gussets for wear, Columbia ® Workshop Manual for instructions. 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.
  • Page 69 Suspension • Do not attempt to disassemble the Barksdale If the vehicle is equipped with an adjust- valve body or the control lever. There are no able leveling valve, the length should be serviceable parts in the valve, and any disas- 8 inches (200 mm).
  • Page 70 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.
  • Page 71 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 72 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 73 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–04 Basic Inspection, Meritor Unitized Wheel Ends .
  • Page 74 Front Axle 33–01 Knuckle Pin Lubrication, cross-tube socket members indicates that the tie-rod end assembly must be replaced. Meritor Axles 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.
  • Page 75 Fig. 3, Wheel Toe-In (overhead view) equipment manufacturer. Freightliner dealers must 7. Place the trammel bar at the front of the tires have proof of this calibration history.
  • Page 76 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 For any Dana Spicer axle that requires lubrication of 08/30/94 f400100a the tie-rod ends, wipe the grease fittings clean, then pump multipurpose chassis grease, NLGI Grade 1 Fig.
  • Page 77 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 78 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 79 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 80 Rear Axle 35–01 Axle Lubricant and Filter recommended drive axle lubricant) must be changed at the Maintenance 2 (M2) interval, Change, and Magnetic instead of the Maintenance 3 (M3) interval rec- Strainer Cleaning ommended in the Maintenance Operation Chart for axles that require only those lubricants rec- (Synthetic Lubricant) ommended in Table...
  • Page 81 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 1, Meritor Drive Axle Recommended Lubricant 5.
  • Page 82 Freightliner Rear Axle Approved Lubricant Type and 8. Remove the chocks, then drive the vehicle, un- Capacity loaded, for 1 or 2 miles (2 or 3 km) at speeds...
  • Page 83 Rear Axle 05/27/93 f350018a 1. Oil Fill Plug 2. Oil Drain Plug 05/27/93 f350017a Fig. 3, Axle Housing Drain and Fill Plugs 1. Magnetic Strainer 2. Power Divider this temperature, the oil will run more freely and Fig. 4, Dana Spicer Tandem-Drive Axle Magnetic ensure that the axle is flushed.
  • Page 84 Rear Axle the standpipe opening. To check fluid Dana Spicer Drive Axle Recommended Lubricant level, see Fig. Lubricant SAE Install and tighten the fill plug 40 to 60 Lubricant Type Condition Viscosity lbf·ft (54 to 81 N·m). Grade Dana Spicer Over-the-Road Two-Speed Axles With Shift Unit 75W–90...
  • Page 85 Rear Axle Commercially available automatic transmission temperature indicator only, and should not be fluid may be used in place of SAE 10 engine oil. used as a fill or level hole. Automatic transmission fluid can be used for all 3. Check that the lubricant is level with the bottom temperatures;...
  • Page 86 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.
  • Page 87 Rear Axle breather more frequently under adverse operat- unit housing. Using a wrench, tighten it an addi- tional 1-1/2 turns. ing conditions. 6. Check the axle housing breather. Make sure that it is unclogged and free from corrosion. See Fig. 7.
  • Page 88 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Nut Check..............40–01 Columbia Maintenance Manual, April 2005...
  • Page 89 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 90 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection ..............41–01 Driveline Lubrication.
  • Page 91 Driveline 41–01 Driveline Inspection 1. Park the vehicle on a flat, level surface, apply the parking brakes, and chock the tires. 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.
  • Page 92 Driveline 05/01/95 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 93 Driveline 05/27/93 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- 10/20/93 f410050a ries drivelines do not require periodic lubrication. A.
  • Page 94 Driveline 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. Fig. 5, Ref. 1. 2.
  • Page 95 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection ........... . . 42–01 Air Dryer Inspection .

  • Page 96: Air Brake System Valve Inspection

    Brakes 42–01 Air Brake System Valve CAUTION Inspection Clamping the end cover or housing in a vise could seriously compromise the air dryer’s ability to NOTE: There is no scheduled air valve mainte- hold air pressure, which could cause a failure in nance on vehicles equipped with Bendix air the brake system.
  • Page 97 Brakes 08/09/95 f421383 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.

  • Page 98: Air Dryer Inspection

    Brakes 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-...

  • Page 99: 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 100 Brakes 05/28/93 f420011a A. Grease Exit 1. Brake Chamber 3. Non-Pressure-Relief 2. Slack Adjuster Grease Fitting Fig. 4, Camshaft Bracket Lubrication Automatic slack adjusters that have a grease fitting must be lubricated periodically to ensure proper 02/01/2001 f421649a brake operation. 1.

  • Page 101: Bendix Ad-Is Air Dryer Desiccant Replacement

    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 42–11 before lubri- cating the slack adjusters.

  • Page 102: Bendix E-6 Foot Control Valve Inspection And Lubrication

    Brakes 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.
  • Page 103 Brakes area from which the pivot pin was removed). Re- place it if necessary. 6. Check the brake pedal rollers for signs of wear or cracks. Replace it if necessary. 7. If the rollers are replaced, replace the roller pin, install a new cotter pin, bend it to 90 degrees and apply Torque Seal (OPG F900 White) to the cotter pin.
  • Page 104 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection..............46–01 Drag Link Lubrication .
  • Page 105 Steering 46–01 Drag Link Inspection steering fluid into the drain pan and dispose of the fluid properly. Plug the return line fitting on the reservoir. WARNING 3. Loosen the clamp and remove the cover along with the filter spring and the filter top plate. All steering system components are critical for NOTE: Always replace the power steering reser- safe operation of the vehicle.
  • Page 106 Steering 46–04 Power Steering Gear properly bled when the steering pump does not labor when turning the wheel. Lubrication 12. Check for leaks in the power steering system and repair as needed. Top off the power steering Sheppard fluid level as needed. Sheppard power steering gears manufactured with- Approved Power Steering Fluids out grease fittings are maintenance-free.
  • Page 107 Steering 46–06 Rack and Pinion Steering 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 108 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 109 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Filter Replacement ............. 47–01 Fuel Separator Sight Bowl Cleaning and Element Replacement.
  • Page 110 Fuel 47–01 Fuel Filter Replacement Refer to the engine manufacturer’s service manual for removal and installation procedures. 47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement ConMet Fuel Separator Sight Bowl Cleaning The only maintenance necessary on ConMet fuel separators is to clean the sight bowl, if equipped. Fig.
  • Page 111 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 lbf·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 lbf·ft (41 N·m).
  • Page 112 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspection (Noise Emission Control)........49–01 Columbia Maintenance Manual, January 2007...
  • Page 113 Replace parts that show leakage, wear, or stack elbow(s) (see Fig. 2), for cracking, dam- damage, with genuine Freightliner parts. age, and dry rot. Replace as needed. Pre-EPA07 Exhaust System Inspecting 1. On all vehicles, check the condition of the muffler body and the top stack.
  • Page 114 Exhaust maintenance inspections. If any discrepancies Definitions of ATS Components are discovered, refer to the engine manufactur- Refer to the following list of definitions of ATS com- er’s service literature for repair instructions. ponents. • After-Treatment System (ATS)—the entire ex- haust system from the turbocharger to the ex- haust stack or tail pipe.
  • Page 115 Exhaust the required torque. If leakage persists, install a new clamp. 2. Check the exhaust pipe, bellows, and each ex- haust seal clamp for leakage, wear, cracks, or damage. Replace damaged components as needed. If leakage exists at a clamp, tighten the nuts to the required torque.
  • Page 116 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, October 2005...
  • Page 117 Doors 72–01 Door Seal, Door Latch, Door Hinges on Vehicles Built on or After 8/1/2005 Door Hinge, and Door Check Lubrication On vehicles built on or after 8/1/2005, the door hinge center pin is recessed in the top loop of the hinge bracket.
  • Page 118 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, October 2005...
  • Page 119 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection............83–01 Air Filter Replacement .
  • Page 120 Heater and Air Conditioner 83–01 Air Conditioner Inspection WARNING 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 08/25/94 f830641 1.
  • Page 121 IMPORTANT: When replacing the air filter, use operation of the HVAC system. only a Freightliner-approved air filter. CAUTION 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires.
  • Page 122 Heater and Air Conditioner 3. Remove the retainer that holds the recirculation 1. Turn off the engine, apply the brakes, and chock air filter in place. See Fig. the tires. 2. Access the sleeper HVAC assembly by raising the mattress and bunk panel to the locked posi- tion.

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