Maintenance Manual

COLUMBIA MAINTENANCE MANUAL

Models: CL112

CL120

STI-409-2 (2/10P)

Published by

Daimler Trucks North America LLC

4747 N. Channel Ave.

Portland, OR 97217

Printed in U.S.A.

Foreword

Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper maintenance program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides information necessary for years of safe, reliable, and cost-efficient vehicle operation.

IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other component and body manufacturers’ instructions for specific inspection and maintenance instructions.

Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip and post-trip inspections, and daily/weekly/monthly maintenance, as outlined in the vehicle driver’s manual. Major components, such as engines, transmissions, and rear axles, are covered in their own maintenance and operation manuals, that are provided with the vehicle. Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner

Dealership has the qualified technicians and equipment to perform this maintenance for you.

They can also set up a scheduled maintenance program tailored specifically to your needs.

Optionally, they can assist you in learning how to perform these maintenance procedures.

IMPORTANT: 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 information, or contact Daimler Trucks North America LLC at the address below.

Environmental Concerns and Recommendations

Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials.

NOTICE: Parts Replacement Considerations

Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage.

© 2001–2010 Daimler Trucks North America LLC

All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks

North America LLC. 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 LLC distributes the following major service publications in paper and electronic

(via ServicePro

®

) formats.

Workshop/Service

Manual

Maintenance Manual

Driver’s/Operator’s

Manual

Service Bulletins

Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, 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, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.

Driver’s/operator’s manuals contain information needed to enhance the driver’s understanding 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/operator’s manuals do not contain detailed repair or service information.

Service bulletins provide the latest service tips, field repairs, product improvements, and related information. Some service bulletins are updates to information 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.

Parts Technical Bulletins

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.

Web-based repair, service, and parts documentation can be accessed using the following applications on the

AccessFreightliner.com website.

ServicePro

PartsPro

EZWiring

ServicePro ® provides Web-based access to the most up-to-date versions of the publications listed above. In addition, the Service Solutions feature provides diagnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service 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 accessed from within PartsPro.

Columbia Maintenance Manual, February 2010

I–1

Introduction

Descriptions of Service Publications

Warranty-related service information available on the AccessFreightliner.com website includes the following documentation.

Recall Campaigns

Field Service 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 are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles.

I–2


Page Description

For an example of a Columbia Maintenance Manual page, see

Fig. 1

.

A B

Cooling

20−01 Coolant Replacement

C

20

Introduction

20−02 Cooling Fan Inspection

Columbia Maintenance Manual, December 2001

D E

11/28/2001

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

f020127


I–3

Introduction

Group No.

Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information

01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine

09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake

13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor

15 . . . . . . . . . . . . . . . . . . . Alternators and Starters

20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator

25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch

26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission

31 . . . . . . . . . . . . . Frame and Frame Components

32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension

33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle

35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle

40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires

41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline

42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes

46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering

47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel

49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust

72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors

83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner

Maintenance Manual Contents

I–4


General Information

00

Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01

Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05

Lubrication and Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04

M1 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06



Maintenance Operation Sets Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09

Metric/U.S. Customary Conversion Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–12

Noise Emission Controls Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10

Service Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02

Torque Specifications Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–13

Vehicle Maintenance Schedule Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03

Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–11


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 program can result in inefficient operation and unscheduled down time.

To determine the correct maintenance intervals for your vehicle you must first determine the type of service or conditions the vehicle will be operating in.

Generally, most vehicles operate under conditions that fall within one of the four types of service described. Before placing your new vehicle in service, determine the type of service (Service Schedule I, II,

III, or IV) that applies to the intended use of the vehicle. 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 operations to be performed at that maintenance interval.

Use the maintenance operation reference numbers to find detailed instructions in the manual on each operation.

Types of Service

Service Schedule I (severe service) applies to vehicles that annually travel less than 6000 miles (10

000 kilometers) or that operate under severe conditions. Examples of severe service, Schedule I 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 climates; frequent short-distance travel; constructionsite 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 conditions. Examples of Schedule II usage are: operation 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 vehicles 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: regional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage.

Service Schedule IV (long haul transport for Optimized Vehicle Configuration) is for vehicles that annually 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 transmission.

•

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 suspension.

•

Equipped with Meritor Q-Plus extended-lube cam brakes and automatic slack adjusters, front and rear.

•

Standard brake system package including Bendix AD-9 air dryer—mounted on the right-hand frame rail, located directly behind the front bumper—with heater, and a Bendix air compressor.

•

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.


00/1

00

Service Schedule Table: 00–02

General Information

Service Schedule

Schedule I

*

(Severe Service) vehicles that annually travel less than 6000 miles (10 000 km)

Maintenance Interval Operation

Initial Maintenance (IM)

Maintenance 1 (M1)

Maintenance 2 (M2)

Maintenance 3 (M3)

Frequency

first every every every

Maintenance Interval

Miles

1000

1000

5000

15,000

km

1600

1600

8000

24 000

Hours

50

50

500

1500

Schedule II

†

(Short-Haul Transport) vehicles that annually travel less than 60,000 miles (100 000 km)


Maintenance 1 (M1) first every

10,000

10,000

16 000

16 000

—

Maintenance 2 (M2)

Maintenance 3 (M3) every every

50,000

150,000

80 000

240 000

Schedule III

†

(Long-Haul Transport) vehicles that annually travel over

60,000 miles (100 000 km)


Maintenance 1 (M1)

Maintenance 2 (M2) first every every

25,000

25,000

100,000

40 000

40 000

161 000

—

Schedule IV

†

(Long-Haul Transport for

Optimized Vehicle Configuration) vehicles that annually travel over

60,000 miles (100 000 km)

Maintenance 3 (M3)


Maintenance 1 (M1)

Maintenance 2 (M2) every first every every

300,000

25,000

25,000

100,000

483 000

40 000

40 000

161 000

—

Maintenance 3 (M3) every 300,000 483 000

* For Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance traveled.

†

Use Schedule I (severe service) maintenance intervals for vehicles that operate under severe conditions, such as extremely poor roads, heavy dust accumulation, extreme climate, frequent short distance travel, construction-site operation, city operation (garbage truck), or farm operation.

Table 1, Service Schedule

00/2


General Information

00

Vehicle Maintenance Schedule Tables: 00–03

Maint. No.

18th

19th

20th

21st

22nd

23rd

24th

25th

13th

14th

15th

16th

17th

26th

27th

28th

29th

30th

1st

2nd

3rd

4th

5th

6th

7th

8th

9th

10th

11th

12th

1st through 30th Maintenance for Service Schedules I and II

Service Schedule I

Maintenance

Interval

Service

Date

Miles km Hours

IM and M1 1000 1600 100

M1

M1

M1

M1 and M2

M1

M1

M1

2000

3000

4000

5000

6000

7000

8000

3200

4800

6400

8000

9600

11 200

12 800

200

300

400

500

600

700

800

M1

M1 and M2

M1

M1

M1

M1

M1, M2, and M3

M1

M1

9000

10,000

11,000

12,000

13,000

14,000

15,000

16,000

17,000

14 400

16 000

17 600

19 200

20 800

22 400

24 000

25 600

27 200

900

1000

1100

1200

1300

1400

1500

1600

1700

M1

M1

M1 and M2

M1

M1

M1

M1

M1 and M2

M1

M1

M1

18,000

19,000

20,000

21,000

22,000

23,000

24,000

25,000

26,000

27,000

28,000

28 800

30 400

32 000

33 600

35 200

36 800

38 400

40 000

41 600

43 200

44 800

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

M1

M1, M2, and M3

29,000

30,000

46 400

48 000

2900

3000

Table 2, 1st through 30th Maintenance for Service Schedules I and II

290,000

300,000

180,000

190,000

200,000

210,000

220,000

230,000

240,000

250,000

260,000

270,000

280,000

90,000

100,000

110,000

120,000

130,000

140,000

150,000

160,000

170,000

Service Schedule II

Miles

10,000

km

16 000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

32 000

48 000

64 000

80 000

96 000

112 000

128 000

144 000

160 000

176 000

192 000

208 000

224 000

240 000

256 000

272 000

288 000

304 000

320 000

336 000

352 000

368 000

384 000

400 000

416 000

432 000

448 000

464 000

480 000

00/3


00


General Information

Maint. No.

48th

49th

50th

51st

52nd

53rd

54th

55th

43rd

44th

45th

46th

47th

56th

57th

58th

59th

60th

31st

32nd

33rd

34th

35th

36th

37th

38th

39th

40th

41st

42nd



Maintenance

Interval

Service

Date

Miles km Hours

M1 31,000 49 600 3100

M1

M1

M1

M1 and M2

M1

M1

M1

32,000

33,000

34,000

35,000

36,000

37,000

38,000

51 200

52 800

54 400

56 000

57 600

59 200

60 800

3200

3300

3400

3500

3600

3700

3800

M1

M1 and M2

M1

M1

M1

M1

M1, M2, and M3

M1

M1

39,000

40,000

41,000

42,000

43,000

44,000

45,000

46,000

47,000

62 400

64 000

65 600

67 200

68 800

70 400

72 000

73 600

75 200

3900

4000

4100

4200

4300

4400

4500

4600

4700

M1

M1

M1 and M2

M1

M1

M1

M1

M1 and M2

M1

M1

M1

48,000

49,000

50,000

51,000

52,000

53,000

54,000

55,000

56,000

57,000

58,000

76 800

78 400

80 000

82 000

83 700

85 300

86 900

88 500

90 100

91 700

93 300

4800

4900

5000

5100

5200

5300

5400

5500

5600

5700

5800

M1

M1, M2, and M3

59,000

60,000

94 900

96 500

5900

6000


590,000

600,000

480,000

490,000

500,000

510,000

520,000

530,000

540,000

550,000

560,000

570,000

580,000

390,000

400,000

410,000

420,000

430,000

440,000

450,000

460,000

470,000


Miles

310,000

km

496 000

320,000

330,000

340,000

350,000

360,000

370,000

380,000

512 000

528 000

544 000

560 000

576 000

592 000

608 000

624 000

640 000

656 000

672 000

688 000

704 000

720 000

736 000

752 000

768 000

784 000

800 000

820 000

837 000

853 000

869 000

885 000

901 000

917 000

933 000

949 000

965 000

00/4


General Information

00


Maint. No.

78th

79th

80th

81st

82nd

83rd

84th

85th

73rd

74th

75th

76th

77th

86th

87th

88th

89th

90th

61st

62nd

63rd

64th

65th

66th

67th

68th

69th

70th

71st

72nd



Maintenance

Interval

Service

Date

Miles km Hours

M1 61,000 98 200 6100

M1

M1

M1

M1 and M2

M1

M1

M1

62,000

63,000

64,000

65,000

66,000

67,000

68,000

99 800

101 400

103 000

104 600

106 200

107 800

109 400

6200

6300

6400

6500

6600

6700

6800

M1

M1 and M2

M1

M1

M1

M1

M1, M2, and M3

M1

M1

69,000

70,000

71,000

72,000

73,000

74,000

75,000

76,000

77,000

111 000

112 700

114 300

115 900

117 500

119 100

120 700

122 300

123 900

6900

7000

7100

7200

7300

7400

7500

7600

7700

M1

M1

M1 and M2

M1

M1

M1

M1

M1 and M2

M1

M1

M1

78,000

79,000

80,000

81,000

82,000

83,000

84,000

85,000

86,000

87,000

88,000

125 500

127 100

128 700

130 400

132 000

134 000

135 200

137 000

138 400

140 000

141 600

7800

7900

8000

8100

8200

8300

8400

8500

8600

8700

8800

M1

M1, M2, and M3

89,000

90,000

143 200

144 800

8900

9000


890,000

900,000

780,000

790,000

800,000

810,000

820,000

830,000

840,000

850,000

860,000

870,000

880,000

690,000

700,000

710,000

720,000

730,000

740,000

750,000

760,000

770,000


Miles

610,000

km

982 000

620,000

630,000

640,000

650,000

660,000

670,000

680,000

998 000

1 014 000

1 030 000

1 046 000

1 062 000

1 078 000

1 094 000

1 110 000

1 127 000

1 143 000

1 159 000

1 175 000

1 191 000

1 207 000

1 223 000

1 239 000

1 255 000

1 271 000

1 287 000

1 304 000

1 320 000

1 340 000

1 352 000

1 370 000

1 384 000

1 400 000

1 416 000

1 432 000

1 448 000

00/5


00


General Information

Maint. No.

91st

92nd

93rd

94th

95th

96th

97th

98th

99th

100th



Maintenance

Interval

Service

Date

Miles km Hours

M1

M1

M1

M1

M1 and M2

M1

M1

M1

M1

M1 and M2

91,000

92,000

93,000

94,000

95,000

96,000

97,000

98,000

99,000

100,000

146 500

148 100

150 000

151 300

153 000

155 000

156 100

157 700

159 300

160 900

9100

9200

9300

9400

9500

9600

9700

9800

9900

10,000


Miles

910,000

km

1 465 000

920,000

930,000

940,000

950,000

960,000

970,000

980,000

990,000

1,000,000


1 481 000

1 500 000

1 513 000

1 530 000

1 550 000

1 561 000

1 577 000

1 593 000

1 609 000

11

12

13

14

8

9

10

1st through 20th Maintenance for Service Schedules III and IV

Maint. No.


Service

Date

Service Schedules III and IV

Miles km

25,000 40 000 1

2

3

4

5

6

7

IM and M1

M1

M1

M1 and M2

M1

M1

M1

50,000

75,000

100,000

125,000

150,000

175,000

80 000

121 000

161 000

201 000

241 000

281 000

15

16

17

18

19

M1 and M2

M1

M1

M1

M1, M2, and M3

M1

M1

M1

M1 and M2

M1

M1

M1

200,000

225,000

250,000

275,000

300,000

325,000

350,000

375,000

400,000

425,000

450,000

475,000

322 000

362 000

402 000

443 000

483 000

523 000

563 000

604 000

644 000

684 000

724 000

764 000

00/6


General Information

00




Maint. No.


Service

Date

Miles km

20 M1 and M2 500,000 805 000

Table 6, 1st through 20th Maintenance for Service Schedules III and IV

26

27

28

29

30

31

32

33

34



Maint. No.


Service

Date

Miles km

21 M1 525,000 845 000

22

23

24

25

M1

M1

M1, M2, and M3

M1

550,000

575,000

600,000

625,000

885 000

925 000

966 000

1 005 800

M1

M1

M1 and M2

M1

M1

M1

M1 and M2

M1

M1

650,000

675,000

700,000

725,000

750,000

775,000

800,000

825,000

850,000

1 046 000

1 086 000

1 127 000

1 167 000

1 207 000

1 248 000

1 287 000

1 328 000

1 368 000

35

36

37

38

39

M1

M1, M2, and M3

M1

M1

M1

875,000

900,000

925,000

950,000

975,000

1 408 000

1 448 000

1 490 000

1 529 000

1 569 000

40 M1 and M2 1,000,000 1 609 000

Table 7, 21st through 40th Maintenance for Service Schedules III and IV

00/7


00

Lubrication and Fluid Level Check: 00–04

General Information

Maintenance Operation 00–04, Lubrication and Fluid

Level Check Operation

Table 8

summarizes all operations that must be performed to complete the Lubrication and Fluid Level Check operation 00–04 called for as an M1 maintenance interval for Service

Schedule I, II, and III vehicles, and as an M2 maintenance interval for Service Schedule IV vehicles.

Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check.

Maint.

Operation

Number

25–01

25–02

25–03

26–02

31–02

31–04

32–02

33–01

33–03

33–05

33–06

Maintenance Operation 00–04

Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV

Operation Description

Service

Schedules I, II, and III (at M1)

Service

Schedule IV

(at M2)

• Eaton Fuller Clutch Release Bearing Lubrication

Clutch Release Cross-Shaft Lubrication

Sleeve Assembly Bronze Bushing Lubrication

Transmission Fluid Level Inspection

Fifth Wheel Lubrication

Trailer Electrical Connector Lubrication

Suspension Lubrication

•

•

•

•

•

•

Check

35–02

41–02

42–05

42–06

Knuckle Pin Lubrication, Meritor Axles

Tie Rod Lubrication, Meritor Axles

Knuckle Pin Lubrication, Dana Spicer Axles

Tie Rod Lubrication, Dana Spicer Axles

Axle Breather and Axle Lubricant Level Inspection

Driveline Lubrication

Dana Spicer Camshaft Bracket Lubrication

•

•

•

•

•

•

•

•

•

46–03

46–04

46–05

Dana Spicer, Haldex, and Gunite Slack Adjuster

Lubrication

Power Steering Fluid Level Inspection

Power Steering Gear Lubrication

Drag Link Lubrication

•

•

•

46–06

72–01

Rack and Pinion Inspection

Door Seal, Door Latch, and Door Hinge Lubrication •

•

Table 8, Maintenance Operation 00-04, Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV

00/8


General Information

00

Initial Maintenance (IM) Operations: 00–05

The Initial Maintenance table lists all maintenance operations that are to be performed at the initial maintenance (IM) interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed. All operations listed in the table, along with the operations listed in the applicable M1 maintenance interval table, must be performed to complete the initial maintenance

(IM).

Maintenance

Operation Number

00–06

31–03

32–03

33–04

40–01

47–03

Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV

Perform all M1 Operations

Frame Fastener Torque Check

Suspension U-Bolt Torque Check

All-Axle Alignment Check

Wheel Nut Check

Fuel Tank Band-Nut Tightening

Table 9, Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV

Check


00/9

00

M1 Maintenance Interval Operations: 00–06

General Information

The M1 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M1 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed.

IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and

Post-Trip Inspections and Maintenance" chapter of the

Columbia ® Driver’s Manual

.

Maintenance


00–04

13–01

20–03

31–01

41–01

42–11

49–01

M1 Maintenance Interval Operations for Service Schedules I, II, and III

Lubrication and Fluid Level Check (includes the following)

•

Eaton Fuller Clutch Release Bearing Lubrication

•


•


•


•


•


•


•


•

Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication

•

Door Seal, Door Latch, and Door Hinge Lubrication

Bendix Air Compressor Inspection

Fan Clutch Check (noise emission control)

Fifth Wheel Inspection

Driveline Inspection

Brake Inspection

Exhaust System Inspection (noise emission control)

Table 10, M1 Maintenance Interval Operations for Service Schedules I, II, and III

Check

Maintenance


13–01

20–03

31–01

31–02

31–04

42–11

49–01

72–01

M1 Maintenance Interval Operations for Service Schedule IV






Brake Inspection



Table 11, M1 Maintenance Interval Operations for Service Schedule IV

Check

00/10


General Information

00


The M2 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M2 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed. Perform all

M1 maintenance interval operations at the M2 maintenance interval.

Maintenance


00–06

01–01

01–02

15–01

20–01

25–02

25–03

25–04

26–02

26–03

32–01

32–03

33–01

33–02

33–03

33–07

33–08

35–02

40–01

42–01

42–03

42–04

42–07

42–08

46–01

46–03

46–04

46–05

46–06

47–01

47–02

83–01


Perform All M1 Operations

Engine Support Fasteners Check (noise emission control)

Engine Drive Belt Inspection

Alternator, Battery, and Starter Check

Pressure Relief Cap Check



Meritor Clutch Release Bearing Lubrication


Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement

Suspension Inspection



Tie Rod Inspection


Basic Inspection, Meritor Unitized Wheel Ends

End-Play Check, Meritor Unitized Wheel Ends


Wheel Nut Check

Air Brake System Valve Inspection

Air Dryer Inspection

Alcohol Evaporator Cleaning and Inspection

Meritor Camshaft Bracket Lubrication

Meritor Slack Adjuster Lubrication

Drag Link Inspection




Rack and Pinion Steering Inspection

Fuel Filter Replacement

Fuel Separator Sight Bowl Cleaning and Element Replacement

Air Conditioner Inspection

Check

00/11


00


General Information

Maintenance


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

00–06

01–01

01–02

15–01

20–01

26–03

32–01

32–03

33–02

33–07

33–08

40–01

41–01

42–01

42–03

42–04

46–01

46–06

47–01

47–02

Maintenance


00–04


Lubrication and Fluid Level Check (includes the following)

•


•


•


•


•


•


•


•


•


•







Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement



Tie Rod Inspection



Wheel Nut Check









Check

Check

00/12


General Information

00


Maintenance


83–01

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

Check


00/13

00


General Information

The M3 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M3 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed. Perform all

M1 and M2 maintenance interval operations at the

M3 maintenance interval.

Maintenance


00–06

00–07

09–01

20–02

26–01

35–01

42–02

42–09

42–10

46–02

M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV



Air Cleaner Element Inspection and Replacement

Radiator Pressure-Flushing and Coolant Change

Manual Transmission Fluid Change, and Magnetic Plug Cleaning (synthetic lubricant)

Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (synthetic lubricant)

Bendix AD–9 Air Dryer Desiccant Replacement

Bendix AD–IS Air Dryer Desiccant Replacement

Bendix E–6 Foot Control Valve Inspection and Lubrication

Power Steering Fluid and Filter Change

Table 14, M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV

Check

00/14


General Information

00

Maintenance Operation Sets Table: 00–09

Maint.

No.

00–04

Maintenance Operation Sets for Groups 00 through 83


Lubrication and Fluid Level Check

Service Schedules

I, II, and III


IV

IM M1 M2 M3 IM M1 M2 M3

• • • • • •

01–01


01–02


01–03

Pacbrake Inspection and Lubrication

*

09–01

Air Cleaner Element Inspection and Replacement

13–01


15–01

20–01

20–02

Radiator Pressure-Flushing and Coolant Change

20–03


25–01

25–02

25–03

25–04



Eaton Fuller Clutch Release Bearing Lubrication



Meritor Clutch Release Bearing Lubrication

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

26–01

Manual Transmission Fluid Change, and Magnetic Plug Cleaning

(Synthetic Lubricant)

26–02


26–03

Manual Transmission Air Filter/Regulator Check, Cleaning, or

Replacement

31–01


31–02


31–03

Frame Fastener Torque Check

31–04


•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

32–01


32–02


32–03


33–01


33–02

Tie Rod Inspection

33–03


33–04

All-Axle Alignment Check

33–05


33–06


33–07


†

33–08


‡

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

00/15


00

Maintenance Operation Sets Table: 00–09

General Information

Maint.

No.

Maintenance Operation Sets for Groups 00 through 83


Service Schedules

I, II, and III


IV

IM M1 M2 M3 IM M1 M2 M3

35–01

Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning

(synthetic lubricant)

• •

35–02


40–01

Wheel Nut Check

41–01


41–02


42–01


•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

42–02

Bendix AD–9 Air Dryer Desiccant Replacement

42–03


42–04


42–05


42–06

Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication

42–07

Meritor Camshaft Bracket Lubrication

42–08

Meritor Slack Adjuster Lubrication

42–09

Bendix AD–IS Air Dryer Desiccant Replacement

42–10

Bendix E–6 Foot Control Valve Inspection and Lubrication

42–11

Brake Inspection

46–01


46–02

46–03

46–04

46–05

46–06

47–01

Power Steering Fluid and Filter Change






47–02


47–03

Fuel Tank Band-Nut Tightening

49–01


72–01


83–01


83–02

Air Filter Replacement

§

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

* No specific lubrication interval. See

MOP 01–03

for more information.

†

Inspect Meritor Unitized Wheel Ends at 200,000 miles (321 869 km), and then every 50,000 miles (80 467 km).

‡

Check the end play at 200,000 miles (321 869 km), and then every subsequent 200,000 miles (321 869 km).

§

Replace the HVAC filters every 6 months regardless of mileage.

Table 15, Maintenance Operation Sets for Groups 00 through 83

00/16


General Information

00

Noise Emission Controls Maintenance: 00–10

Noise Emission Control

Maintenance

Federal Law, Part 205:

Transportation Equipment Noise

Emission Controls

Part 205, Transportation Equipment Noise Emission

Controls, requires the vehicle manufacturer to furnish, with each new vehicle, such written instructions for the proper maintenance, use, and repair of the vehicle by the ultimate purchaser to provide reasonable assurance of the elimination or minimization of noise-emission-control degradation throughout the life of the vehicle. In compliance with the law, the noise emission controls maintenance information in each applicable group of this manual, in conjunction with the vehicle workshop manual, provides these instructions to owners.

Recommendations for

Replacement Parts

Replacement parts used for maintenance or repair of noise emission controls should be genuine Freightliner parts. If other than genuine Freightliner parts are used for replacement or repair of components affecting noise emission control, the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine Freightliner parts in performance and durability.

Freightliner Noise Emission

Controls Warranty

Refer to the vehicle owner’s warranty information book for warranty information concerning noise emission controls.

Tampering with Noise Controls is

Prohibited

Federal law prohibits the following acts or the causing thereof:

1.

The removal or rendering inoperative by any person (other than for purposes of maintenance, repair, or replacement) of any device or element of design incorporated into any new vehicle for the purpose of noise control, prior to its sale or delivery to the ultimate purchaser, or while it is in use.

2.

The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

A. Removal of engine noise-deadening panels.

B. Removal of cab-tunnel or hood noisedeadening panels.

C. Removal of, or rendering inoperative, the engine speed governor so as to allow engine speed to exceed manufacturer’s specifications.

D. Removal of, or rendering inoperative, the fan clutch, including bypassing the control on any thermostatic fan drive to cause it to operate continuously.

E. Removal of the fan shroud.

F.

Removal of, or rendering inoperative, exhaust components, including exhaust pipe clamping.

G. Removal of air intake components.

Maintenance Instructions

Scheduled intervals are in the maintenance tables in this group. A "Verification of Inspections Log (Groups

01, 20, and 49)" follows, and should be filled in each time noise emission controls on the vehicle are maintained or repaired.

00/17


00

Verification of Inspections Log: 00–11

General Information

Verification of Inspections Log

Verification of Inspections Log, Group 01

Verification of Inspections Log — Group 01 — Engine Mounts

Date Mileage Item Cost Maintenance Facility


Date Mileage

Verification of Inspections Log — Group 20 — Fan Clutch

Item Cost Maintenance Facility

00/18


General Information

00

Verification of Inspections Log: 00–11


Date Mileage

Verification of Inspections Log — Group 49 — Exhaust System Components

Item Cost Maintenance Facility


00/19

00

Metric/U.S. Customary Conversion Tables: 00–12

General Information

When You Know U.S.

Customary

Length

inches (in) inches (in) feet (ft) yards (yd) miles (mi)

Area

square inches (in

2

) square inches (in

2

) square feet (ft

2

)

Volume

cubic inches (in

3

) cubic inches (in

3

) cubic inches (in

3

) fluid ounces (fl oz) pints (pt) quarts (qt) gallons (gal) cubic feet (ft

3

) cubic feet (ft

3

)

Weight/Force

Multiply

25.4

2.54

By

0.3048

0.9144

1.609

645.16

6.452

0.0929

16387.0

16.387

0.01639

29.54

0.47318

0.94635

3.7854

28.317

0.02832

To Get Metric

When You

Know Metric

millimeters (mm) centimeters (cm) meters (m) meters (m) kilometers (km) square millimeters (mm square centimeters (cm

2 square meters (m

2

) cubic millimeter (mm

3 cubic centimeters (cm

3 liters (L) milliliters (mL) liters (L) liters (L) liters (L) liters (L) cubic meters (m

3

)

)

2

)

)

)

Multiply

By

0.03937

0.3937

3.281

1.094

0.6215

0.00155

0.155

10.764

ounces (av) (oz) pounds (av) (lb)

U.S. tons (t)

U.S. tons (t)

28.35

0.454

907.18

0.90718

grams (g) kilograms (kg) kilograms (kg) metric tons (t)

0.03527

2.205

0.001102

1.1023

Torque/Work Force

inch–pounds (lbf·in) foot–pounds (lbf·ft)

Pressure/Vacuum

inches of mercury (inHg)

11.298

1.3558

Newton–centimeters (N·cm)

Newton–meters (N·m)

0.08851

0.7376

3.37685

kilo Pascals (kPa) 0.29613

pounds per square inch (psi) 6.895

kilo Pascals (kPa) 0.14503

Table 16, Metric/U.S. Customary Conversion

0.000061

0.06102

61.024

0.03381

2.1134

1.0567

0.2642

0.03531

35.315

To Get U.S. Customary

inches (in) inches (in) feet (ft) yards (yd) miles (mi) square inches (in square inches (in square feet (ft

2 cubic inches (in

2

2

)

3

) cubic inches (in

3

) cubic inches (in

3

) fluid ounces (fl oz) pints (pt) quarts (qt) gallons (gal) cubic feet (ft

3

) cubic feet (ft

3

) ounces (av) (oz) pounds (av) (lb)

U.S. tons (t)

U.S. tons (t) inch–pounds (lbf·in) foot–pounds (lbf·ft) inches of mercury (inHg) pounds per square inch (psi)

)

)

When You Know

degrees Fahrenheit (°F)

Subtract

32

Then

Divide By

To Get

When You

Know

Multiply

By

1.8

degrees Celcius (°C) 1.8

Table 17, Temperature Conversion

Then

Add

32

To Get

degrees Fahrenheit (°F)

00/20


General Information

00

Torque Specifications Tables: 00–13

Thread

Diameter–

Pitch

Torque Values for U.S. Customary Thread Fasteners With Lubricated

* or Plated Threads

†

Regular Hex Flanged

Grade 5

Bolt

Grade 5 or

B Nut

Torque: lbf·ft (N·m)

Grade 8 or

8.2 Bolt

Grade 8 or

C Nut


Grade 5

Bolt

Grade B

Nut


Grade 8 or

8.2 Bolt

Grade G

Nut


1/4–20

1/4–28

5/16–18

5/16–24

3/8–16

3/8–24

7/16–14

7/16–20

1/2–13

1/2–20

9/16–12

9/16–18

5/8–11

5/8–18

3/4–10

3/4–16

7/8–9

7/8–14

1–8

1–12

1–14 f230002

7 (9)

8 (11)

15 (20)

16 (22)

26 (35)

30 (41)

42 (57)

47 (64)

64 (87)

72 (98)

92 (125)

103 (140)

128 (173)

145 (197)

226 (306)

253 (343)

365 (495)

402 (545)

—

—

— f230003 f230004

8 (11)

9 (12)

16 (22)

17 (23)

28 (38)

32 (43)

45 (61)

50 (68)

68 (92)

77 (104)

98 (133)

110 (149)

136 (184)

154 (209)

241 (327)

269 (365)

388 (526)

427 (579)

582 (789)

637 (863)

652 (884) f230005 f230006

6 (8)

7 (9)

13 (18)

14 (19)

23 (31)

25 (34)

35 (47)

40 (54)

55 (75)

65 (88)

80 (108)

90 (122)

110 (149)

130 (176)

200 (271)

220 (298)

320 (434)

350 (475)

—

—

— f230007

* 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

f230008

10 (14)

12 (16)

21 (28)

23 (31)

37 (50)

42 (57)

60 (81)

66 (89)

91 (123)

102 (138)

130 (176)

146 (198)

180 (244)

204 (277)

320 (434)

357 (484)

515 (698)

568 (770)

—

—

— f230009

00/21


00


General Information

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)

*

Plain (Unplated) Threads

†

Regular Hex Flanged

Thread

Diameter–

Pitch

Grade 5 Bolt

Grade 5 or B

Nut

Grade 8 or 8.2

Bolt

Grade 8 or C

Nut

Grade 8 or 8.2

Bolt

Grade G Nut

Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230002 f230003 f230004 f230005 f230008 f230009

1/4–20

1/4–28

5/16–18

5/16–24

3/8–16

3/8–24

7/16–14

7/16–20

1/2–13

1/2–20

9/16–12

9/16–18

5/8–11

5/8–18

3/4–10

3/4–16

7/8–9

7/8–14

1–8

1–12

1–14

8 (11)

9 (12)

15 (20)

17 (23)

28 (38)

31 (42)

45 (61)

50 (68)

70 (95)

75 (102)

100 (136)

110 (149)

135 (183)

155 (210)

240 (325)

270 (366)

385 (522)

425 (576)

580 (786)

635 (861)

650 (881)

10 (14)

12 (16)

22 (30)

25 (34)

40 (54)

45 (61)

65 (88)

70 (95)

95 (129)

110 (149)

140 (190)

155 (210)

190 (258)

215 (292)

340 (461)

380 (515)

540 (732)

600 (813)

820 (1112)

900 (1220)

915 (1241)

* Threads may have residual oil, but will be dry to the touch.

†

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

—

—

22 (30)

—

40 (54)

—

65 (88)

—

95 (129)

—

140 (190)

—

190 (258)

—

340 (461)

—

—

—

—

—

—

00/22


General Information

00


Torque Values for Metric Thread Fasteners With Lubricated

* or Plated Threads

†

Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut

Thread

Diameter–Pitch

Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

8.8

f230010

8 f230011

10.9

f230012

10 f230013

M6

M8

M8 x 1

M10

M10 x 1.25

M12

M12 x 1.5

M14

M14 x 1.5

M16

M16 x 1.5

M18

M18 x 1.5

M20

M20 x 1.5

M22

M22 x 1.5

M24

M24 x 2

M27

M27 x 2

M30

M30 x 2

5 (7)

12 (16)

13 (18)

24 (33)

27 (37)

42 (57)

43 (58)

66 (89)

72 (98)

103 (140)

110 (149)

147 (199)

165 (224)

208 (282)

213 (313)

283 (384)

315 (427)

360 (488)

392 (531)

527 (715)

569 (771)

715 (969)

792 (1074)

*

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 20, Torque Values for Metric Thread Fasteners With Lubricated or Plated

Threads

7 (9)

17 (23)

18 (24)

34 (46)

38 (52)

60 (81)

62 (84)

95 (129)

103 (140)

148 (201)

157 (213)

203 (275)

229 (310)

288 (390)

320 (434)

392 (531)

431 (584)

498 (675)

542 (735)

729 (988)

788 (1068)

990 (1342)

1096 (1486)

00/23


Engine

01



Engine Drive Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–02

Engine Support Fasteners Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–01

Pacbrake Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–03

Columbia Maintenance Manual, January 2007

Engine

01

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 removed for service. For vehicles manufactured prior to

January 2007, perform the following check.

Check the rear engine support fasteners (see

Fig. 1

,

Ref. 4) for tightness. Tighten the 3/4-inch fasteners

215 to 265 lbf·ft (292 to 359 N·m).

Check the front engine support fasteners for tightness. Tighten the 5/8-inch fasteners 125 lbf·ft (170

N·m).

NOTE: At engine overhaul, and whenever the engine has been removed, inspect the lower and upper isolators (Refs. 1 and 6), and replace them if they are worn. See Group 01 of the

Columbia

®

Workshop Manual for procedures.

5

2

6

1

4

3

2

10/05/94

1.

Lower Isolator

2.

Engine Support Washer

3.

3/4–10 Capscrew

4.

3/4–10 Hexnut

5.

Engine Mount

6.

Upper Isolator

Fig. 1, Engine Rear Mount

01–02 Engine Drive Belt

Inspection

f220047a

Worn or loose drive belts may cause premature bearing failure or engine overheating. Excessive tension, or too little tension on the belt may result in excessive 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 sidewalls and bottom. Inspect all belts for the following conditions, then perform the "Belt Tension Inspection."

Visual Inspection

1.

Inspect the belt for glazing. See

Fig. 2

, Ref. A.

Glazing is represented by shiny sidewalls, and is caused by friction created when a loose belt slips in the pulleys. It can also be caused by oil or grease on the pulleys.

2.

Check the belt for ply separation. See

Fig. 2

,

Ref. B. Oil, grease, or belt dressing can cause the belt to fall apart in layers. Repair any oil or coolant leaks that are affecting the belts before replacing the drive belts. Do not use belt dressing 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 installation.

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, place a stetho-


01/1

01

Engine

A

B

D

E

C

F

11/21/94

A. Glazing

B. Separating Layers

C. Streaked Sidewalls

D. Tensile Break

E. Uneven Ribs

F.

Cracks f150010a

Fig. 2, Drive Belt Replacement Conditions

scope on the component being checked, not the pulley, to isolate the area from outside interference.

8.

Inspect all pulleys for foreign objects, oil, or grease in the grooves.

2.

Install a belt tension gauge at the center of the belt’s longest free-span. Check belt tension. See

Table 1

for belt tension specifications.

3.

If belt tension is not correct, see Group 01 of the

Columbia

®

Workshop Manual to adjust belt tension.

Belt Tension Inspection

Threaded-Adjustment Type

1.

Apply the parking brakes and chock the tires.

Engine

Cummins ISB, ISC, ISM

Mercedes-Benz MBE900

Drive Belt Tensions

Component

Refrigerant Compressor

Fan and Alternator

Refrigerant Compressor

Table 1, Drive Belt Tensions

Belt Tension: lbf (kg)

100 (45)

29.5 (27.9)

30.0 (28.4)

01/2


Engine

Spring-Tension Type

On belts equipped with a spring tensioner, belt tension is automatically adjusted. Check that the tensioner is holding tension on the belt by inserting the end of a breaker bar in the 1/2-inch square hole on the forward face of the tensioner, and rotating the tensioner away from the belt. When the breaker bar is slowly released, the tensioner should return to its original position. The tensioner should rotate smoothly with no binding. If not, see Group 01 of the

Columbia

® structions.

Workshop Manual for replacement in-

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 inconsistently or seasonally, it will be necessary to perform preventative maintenance. If the vehicle is exposed 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 nonpetroleum-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 affected 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 improperly functioning or non-functioning brake. If it is necessary to periodically start the engine, attain normal operating temperatures before shutting down the engine.


01

01/3

Air Intake

09



Air Cleaner Element Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–01


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

2

22 inH

2 inH

2

O on a vehicle with a Detroit Diesel engine,

O on a vehicle with an MBE engine, or 25

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, 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, inspect 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 inH

2

22 inH

2

O on a vehicle with a Detroit Diesel engine,

O on a vehicle with an MBE engine, or 25 inH

2

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 restriction indicator.


09

09/1

Air Compressor

13



Bendix Air Compressor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 connections 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



Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01

Columbia Maintenance Manual, October 2008

Alternators and Starters

15

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 fasteners; 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 without binding. Engines equipped with a serpentine, or poly-V belt have automatic belt tensioners and do not require belt tension inspection.

3.

Check that all electrical connections at the alternator 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 charging cable terminates.

4.

Inspect the battery cables for wear, and replace them if they are damaged. Clean the cable connector 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.

4.2

4.3

4.4

Inspect the retainer assembly or battery hold-downs, and the battery box. Replace worn or damaged parts. Remove any corrosion 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.

Check that foreign objects such as stones, bolts, and nuts are removed from the battery box.

After cleaning, connect the cables to the batteries and tighten them to the torque specifications listed on the battery, generally 10 to 15 lbf·ft (14 to 20 N·m).

4.5

Coat the battery terminals with dielectric grease.

5.

Check the alternator wiring for missing insulation, kinks, and heat damage. Replace or repair as needed.

6.

Check the terminals on the battery shut-off switch and the magnetic switch. Make sure the terminal connections are clean and tight. Coat the terminal connections with dielectric red enamel after cleaning.


15/1

Engine Cooling/Radiator

20



Fan Clutch Check (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03

Pressure Relief Cap Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01

Radiator Pressure-Flushing and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02



20

20–01 Pressure Relief Cap

Check

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 in a surge of scalding coolant that could cause serious 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.

3.

There is a second valve in the radiator cap that opens under vacuum. This prevents the collapse of hoses and other parts that are not internally supported when the system cools. Inspect the vacuum-relief valve to be sure it is not stuck.

4.

Make sure that the cap seals properly on the coolant filler neck seat, and that the radiator cap gasket is not damaged. On vehicles with screw-on caps with O-rings, make sure that the

O-ring is not cracked or deteriorated. Replace the cap if the gasket shows deterioration or damage.

20–02 Radiator Pressure-

Flushing and Coolant

Change

NOTE: For additional instructions on cleaning and flushing the engine cooling system, see the

1

2

3

06/08/95

1.

Low-Coolant-Level Sensor

2.

SAE Cap (for coolant overflow pressure relief only)

3.

Fill Cap

Fig. 1, Surge Tank

Columbia Maintenance Manual, January 2007 f500244

20/1

20

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 container should hold at least 60 quarts (59 liters) of fluid.

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 in a surge of scalding coolant that could cause serious personal injury.

3.

Remove the surge tank cap.

WARNING

Do not attempt to drain the cooling system until the coolant and engine are cool. Draining the cooling system prior to the system cooling could cause severe personal injury due to scalding.

4.

Remove the drain plugs at the radiator side tank and at the lower radiator outlet pipe elbow. See

Fig. 2

. Allow the coolant to drain.

5.

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.

CAUTION

When flushing the radiator, do not apply more than 15 psi (100 kPa) air pressure. Excessive pressure 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.

7.

Shut off the air at the pressure gun nozzle and allow the radiator to refill with water.

1

1

06/29/95

NOTE: Cummins engine shown.

1.

Coolant Drain Plug

Fig. 2, Coolant Drain Plug Location

f011008

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 lbf·in (620 N·cm). These clamps are now standard on hoses with an inside diameter greater than 2 inches (51 mm).

When installing Breeze Constant-Torque hose clamps, the clamps must be tightened to the correct torque. The screw tip of the clamp must extend about 1/4 inch (6 mm) from the clamp housing, and the Belleville washer stacks must be collapsed almost flat. Use a torque wrench to install these clamps correctly. The correct installation torque is as follows:

For Breeze Constant-Torque clamps with a 5/16inch tightening screw hex: 55 lbf·in (620 N·cm).

For Breeze Constant-Torque clamps with a 3/8inch tightening screw hex: 90 lbf·in (1020 N·cm).

20/2



20

02/28/96

A

Fig. 3, T-Bolt Type Hose Clamp

B f200326

1

08/15/94 f200286

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 automatically adjust and keep consistent sealing pressure. During vehicle operation and shutdown, the screw tip may adjust according to temperature and pressure changes. The torque may need to be adjusted for individual applications.

11. Place a pan under the coolant filter to catch engine coolant.

12. Remove the coolant filter with a strap or chain wrench. Install a new coolant filter and tighten.

IMPORTANT: On vehicles with EPA07 compliant engines, the coolant capacity varies depending on the engine and accessory installation. After servicing the cooling system, always verify that the coolant level is between the MIN and MAX lines on the surge tank.

13. Fill the cooling system with new coolant. See

Table 1

for the vehicle’s coolant capacity. Certain equipment such as fuel heaters, water filters, and auxiliary heaters may increase the coolant capacity and require additional coolant. The cooling system is filled when the coolant level reaches the MAX line on the surge tank. Freightliner recommends the use of a precharged and premixed antifreeze when refilling the cooling system. See

Table 2

for a list of some of the precharged antifreeze available. Use of an equivalent antifreeze to those listed in the table is also acceptable.

Always check that the antifreeze meets Freightliner’s specifications and is at the proper concentration for protection in the vehicle operating area. See

Table 3

for antifreeze protection information. Freightliner specifies that antifreeze must be an ethylene glycol solution that meets GM

6038 M Engineering Standards or a ethylene glycol solution that has less than 0.1% anhydrous sodium metasilicate, and meets either GM 1825

M or GM 1899 M Engineering Standards. If supplemental coolant additives are being used, add the supplements to the coolant as necessary. 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)

Engine

CAT C10/C12

Capacity with 1000 sq. inch Radiator:

Capacity with 1200 sq. inch Radiator:

39.5 qt (37.4 L) 40.6 qt (38.5 L)

CAT

Cummins

53.2 qt (50.4 L)

39.0 qt (37.0 L)

54.1 qt (51.5 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)

20/3


20


Manufacturer

Caterpillar

Antifreeze

Caterpillar Diesel Engine Antifreeze/Coolant

Type

Contains supplement additives. Available as a premixed solution.

Cummins

Detroit Diesel

Fleetguard

®

Compleat Premix

Detroit Diesel Power Cool

Old World Industries Fleet Charge

™

Premixed solution with supplement additives

Premixed solution with supplement additives

With supplement additives

Table 2, Approved Antifreeze

Cooling

System

Capacity gal (L)

*

2 (8)

Maximum Coolant Protection in °F (°C) at Various Antifreeze ConcentrationS

ETHYLENE-GLYCOL-BASE ANTIFREEZE REQUIRED gallons (liters)

3 (11) 4 (15) 5 (19) 6 (23) 7 (26) 8 (30) 9 (34)

10

(38)

10 (38)

16 (–9) 4 (–16) –12 (–24) –34 (–37) –62 (–52)

†

11 (42)

18 (–8) 8 (–13) –6 (–21) –23 (–31) –47 (–44) –62 (–52)

†

12 (45)

19 (–7) 10 (–12) 0 (–18) –15 (–26) –34 (–37) –57 (–49)

13 (49)

21 (–6) 13 (–11) 3 (–16) –9 (–23) –25 (–31) –45 (–43) –62 (–52)

†

14 (53)

15 (–9) 6 (–14) –5 (–19) –18 (–28) –34 (–37) –54 (–48)

15 (57)

16 (61)

16 (–9)

17 (–8)

8 (–13)

10 (–12)

0 (–18)

2 (–17)

–12 (–24)

–8 (–22)

–26 (–32)

–19 (–28)

–43 (–42)

–34 (–37)

–62

(–52)

†

–52

(–47)

–62

(–52)

†

11

(42)

12

(45)

17 (64)

18 (68)

18 (–8)

19 (–7)

12 (–11)

14 (–10)

5 (–15)

7 (–14)

–4 (–20)

0 (–18)

–14 (–26)

–10 (–23)

–27 (–33)

–21 (–29)

–42

(–41)

–34

(–37)

–58

(–50)

–50

(–46)

–62

(–52)

†

19 (72)

20 (76)

20 (–7) 15 (–9)

16 (–9)

9 (–13)

10 (–12)

2 (–17)

4 (–16)

–7 (–22)

–3 (–19)

–16 (–27)

–12 (–24)

–28

(–33)

–22

(–30)

–42

(–41)

–34

(–37)

–56

(–49)

–48

(–44)

–62

(–52)

†

*

For cooling system capacities not shown, the required amount of antifreeze can be calculated, using the following: Ethylene-glycol-base antifreeze in a 25% solution protects to 10°F (12°C), 33% to 0°F (–18°C), 40% to –12°F (–24°C), 50% to –34°F (–37°C), and 60% to –62°F (–52°C).

†

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 ethylene-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 (precharged 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 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



20

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 terminals. 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 could cause personal injury. If the vehicle is equipped with an air starter, be sure that the air starter reservoir is drained.

2.

Inspect the electrical connections and wires to the fan clutch solenoid. Secure the connection if loose; replace wires and connectors if damaged.

3.

Clean the fan clutch air solenoid valve filter, if equipped.

3.1

3.2

Unscrew the fan clutch solenoid valve air filter and remove its element.

Clean the filter element with cleaning solvent.

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 components.

5.

Check the fan belt for wear, tension, and alignment. Correct as needed.

6.

Check for wear on the friction facing. See

Fig. 5

.

Replace the friction facing if it is worn to a 1/16inch (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

2

3

4

5

1

08/08/94

1.

System Sentry ® Fuse

2.

Safeguard Hole

3.

Friction Facing

Fig. 5, Horton Advantage Fan Clutch

f200290

4.

Piston Friction Disc

5.

Air Chamber down the engine. Separate the halves of the fan solenoid connector. The fan clutch should engage.

If the fan does not operate correctly, see Group

20 of the Columbia ® Workshop Manual for troubleshooting and repair procedures.

8.

With the air system charged to 120 psi (827 kPa), and with the fan solenoid connector halves separated, check the fan clutch for audible air leaks, using a suitable listening device.

9.

If a leak is detected, remove the fan blade. Using a soapy water solution, check the fan clutch at the following locations to find the source of the leak. Install a new seal kit. See Group 20 of the

Columbia

®

Workshop Manual for repair procedures.

9.1

9.2

9.3

9.4

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.

Check for air leaks between the air chamber and the piston friction disc. Air leakage means the large O-ring (Ref. 14) is damaged.

Check for air leaks around the safeguard hole on the piston friction disc. Air leakage means the small O-ring (Ref. 18) is damaged.

Check for air leaking from the System

Sentry

® fuse. Leaking air means the clutch has gotten so hot the lead alloy in


20/5

20


7

8

6

5

17

18

19

20

21

22

23

1

2

3

4

14

15

11

12

13

16

9

10

24

03/30/95

1.

Mounting Bracket

2.

Rear Sheave Bearing

3.

Inner and Outer Bearing

Spacers

4.

Forward Sheave Bearing

5.

Sheave

6.

Friction Facing

7.

Journal Spacer

8.

Socket-Head Capscrew

9.

Rear Hub Bearing

10. Bearing Spacer

11. Splined Hub

12. Forward Hub Bearing

13. Piston Friction Disc

14. Large O-Ring

15. Locknut

16. Cartridge Assembly

17. Face Seal

18. Small O-Ring

19. Air Chamber

20. Socket-Head Capscrew

21. Stud Bolt

22. Lockwasher

23. Hexnut

24. Piston Assembly f200194a

Fig. 6, Horton Advantage Fan Clutch Components

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:

10.1

Connect the halves of the fan solenoid connector.

10.2

Turn off the air conditioner.

10.3

Start the engine and charge the air system to 120 psi (827 kPa). Tests must be performed with the engine temperature below 205°F (96°C) for Caterpillar engines, and below 200°F (93°C) for Cummins and Detroit Diesel engines.

10.4

10.5

10.6

Set the toggle switch to ON; the fan clutch should engage.

Apply the foot brake, and release the parking brakes.

Set the toggle switch to AUTO or OFF; air should exhaust and the fan clutch should disengage. Replace the switch if necessary.

11. If the fan stays engaged at all times on a Detroit

Diesel engine, check the circuit breaker labeled

"engine fan."

20/6



20

Kysor K22RA Fan Clutch

1.


WARNING

If the engine starts during this procedure, the fan could cause personal injury. If the vehicle is equipped with an air starter, be sure that the air starter reservoir is drained.

2.

Measure the distance from the back surface of the fan clutch retaining plate to the forward-most edge of the fan belt pulley. See

Fig. 7

, Ref. A.

3

2

4

5

1

6

A

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

2.

Retaining Plate

3.

Fan Pulley

4.

Air Inlet (from solenoid valve)

5.

Air Cylinder

6.

Fan

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 pressure to the air cylinder—the bearing housing will move backwards, disengaging the clutch. Again, measure the distance from the back surface of 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

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.


WARNING

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 element.

3.2

3.3

3.4

Clean the filter element with cleaning solvent.

Using a clean, lint-free cloth, wipe off any excess solvent.

Reassemble the clutch valve solenoid air filter, then install it on the vehicle.


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 components.

5.

Check the fan belt for wear, tension, and alignment. Correct if necessary.

6.

Check for wear on the friction facing. Replace the friction facing if it is worn to a 3/16-inch (4.8mm) 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).

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 assembly, 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.

9.

If a leak is detected, remove the fan blade. Install a new seal kit. See Group 20 of the

Columbia ® Workshop Manual for repair procedures.

10. Check the fan drive for discoloration or any other signs of slipping or overheating.

NOTE: The fan clutch may slip if the air supply pressure is below 70 psi (483 kPa) or if there is a leak inside the fan clutch. Any leak must be remedied.

11. Check the fan clutch bearings.

11.1

Turn the fan in both directions and feel for worn hub bearings.

11.2

If possible, remove the drive belt and check for worn sheave bearings by turning 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 .

05/30/2002 f200581

Fig. 8, Checking for Air Leaks (Horton DriveMaster)

20/8


Clutch

25



Clutch Release Cross-Shaft Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–02

Eaton Fuller Clutch Release Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01

Meritor Clutch Release Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–04

Sleeve Assembly Bronze Bushing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–03

Columbia Maintenance Manual, April 2005

Clutch

25

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 bearing, 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 extends outside of the clutch housing. It is not necessary to remove the clutch inspection plate when the lubrication extension is used.

NOTE: For lubrication of the release bearing,

Eaton Fuller recommends a lithium-base hightemperature 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, lubricate 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 internally, 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.

05/27/93

Fig. 1, Release Bearing Grease Fitting

f250081a

1

2

08/10/2009

1.

Sleeve Bushing Contact Point

2.

Yoke Finger Contact Points

Fig. 2, Grease the Contact Points

f250444

See

Fig. 3

and

Fig. 4

. Wipe any dirt from the grease

fittings, and lubricate with multipurpose chassis grease.

25–03 Sleeve Assembly Bronze

Bushing Lubrication

Vehicles equipped with the sealed clutch release bearing require lubrication of the bronze bushing located between the clutch bearing housing and the transmission input shaft. Use a pressure-type grease


25/1

25

Clutch

1

2

10/19/93

1.

Clutch Release Cross-Shaft

2.

Grease Fitting f250048a

Fig. 3, Cross-Shaft Grease Fitting, Left-Side

1.


2.

Remove the clutch inspection plate.

NOTE: Some clutch release bearings are equipped with a lubrication extension that extends 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 hightemperature grease that meets the NLGI grade three specification.

3.

Wipe any dirt from the grease fitting. See

Fig. 1

.

Using a pressure-type grease gun equipped with recommended grease, lubricate the bearing until excess grease purges from the rear of the release bearing (toward the transmission).

CAUTION

Do not over-lubricate the clutch release bearing.

Over-lubrication could contaminate the clutch internally, 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.

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 bearing with a grease fitting, lubricate the bearing as follows:

25/2


Transmission

26



Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement . . . . . . . . . . . . . . . . . . . . . . . 26–03

Manual Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic

Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02


Transmission

26

26–01 Manual Transmission

Fluid Change, and

Magnetic Plug Cleaning

(Synthetic Lubricant)

CAUTION

Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage. Do not overfill the transmission. 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 additives, 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 transmission fluid reaches operating temperature.

Shift the transmission to neutral (N) and shut down the engine.

2.

Park the vehicle on level ground, apply the parking 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 convenient steel slug to short the two magnetic poles and divert the magnetic field.

Install and tighten each drain plug 50 lbf·ft (68

N·m).

NOTE: The optional transmission fluid filter is a remote-mount, spin-on type, and is located between the transmission and the fluid cooler. The filter bracket is attached to the frame rail or some other near-by location. The filter is mounted in a vertical position, and should be filled with fluid before installation to assure the proper fluid level. For optimum transmission performance, 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 counterclockwise motion to separate the filter from the mounting. Carefully spin the filter off the mount and remove it from the vehicle.

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 transmission lubricants. See

Table 2

for Meritor transmission lubricant capacities and

Table 3

for

Eaton Fuller transmission lubricant capacities.

A

B

05/27/93

A. Full B. Low f260006a

Fig. 1, Checking Transmission Fluid Level


26/1

26

Transmission

Approved Manual Transmission Lubricants

Transmission

Model

Lubricant Type

*

Temp.

Range

SAE

Viscosity

Eaton Fuller Transmissions

†

MobilTrans SHC 50

(RN 2952 E-5)

All 50W

All Eaton

Fuller

Synthetic transmission lubricant approved by

Eaton

All 50W

FreedomLine

Meritor Transmissions

MobilTrans SHC 50

(RN 2952 E-5)

All 50W

All other

Meritor

Synthetic engine oil meeting Meritor spec

0–81, or MIL–L–2104D or –2104E

All 50W

*

Do not mix types or brands of fluid. Multi-weight and extreme-pressure gear fluids are not recommended.

†

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)

M/MO (all)

Meritor M/MO Series

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 established 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 transmission. Tighten the plug as follows:

•

25 to 35 lbf·ft (34 to 48 N·m) for Eaton

Fuller transmissions with 3/4-inch pipe threads.

•

60 to 75 lbf·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

RTLO Series

13.0 (12.3)

14.0 (13.2)

10-Speed Deep Reduction

RTO–14908LL

RTO–16908LL

14.0 (13.2)

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

All Models

14.0 (13.2)

15-Speed RTO Series

14.0 (13.2)

All 18-Speed Series

RTLO Series

18-Speed Autoshift AS2 (all)

14.0 (13.2)

* 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

•

44 lbf·ft (60 N·m) for all ZF Meritor

FreedomLine automated transmissions.

•

35 to 50 lbf·ft (48 to 67 N·m) for all other

Meritor transmissions.

9.

Operate the vehicle to check for correct operation.

26/2


Transmission

26

26–02 Transmission Fluid

Level Inspection

CAUTION

Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage. Do not overfill the transmission. 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 additives, 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.

If 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:

•

25 to 35 lbf·ft (34 to 48 N·m) for transmissions with 3/4-inch pipe threads.

•

60 to 75 lbf·ft (81 to 102 N·m) for transmissions with 1-1/4-inch pipe threads.

•

44 lbf·ft (60 N·m) for all ZF Meritor

FreedomLine automated transmissions.

•

35 to 50 lbf·ft (48 to 67 N·m) for all other

Meritor transmissions.

26–03 Manual Transmission Air

Filter/Regulator Check,

Cleaning, or

Replacement

Eaton Fuller

1.

Apply the parking brakes, and chock the rear tires. Drain the air reservoirs.

WARNING

Drain the air supply; if the air supply is not drained before the air filter/regulator is serviced, serious injury and component damage could result.

2.

Clean the outside of the air filter/regulator with cleaning solvent. See

Fig. 2

.

05/27/93 f260037a

Fig. 2, Air Filter/Regulator Location (Eaton Fuller transmission shown)

3.

Remove the end cap, large O-ring, and filter element from the filter housing. See

Fig. 3

. Remove

the small O-ring from the end cap.

26/3


26

Transmission

2

3

4

5

6

7

1

10/17/2001

1.

Air Regulator

2.

Housing

3.

Large O-Ring

4.

Filter Element

5.

6.

7.

Small O-Ring

End Cap

Plug f260052a

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 keeping air pressure between 58 and 63 psi (400 to

435 kPa), replace the air filter/regulator. It cannot be repaired.

WARNING

Wear safety goggles when using compressed air to clean parts, as permanent harm to eyes could result from flying debris.

4.

Clean the filter element by dipping it in alcohol or other cleaning solvent. Blow compressed air through the element (inside to outside) to loosen surface dirt and to dry the element. If it is not damaged, the sintered metallic filter element will last the life of the vehicle.

Wipe out the filter housing with a clean, dry, lintfree 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 install 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.

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.


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 system for the source of the fluid, and service it as needed.

3.

Install the element in the filter/regulator assembly.

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 lbf·ft (14 to 20 N·m).

5.

Build air pressure in the system, check for leaks, and make any needed repairs.

26/4


Frame and Frame Components

31



Fifth Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–01

Fifth Wheel Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–02

Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–03

Trailer Electrical Connector Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–04



31

31–01 Fifth Wheel Inspection

WARNING

All fifth wheel maintenance, adjustment, and rebuilding must be done only by a qualified mechanic. Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor, which could result in personal injury or property damage.

Parts are under spring compression. Wear safety goggles while servicing the fifth wheel. Failure to do so can result in personal injury, due to parts ejecting with force.

Fontaine

1.

Disconnect the tractor from the trailer. For instructions, see Chapter 10 of the

Driver’s Manual .

Columbia

®

2.

Thoroughly steam clean the fifth wheel.

3.

Look for cracks in the fifth wheel assembly, mounting brackets, and mounting parts.

4.

Check the jaw and stationary jaw for mushrooming, and check that the serrations at the jaw and wedge are in good condition.

5.

Test the safety lock latch for ease of operation.

NOTE: The safety lock latch is located at the front of the fifth wheel on the top plate.

6.

Check for loose nuts or bolts on the fifth wheel and the mounting. See

Fig. 1

. Set a torque

wrench to the maximum torque value for the bolt being checked, and confirm that the torque is to specification. Do not loosen the bolt to check the torque. See

Group 00

for bolt torque specifications.

7.

Check all springs to see if they are securely fastened, and are not deformed.

WARNING

Do not disassemble the fifth wheel to inspect the springs. The springs are under extreme pressure, and could cause serious injury.

8.

Check wedge adjustment.

8.1

Open the kingpin lock, and vertically insert a 2-inch (50-mm) diameter shaft.

8.2

Release the lock by tripping the release latch at the bottom of the throat.

8.3

Adjust the wedge stop at the end of the wedge to approximately 1/4-inch (6-mm) clearance by turning the wedge stop rod located on the right side of the top plate.

9.

Replace 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 moving 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


for lubrication instructions.

Holland

1.

Disconnect the tractor from the trailer. For instructions, see the Columbia

®

Driver’s Manual .

2.


3.

Check for loose nuts or broken bolts on the fifth wheel assembly.

4.

Inspect for cracks or wear on the mounting bolts.

5.

Inspect for improper locking action and for cracks or wear on the jaw locking mechanism.

6.

Check the depth of the grease grooves. If the depth of the grooves is 1/8 inch or less, replace the fifth wheel top plate. See Group 31 of the

Columbia

®

Workshop Manual .

7.

Check the condition of the X-pattern cast into the underside of the fifth wheel top plate. See

Fig. 2

.

The fifth wheel top plate must be removed to check the X-pattern.

7.1

Remove the roll pins from the bushing pins. Remove the bushing pins from the slide mount. Using a hoist, lift the fifth wheel top plate off of the vehicle.

7.2

7.3

Turn the fifth wheel top plate over with the locks open. Check the condition of the X-pattern in the pockets. If the

X-pattern is worn away, replace the fifth wheel top plate.

Install the fifth wheel top plate, bushing pins, and roll pins.


31/1

31


13

10

14

15

11

1

2

12

3

16

14

9

4

17

18

1

1

2

3

4

20

19

21

22

21

23

25

5

6

7

1

6

09/18/95

1.

3/16" x 1" Cotter Pin

2.

Lower Bracket Retainer Pin

3.

Grease Fitting

4.

Lower Bracket Pin

5.

Wedge Stop Rod

6.

Flatwasher

7.

Wedge Stop Rod Spring

8.

Wedge Stop Rod Nut

9.

Side Release Upper Assembly

10. Leaf Spring

8

23

24

11. 1/4–20 x 3/8" Thread-Cutting

Screw

12. Step Jaw and Wedge

13. Jaw Spring

14. 1/4" x 3" Cotter Pin

15. Timer

16. Wedge Spring

17. Pull Handle

18. Bumper Handle Spring

21

26

Fig. 1, Fontaine H5092 Series Fifth Wheel (left-side-release shown)

f310476

19. 1/2–13 x 2" Bumper Pivot Bolt

20. Bumper

21. Flatwasher

22. 5/16" Bumper Pivot Bushing

23. 1/2–13 Locknut

24. 7/16" Handle Pivot Bushing

25. Operating Handle (side-release only)

26. 1/2–13 x 2" Handle Pivot Bolt

8.

Inspect for fatigue or cracked welds.

9.





See



Castloc II and Simplex Series

1.

Disconnect the tractor from the trailer. For instructions, see the

Columbia ® Driver’s Manual

.

2.


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).

4.

When the wheel is locked, the safety latch must swing free and fall freely into position. See

Fig. 3

.

31/2



16

15

18

17

15

7

6

5

4

3

2

1

8

9

10

31

14

14

08/29/95

1.

Locknut, 3/4–16

2.

Washer

3.

Rubber Washer

4.

Lock Adjustment Tag

5.

Yoke Shaft

6.

Yoke Sub-Assembly

11

12

13

13

7.

Torsion Spring

8.

Roll Pin

9.

Secondary Lock, Right-Hand

10. Cam Plate

11. Lock Guard

12. Pin

Fig. 2, Holland Fifth Wheel

5.

The lever bar and operating handle must be in proper alignment. See

Fig. 4

. Compare the lever

bar and operating handle alignment to a new, or a properly operating lever bar and operating handle. Replace any bent or misaligned lever bar or operating rod.

13. Lock Pin

14. Lock Jaw

15. Washer

16. Right-Hand Release Handle

17. Left-Hand Release Handle

18. Secondary Lock, Left-Hand f310472

6.

Check all cotter pins for cracking or damage. Replace any cotter pin that shows any signs of damage.

7.

Level the fifth wheel plate to a horizontal position. Measure the height from a stationary mounting point (see

Fig. 5

, Ref. 3), such as the


31/3

31


A

1

2

3

4

11/28/95

1.

Lubricant Grooves

2.

Safety Latch

Fig. 3, Simplex Series Fifth Wheel

f310353b

3.

Lock Control Handle

4.

Mount

1

2

09/15/95

1.

Operating Handle 2.

Lever Bar f310470

Fig. 4, Lever Bar and Operating Handle Alignment

frame rail to the top of the fifth wheel plate (Ref.

1). Pry up on the fifth wheel plate (Ref. 4) below the pin boss, and measure the vertical movement (Ref. 5). The bracket connection provides a

9/32-inch (7-mm) vertical clearance to provide cushioning and to avoid downward pin-loading while retaining minimum plate lift. If the plate lift

(Ref. A) exceeds 5/16 inch (8 mm) as a result of wear or rubber deterioration, install new, standard or oversized bracket-shoe rubber pads; see

Group 31 of the Columbia

® for replacement instructions.

Workshop Manual

5

1

2

3

4

08/31/95

A. Extended Top Plate Lift Height

1.

Fifth Wheel Top Plate

2.

Fifth Wheel Frame Mount

3.

Frame Rail

4.

Lifting Point

5.

Static Top Plate Height

Fig. 5, Measuring Fifth Wheel Top Plate Lift

f310475

NOTE: Do not measure plate lift immediately after a trailer has been uncoupled from the fifth wheel. The rubber may have taken a temporary set, which will normally recover after being uncoupled 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.





See



31–02 Fifth Wheel Lubrication

To maintain proper fifth wheel operation, always lubricate the fifth wheel after an inspection has been performed.

IMPORTANT: Lubricate the fifth wheel:

•

After power washing, or steam cleaning.

31/4



31

•

If the vehicle operates in harsh conditions such as salt spray from road surfaces, or in extremely dusty environments.

•

After any service that requires removal of lubrication from the fifth wheel head or components.

WARNING

Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor, which could result in personal injury or property damage.

Fontaine

Use a multipurpose extreme pressure (EP) chassis grease to lubricate all moving parts on the fifth wheel. When lubricating the top plate at the grease fittings for the bracket bearing area, tilt the top plate forward and backward to evenly distribute the grease. Using a pry tool, separate the jaw and wedge and lubricate the serrations using a brush to distribute the grease. On slide-mount applications, lubricate the slide rail and tapered wedges for smooth operation.

Once the moving parts of the fifth wheel are lubricated, apply a liberal coating of grease to the top plate and the trailer kingpin plate.

Holland

Lubricate all moving parts with a multipurpose chassis grease. Lubricate the two grease fittings located on either side of the top plate with a multipurpose chassis grease.

Once the fifth wheel’s moving parts are lubricated, apply a heavy coat of grease to the top plate by direct application. On slide-mount applications, lubricate the baseplate rails and the plungers for smooth operation.

Castloc II and Simplex Series

Use a chassis or multipurpose grease to lubricate the two grease fittings located on either side of the fifth wheel top plate. Lubricate the two grease fittings located 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 slidemount applications, lubricate the slider lock pockets and the slider bracket.

31–03 Frame Fastener Torque

Check

Frame brackets and components secured with Huckbolt

® fasteners do not require a torque check, however, they should be inspected for damage. Frame brackets and components secured with conventional bolts and nuts are to be checked at Initial Maintenance (IM). See

Fig. 6

for pre-EPA2007 engine mounts. Check the torque of frame fasteners to offset 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 reading 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.

CAUTION

Make sure frame fasteners are properly tightened.

Continued vehicle operation with loose fasteners could result in bracket or frame damage.

NOTE: Engine supports on vehicles built from

January 2007 do not require checking.

Check the fasteners at the following locations:

•

Axle Stops

•

Deck Plates

•

Engine Trunnion Supports

•

Equalizer Brackets

•

Exhaust Brackets

•

Fifth Wheel Legs

•

Fifth Wheel Mountings

•

Frame Crossmembers and Gussets

•

Front Frame Brackets


31/5

31


9

10

1

2

3

6

7

4

5

5

8

11

2

12

10

13

03/30/95

1.

Capscrew, 3/4– x 4.5

Inch, Grade 8

2.

Washer, 3/4 Inch

3.

Engine Leg

4.

Capscrew, 1/2–13 x

1.5 Inch, Grade 8

5.

Washer, 1/2 Inch

6.

Upper Isolator f220054

7.

Rear Engine Mount

8.

Nut, 5/16–18

9.

Capscrew, 5/8–11 x

2.5 Inch, Grade 8

10. Washer, 5/8 Inch

11. Lower Isolator

12. Nut, 3/4–10

13. Nut, 5/8–11

Fig. 6, Rear Engine Mount Assembly (pre-EPA07 engines)

•

Front Suspension Spring Brackets

•

Fuel Tank Brackets

•

Radius Rods

•

Rear Engine Supports

•

Rear Suspension Spring Brackets

•

Shock Absorbers

•

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 for repair or replacement 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 terminals 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.

31/6


Suspension

32



Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01

Suspension Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02

Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–03


Suspension

32

32–01 Suspension Inspection

Front Suspension Check

WARNING

Do not replace individual leaves of a damaged leaf spring assembly; replace the complete spring assembly. Visible damage (cracks or breaks) to one leaf causes hidden damage to other leaves. Replacement 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 assembly could cause an accident resulting in property damage, serious personal injury, or death.

Inspect the front spring assemblies for cracked, broken, or abnormally bent leaves. If any of these conditions exist, replace the spring assembly. See Group

32 of the tions.

Columbia

®

Workshop Manual for instruc-

Composite Springs

The Commercial Vehicle Safety Alliance (CVSA) defines 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 composite spring assemblies, Section 9, Suspension, Pages 44 to 45.

Inspect the Liteflex spring for cracks that result in an out-of-service condition as follows (see

Fig. 1

):

• a side to side crack extending beyond 3/4 of the length of the spring;

• a top to bottom crack extending beyond 3/4 of the length of the spring;

• intersecting cracks of any length.

The Liteflex composite spring should also be removed from service if splintering has occured to the point where noticeable vehicle ride height loss has occurred.

A

B

C

08/14/2008 f321135

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 ® Workshop Manual for replacement instructions.

32/1


32

Suspension

11/27/95 f320465

Fig. 2, Direct-Acting Shock Absorber (front suspension shown)

Rear Suspension Check

Freightliner Spring Suspension

WARNING

Do not replace individual leaves of a damaged leaf spring assembly; replace the complete spring assembly. Visible damage (cracks or breaks) to one leaf causes hidden damage to other leaves. Replacement of only visibly damaged parts is no assurance that the spring is safe. Failure to replace a damaged spring assembly could cause an accident, resulting in serious personal injury or property damage.

Replace worn, cracked, or damaged spring brackets. Failure to do so could result in bracket breakage, possibly leading to loss of vehicle control 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 damaged parts. See Group 32 of the Columbia ®


NOTICE

Failure to replace the suspension crossmember or gussets if they are cracked, worn, or otherwise damaged could result in damage to the vehicle chassis.

3.

Without detaching the torque arms, attempt to move (by hand) each radius-rod end up, down, in, and out. If there is any movement, replace the torque arm. If a torque arm needs to be replaced, see Group 32 of the shop Manual for instructions.

Columbia ® Work-

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 reasons:

• if there are gaps between the rubber bushing and the pin or outer steel sleeve;

• if either bushing end contacts a torque arm pin mounting bolt;

• if there are cracks in the bushing;

• if part of the rubber bushing extends beyond 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


Suspension

32

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.

A

1

2

1

A

3

3

2

05/27/93

A. Measure the change in gap at this point.

1.

Equalizer Bracket

2.

Equalizer

3.

Pry Bar

Fig. 4, Side View of the Equalizer

f320022a

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 fastener 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 assembly. Visible damage (cracks or breaks) to one leaf causes hidden damage to other leaves. Replacement 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 assembly 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-

4

05/27/93

A. 1/8" (3 mm) Clearance

1.

Frame Fasteners

2.

Frame Rail

3.

Pry Bar

4.

5.

5

Equalizer f320023a

Equalizer Bracket

Fig. 5, Top View of the Equalizer

ditions exist, replace the damaged bracket(s). See

Group 32 of the Columbia ® Workshop Manual for instructions.

WARNING

Replace worn, cracked, or damaged spring brackets. Failure to do so could result in bracket breakage, possibly leading to loss of vehicle control 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

®


IMPORTANT: Before checking the AirLiner suspension 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 following:

•

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 lbf·in (500 N·cm). Any damage to the valve housing will void the warranty.


32/3

32

Suspension

•

Do not attempt to disassemble the Barksdale valve body or the control lever. There are no serviceable parts in the valve, and any disassembly will void the warranty.

NOTICE

When removing or loosening a Barksdale heightcontrol 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 bracket. Because the mounting studs are threaded into the valve body, loosening the nuts without holding the studs can tighten the studs, which can crush the valve body and damage the valve. Conversely, tightening the nuts without holding the studs can back the studs out, causing a separation of the two halves of the valve body, and possibly a leak.

1.

Park the vehicle on a level surface, using a light application of the brakes. Do not apply the parking 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.

A

3.1

3.2

If the vehicle is equipped with an adjustable leveling valve, the length should be

8 inches (200 mm). If the length is incorrect, see Group 32 of the Columbia

®

Workshop Manual for adjustment procedures.

If the vehicle is equipped with a fixed leveling valve, see Group 32 of the

Columbia

®

Workshop Manual for the overtravel lever length for the rear axle installed in your vehicle.

4.

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 (dualdrive) rear axle configurations, measure the distance from the bottom of the forwardmost left axle stop to the top of the axle U-bolt pad. See

Fig. 7

, Ref. A. The correct distance for single

and dual-drive rear axles is between 2-3/8 inches and 2-7/8 inches (60 to 73 mm).

1

A

4

1

2

3

5

05/15/95 f320410

A. Measure the length of the overtravel lever between these two points.

1.

2.

V-Shaped Mark

Adjustment Locknut

3.

Overtravel Lever

4.

Cotter Pin

5.

Linkage Rod

Fig. 6, AirLiner Overtravel Lever and Linkage Rod

Measurement

08/16/96

A. Measure height here.

1.

Left Forwardmost Axle Stop

Fig. 7, AirLiner Axle Stop Measurement

f320453

32/4


Suspension

32

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 inspection.

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 freeplay 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 replacement.

4.

Lift the rear of the vehicle and support the frame on jack stands to unload the suspension components. 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 micrometer, vernier, or dial caliper can be used to determine 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 inspect the cans for cracks, severe corrosion, and distortion. If any of these conditions are present, or the restrictor can is missing, replace the restrictor can.

A

B

1

09/27/95

A. Non-Wear Area

1.

Walking Beam

B. Wear Area

Fig. 8, Walking Beam End Wear Thickness

f320432

WARNING

Replace all cracked or missing restrictor cans.

Failure to do so could lead to loss of vehicle control, which could result in property damage, serious personal injury, or death.

32–02 Suspension Lubrication

Front Suspension

Wipe all dirt away from the grease fittings (if equipped) on the spring-eye bushings. Apply multipurpose chassis grease with a pressurized grease gun until old grease is forced out.

NOTE: Service Schedule IV vehicles equipped with a 12,000 lb (5452 kg) front axle are fitted with maintenance-free rubber bushings, and do not require lubrication.


32/5

32

Suspension

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 bushings by applying multipurpose chassis grease at the grease fitting until old grease is forced out from the cap-and-tube assembly. See

Fig. 9

.

the bushings and pins to allow the proper flow of lubricant around them.

3.

Use a multipurpose chassis grease and lubricate the bronze, ball-indented bushings in the spring eyes at the grease fitting. See

Fig. 10

. Continue

to lubricate until grease exits both ends of the bushing. If the pin will not accept lubricant, remove the pin and clean the lubrication channels where lubricant may have hardened. Remove the safety stands.

4

2

3

1

A

1

05/27/93

A. Lubricate here.

1.

Cap-and-Tube Assembly Bushing

Fig. 9, Equalizer Assembly Lubrication

320020a

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 vehicle with safety stands. This relieves the load on

09/15/95

1.

Bronze Bushing

2.

Lubrication Hole

2

4

1 f320424

3.

Grease Fitting

4.

Lubrication Groove

Fig. 10, Hendrickson RT2 and RTE2 Series Bushing

Lubrication

Neway

No lubrication is required on Neway rear suspensions.

Reyco

No lubrication is required on Reyco rear suspensions.

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


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: lbf·ft (N·m)

5/8–18

Stage 1: Hand Tighten

Stage 2: 60 (81)

Stage 3: 200 (271)

Stage 4: 180 to 230 (245 to 313)

3/4–16

7/8–14

1–14


Stage 2: 60 (81)

Stage 3: 200 (271)

Stage 4: 270 to 330 (367 to 449)


Stage 2: 60 (81)

Stage 3: 200 (271)

Stage 4: 420 to 500 (571 to 680)

Stage 1: Hand tighten

Stage 2: 60 (81)

Stage 3: 200 (271)

Stage 4: 520 to 600 (707 to 816)

* Tighten in a diagonal pattern as shown in

Fig. 11

.

Table 1, Spring Assembly U-Bolt High Nut Torque

Values

4 1

01/05/99

2 3 f320783

Fig. 11, Tightening Pattern for U-Bolt High Nuts


32

32/7

Front Axle

33



All-Axle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04

Basic Inspection, Meritor Unitized Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–07

End-Play Check, Meritor Unitized Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–08

Knuckle Pin Lubrication, Dana Spicer Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–05

Knuckle Pin Lubrication, Meritor Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01

Tie Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–02

Tie Rod Lubrication, Dana Spicer Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–06

Tie Rod Lubrication, Meritor Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–03


Front Axle

33

33–01 Knuckle Pin Lubrication,

Meritor Axles

CAUTION

Use regulated pressure when lubricating the knuckle assemblies, otherwise damage could result 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% 12hydroxy 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 pressure without damage, and is designed to have grease pumped out through it during lubrication.

Even if grease leaks out around the top, or bottomplate gasket, continue pumping until new grease is seen at the bushing seal opposite the grease fitting.

See

Fig. 1

.

1 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 instructions, refer to Group 33 of the Columbia

®

Workshop Manual .

OK

OK

1

A

1

09/06/96

A. Grease Exit

1.

Grease Fitting

Fig. 1, Meritor Knuckle Pin Lubrication

33–02 Tie Rod Inspection

f320032a

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

02/27/2007 f320033a

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.


33/1

33

Front Axle

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.

Using spray paint or a piece of chalk, mark the entire center rib of each front tire.

4.

Place a scribe or pointed instrument against the marked center rib of each tire, and turn the tires.

The scribe must be held firmly in place so that a single straight line is scribed all the way around each front tire.

5.

Place a turn-plate or turntable under both front tires. Remove the safety stands and lower the vehicle. Remove the lock-pins from the gauges; make sure the tires are exactly straight ahead.

NOTE: If turn-plates or turntables are not available, lower the vehicle. Remove the chocks from the rear tires and release the parking brakes. Move the vehicle backward, then forward 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.

A

B

08/29/94

NOTE: B minus A equals toe-in.

Fig. 3, Wheel Toe-In (overhead view)

f330082a

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

.

08/30/94 f330014a

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 . If corrections are needed, refer to Group 33 of the Columbia

®

Workshop Manual for instructions on adjusting the toe-in.

33/2


Front Axle

33

1

A

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 result 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 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12hydroxy 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

11/21/95

A. Grease Exit

1.

Grease Fitting f330129

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

(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.

33–07 Basic Inspection, Meritor

Unitized Wheel Ends

1.

Park the vehicle on a level surface, set the parking 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.

WARNING

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.


33/3

33

Front Axle

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.

If 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 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 parking 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.

WARNING

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.

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.

9.

Without rotating the hub, grasp it at the 3 and 9 o’clock positions, and push it straight in. Note the reading on the dial indicator.

Pull the hub straight out. Note the reading on the dial indicator.

The difference between the two measurements is the end-play.

10. If the end-play is less than 0.003 inch (0.08 mm), go to the step for installing the hub cap.

If the end-play is 0.003 inch (0.08 mm) or greater, go to the next step.

11. Remove the outer locknut and tabbed washer from the axle spindle.

12. Loosen, but don’t remove, the inner locknut.

13. While rotating the hub a minimum of five rotations, tighten the inner locknut 600 lbf·ft (813

N·m).

14. Install the tabbed washer and outer locknut.

Tighten 250 lbf·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 instructions, see Group 33 of the

Workshop Manual .

Columbia ®

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


Front Axle

33

If the hub rotates smoothly and without noise, go to the next step.

18. Bend an opposing tab of the tabbed washer over a flat of the outer locknut.

19. Install the wheel and tire assembly. Hand-tighten the wheel nuts.

20. Raise the vehicle, remove the jackstands, then lower the vehicle.

21. Tighten the wheel nuts 500 lbf·ft (678 N·m).

22. Install the hub cap.

If installing a metal hub cap, go to the next step.

If installing a plastic hub cap, do the following:

22.1

Apply a continuous 1/8-inch (3-mm) bead of RTV silicone sealant to the outside first thread of the hub cap. Apply the sealant around the entire circumference.

IMPORTANT: Use only the following RTV sealants on the hub cap:

•

Meritor part number 2297-Z-7098

•

Three Bond ®

•

Loctite ® Ultra Grey Adhesive Sealant 18581

22.2

Install the hub cap by hand until it is seated.

NOTE: Disregard the torque value embossed on the hub cap.

22.3

Using a torque wrench, tighten the hub cap 75 lbf·ft (102 N·m).

If you cannot tighten the hub cap to the correct torque value, or if it makes a popping sound while being tightened, replace it with a new one.

23. 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 lbf·ft (475 N·m).

NOTE: If you cannot tighten the hub cap to the correct torque value, or if it makes a popping sound while being tightened, replace it with a new one.

24. Remove the chocks from the tires.


33/5

Rear Axle

35



Axle Breather and Axle Lubricant Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02

Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (Synthetic

Columbia Maintenance Manual, July 2005

Rear Axle

35

35–01 Axle Lubricant and Filter

Change, and Magnetic

Strainer Cleaning

(Synthetic Lubricant)

CAUTION

Failure to change the axle lubricant at more frequent intervals, when adverse operating conditions require, could result in axle damage.

For all axles, including tandem-drive axles and twospeed 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 III and IV vehicles is extended 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 equalizer may slip or stick. When this happens, you will hear intervals of shrill noises when the vehicle operates at low speed, or when the vehicle makes sharp turns. Use a "limited-slip friction modifier" to correct this slip/stick condition. Add 1.6 ounces (35 mL) of additive for each pint (0.5 L) of lube capacity.

For all GL-5 oils, add one of the following limited-slip friction modifiers:

•

Lubrizol No. 6178 (Lubrizol Corporation)

•

DSL-178 (Guardsman Products)

•

Equa-Torque No. 2411 (Sta-Lube Corporation)

•

Equa-Torque No. 2414 (Sta-Lube Corporation)

IMPORTANT: These friction modifiers generally deteriorate faster than conventional extremepressure additives, so the lubricant change schedule must be shortened when using these additives. The traction equalizer additive (and recommended drive axle lubricant) must be changed at the Maintenance 2 (M2) interval, instead of the Maintenance 3 (M3) interval recommended in the Maintenance Operation Chart for axles that require only those lubricants recommended 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

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.

35/1


35

Rear Axle

Recommended

Lubricant Type

Meritor Drive Axle Recommended Lubricant

Ambient Temperature

Lubricant SAE

Viscosity Grade

Synthetic Gear Oil

–40°F (–40°C) and Up

*

–40°F (–40°C) and Up *

75W–90

75W–140

*

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.

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

5.3

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.

Each time the oil is changed, replace any magnetic drain plug that does not meet the minimum pickup capacity.

NOTE: Meritor recommends plugs with elements 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 lbf·ft (47 N·m).

6.

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

.

A

B

Meritor Specification

0–76–N

0–76–M

08/17/2009

A. Correct (lube level at bottom of fill hole)

B. Incorrect (lube level below fill hole)

Fig. 2, Axle Lubricant Level Inspection

f350061a

Meritor Drive Axle Lubricant Capacities

Axle Model Capacity:

* pt (L)

Single-Drive, Single Reduction

†

RS–21–160

RS–23–160

39.5 (18.7)

39.5 (18.7)

RS–23–161

RS–23–185

37.2 (17.6)

47.3 (22.4)

RS–25–160 37.2 (17.6)

Tandem-Drive, Single Reduction

RT–40–145, RT–40–145A,

RT–40–145P

RT–44–145, RT–44–145P

Forward

Rear

Forward

30.2 (14.3)

25.8 (12.2)

29.3 (13.9)

Rear

Forward

25.1 (11.9)

39.1 (18.5)

RT–46–160, RT–46–160P

Rear 34.4 (16.3)

* Quantities listed are approximate. Fill axle until lubricant is level with bottom of fill hole with vehicle on level ground.

†

See "Traction Equalizer Additives" in the text.

Table 2, Meritor Drive Axle Lubricant Capacities

35/2


Rear Axle

35

6.2

Install and tighten the fill plug 35 lbf·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 interaxle differential housing.

8.

Remove the chocks, then drive the vehicle, unloaded, 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 lb

(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 require 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 rear axle drain plug.

Drain the oil when it is warm. At this temperature, the oil will run more freely and ensure that the axle is flushed.

4.


4.1


4.2

4.3

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.

After the first oil is changed, inspect the drain plug each time for large quantities of metal particles.

4.4

After cleaning, install the drain plug(s) and tighten to 41 lbf·ft (55 N·m).

5.

Fill the axle with the recommended lubricant.

See

Table 3

for recommended drive axle lubricants and drive axle lubricant capacities.

Freightliner Rear Axle Approved Lubricant Type and

Capacity

Lubricant Type Axle

Oil Capacity:

Quarts (liters)

Hubs

Full

Hubs

Dry

80W/90 Gear Oil

75W/90 Synthetic

Gear Oil

80W/90 Gear Oil

Forward

Tandem

14.3

(13.5)

15.9

(15.0)

75W/90 Synthetic

Gear Oil

Single & Rear

Tandem

10.6

(10.0)

12.2

(11.5)

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 indicator only, and should not be used as a fill or level hole.

5.1

5.2

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

.

Install and tighten the fill plug 41 lbf·ft (55

N·m).

Dana

®

Spicer

®

IMPORTANT: The use of friction modifiers is not approved in Dana drive axles.

1.


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°F (65°C to 93°C). At


35/3

35

Rear Axle

1

2

2

05/27/93

1.

Oil Fill Plug 2.

Oil Drain Plug

Fig. 3, Axle Housing Drain and Fill Plugs

f350018a 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 magnetic 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 cover.

WARNING

Always wear eye protection when using compressed 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

4.3

Wash the strainer in solvent, and blow it dry with compressed air to remove oil and metal particles.

Install and tighten the magnetic strainer

40 to 60 lbf·ft (54 to 81 N·m).

5.


1

05/27/93

1.

Magnetic Strainer 2.

Power Divider f350017a

Fig. 4, Dana Spicer Tandem-Drive Axle Magnetic

Strainer

5.1

5.2


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

5.4

After the first oil is changed, inspect the drain plug each time for large quantities of metal particles.

After cleaning, install the drain plug(s) and tighten to 40 to 60 lbf·ft (54 to 81

N·m).

6.

Fill the axle with the recommended lubricant.

See

Table 4

for recommended drive axle lubricants, and

Table 5

for drive axle lubricant capacities.

35/4


Rear Axle

35

Dana Spicer Drive Axle Recommended Lubricant

Lubricant Type Condition

Lubricant SAE

Viscosity

Grade

Dana Spicer

Roadranger

®

Synthetic Drive Axle

Lubricants, or

Equivalent with

Military Specification

MIL–L–2105D

Over-the-Road

Service

Off-Highway

Equipment, or

Under Extra

Heavy Loads

75W–90

80W–140

Table 4, Dana Spicer Drive Axle Recommended

Lubricant

Dana Spicer Drive Axle Lubricant Capacities

Axle Type Axle Model

Capacity:

*

Pints (liters)

Single-Drive Axle Installation

23080S, 23080D 40 (18.9)

Single

Reduction

23105S, 23105D 48 (22.7)

Single

Reduction

Tandem-Drive Axle Installation

DD404, DD404–P 31 (14.7)

†

DS404, DS404–P

DS461–P

DT402, 402–P

39 (18.5)

†

43 (20.3)

†

34 (16.1)

†

2-Speed (dualrange)

DT451–P

DT461–P

39 (18.5)

†

43 (20.3)

†

Double

Reduction

DP451–P

DP461–P

34 (16.1)

†

43 (20.3)

†

* Quantities listed are approximate. Fill axle until lubricant is level with bottom of fill hole with vehicle on level ground.

†

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

6.2

the standpipe opening. To check fluid level, see

Fig. 2

.

Install and tighten the fill plug 40 to 60 lbf·ft (54 to 81 N·m).

Two-Speed Axles With Shift Unit

Dana Spicer and Meritor

1.

Remove the shift unit housing cover. See

Fig. 5

.

Drain and discard the old lubricant. Discard the housing cover gasket.

1

3

2

08/06/93

1.

Housing Cover Gasket

2.

Oil Fill Plug

3.

Shift Unit Housing Cover

Fig. 5, Two-Speed-Axle Shift Unit

f350021a

2.

Thoroughly wash the axle shift parts and housing cover, and allow them to air dry.

3.

Install the housing cover and a new cover gasket. Tighten the housing cover capscrews 90 to

110 lbf·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 engine 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 heavyduty 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).


35/5

35

Rear Axle

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 fluid.

4.

Using the recommended lubricant, fill the shift unit housing through the oil fill hole until the lubricant 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 additional 1-1/2 turns.

35–02 Axle Breather and Axle

Lubricant Level

Inspection

For all axles, including tandem-drive axles and twospeed 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

®

CAUTION

Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage.

1.


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 temperature indicator only, and should not be used as a fill or level hole.

3.

Check that the lubricant is level with the bottom of the fill hole. See

Fig. 2

. If low, check for oil

leaks, and correct as needed.

4.

Install and tighten the fill plug 35 lbf·ft (47 N·m).

IMPORTANT: Always check the axle breather whenever checking lubricant level. Check the breather more frequently under adverse operating 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 replace it as needed.

1

2

3

06/07/94

1.

Axle Housing

Breathers

Fig. 6, Meritor Axle Housing Breathers

f350062a

2.

Carrier Oil Fill Plugs

3.

Interaxle Differential

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 recommended 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


Rear Axle

35

Freightliner

CAUTION


1.


IMPORTANT: After 300,000 miles (500 000 km), oil level must be checked at each M1 interval on

Freightliner axles.

2.

Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier. Remove the plug. Check lubricant level when the axle is cold, or near room temperature.

NOTE: Some Freightliner axles have a small tapped and plugged hole near and below the housing oil fill hole. This smaller hole is for a lubricant temperature indicator only, and should not be used as a fill or level hole.

3.

Check that the lubricant is level with the bottom of the fill hole. See

Fig. 2

. If low, check for oil

leaks, and correct as needed.

4.

Install and tighten the fill plug 41 lbf·ft (55 N·m).

IMPORTANT: Always check the axle breather whenever checking lubricant level. Check the breather more frequently under adverse operating 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 recommended 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.

Dana

®

Spicer

®

CAUTION


1.


2.

If the 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).

3

2

1

06/07/94

1.

Axle Housing Breather

2.

Fill Plug

3.

Temperature Indicator Plug f350002a

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 lbf·ft (54 to 81 N·m).

IMPORTANT: Always check the axle breather whenever checking lubricant level. Check the


35/7

35

Rear Axle breather more frequently under adverse operating conditions.

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

CAUTION

Failure to keep lubricant at the specified level could cause damage to the axle shift unit.

1.

Clean the shift unit oil fill plug, and the area surrounding 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 0°F (–18°C), use SAE 10 heavy-duty engine 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 heavyduty 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 unit housing. Using a wrench, tighten it an additional 1-1/2 turns.

35/8


Wheels and Tires

40



Wheel Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–01


Wheels and Tires

40

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 sequence.

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 .

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 sequence shown in

Fig. 1

.

1

2

10

1

8

7

4

3 6

5

6

5 4

3

A

8

09/18/2001

A. 8-Stud Disc Wheel

7 9

2

B

f400164

B. 10-Stud Disc Wheel

Fig. 1, Wheel Nut Tightening Sequence

Disc Wheel Fastener Torques

Description Nut Size Wheel Manufacturer

10-Hole and 8-Hole Hub-Piloted Disc Wheel With Two-Piece Flange Nuts

*


Front and Rear Wheel Nut

Nuts on Double-Threaded Wheel Studs

M22 x 1.5

M22 x 1.5

All

All

Double-Threaded Wheel Stud Retainer Nut 3/4–16 All

10-Hole Stud-Piloted Disc Wheel With Inner and Outer Nuts

†

Front Wheel Nut 1-1/8–16 All

450–500 (610–678)

390–450 (529–610)

175–200 (235–270)

450–500 (610–678)

Rear Wheel Inner Nut

Rear Wheel Outer Nut

3/4–16

1-1/8–16

All

All

450–500 (610–678)

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.

†

Torque values for stud-piloted wheels are given for clean, dry threads.

Table 1, Disc Wheel Fastener Torques

40/1


Driveline

41



Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01

Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02

Columbia Maintenance Manual, March 2000

Driveline

41

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 connection, which could eventually result in serious vehicle damage. Do not over-tighten bearing-cap capscrews or yoke-strap capscrews.

2.

For driveline universal joints with bearing caps, tighten bearing-cap capscrews 43 lbf·ft (49 N·m).

See

Fig. 1

, Ref. 1.

For RPL series universal joints, tighten bearingcap capscrews 125 lbf·ft (169 N·m). See

Fig. 2

.

For driveline universal joints with yoke straps, tighten yoke-strap capscrews 125 lbf·ft (169

N·m). See

Fig. 3

.

ME

R I TOR

1

2

04/13/98

1.

Self-Locking

Capscrew

1 1

2.

Adhesive Band f410155a

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.

12/09/97 f410182

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 leakage 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 endyoke 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 bearings can be felt or seen, replace the U-joint assembly.

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 specifications. 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


41/1

41

Driveline

14

15

13

16

3

7

8

9

12

11

1

2

6

10

5

4

3

05/01/95

NOTE: Not all fasteners are shown.

1.

Transmission

2.

Transmission Output-Shaft

End-Yoke (yoke-strap type)

3.

U-Joint Assembly

4.

Bearing Cap Self-Locking

Capscrew

5.

Bearing Cap

6.

U-Joint Cross

7.

Bearing Cup (for yoke strap)

8.

Yoke Strap and Capscrew

9.

Slip-Joint Assembly

10. Sleeve-Yoke (bearing-cap type)

11. Dust Cap f410067b

12. Splined Stub Shaft

13. Driveshaft Tube

14. Tube-Yoke (bearing-cap type)

15. Axle Input-Shaft End-Yoke

(yoke-strap type)

16. Rear Axle

Fig. 3, Components of a Basic Driveline

greater than 0.007 inch (0.18 mm), replace both the sleeve-yoke and the splined shaft.

7.

Visually examine the driveshaft tubes for dents, bends, twists, or other damage. If any tube appears to be damaged, refer to Group 41 of the

Columbia

®

Workshop Manual for repair and replacement instructions.

8.

Examine the driveshaft for evidence of missing balance weights, and for build-up of foreign material. 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 assistance in determining the correct driveshaft length.

41/2


Driveline

41

5

1

3

2

3

7

4

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 Series drivelines do not require periodic lubrication.

1.

Park the vehicle on a flat surface, apply the parking 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 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 lbf·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.

If grease does not appear at one seal, use a prying tool to pry the U-joint trunnion away from the non-purging seal, or tap the driveshaft or yoke

6

8

3

1

A

10/20/93 f410050a

A. After grease appears, cover the pressure-relief hole while continuing to lubricate.

1.

Slip Joint Grease Fitting (with grease gun attached)

2.

Yoke Plug

3.

Grease

4.

Half-Round Yoke

5.

Yoke Plug Pressure-Relief Hole

6.

Slip Joint Seal

7.

Full-Round Yoke

8.

U-Joint Grease Fitting

Fig. 5, Slip Joint and U-Joint Lubrication

with a plastic or rawhide mallet on the side opposite the dry seal, while continuing to lubricate. If grease still does not appear, loosen the capscrews at the bearing with the dry seal, to relieve seal tension. Lubricate the U-joint until new grease is seen at the seal, then tighten the capscrews 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.

7.

Wipe the purged grease from the seals, and any excess grease from the grease fitting.


41/3

41

Slip Joint Spline Lubrication

NOTE: Vehicles equipped with Meritor RPL Series 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.

2.

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.

3.

Wipe the purged grease from the pressure-relief hole and slip joint seal, and any excess grease from the grease fitting.

Driveline

41/4


Brakes

42



Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01

Air Dryer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03

Alcohol Evaporator Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–04

Bendix AD–9 Air Dryer Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02

Bendix AD–IS Air Dryer Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–09

Bendix E-6 Foot Control Valve Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–10

Dana Spicer Camshaft Bracket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–05

Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–06

Meritor Camshaft Bracket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–07

Meritor Slack Adjuster Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–08


Brakes

42

42–01 Air Brake System Valve

Inspection

NOTE: There is no scheduled air valve maintenance 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 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).

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 capscrew, 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-tohousing O-ring.

9.

Clamp the desiccant cartridge in a vise.

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 desiccant cartridge.

NOTE: A substantial torque, up to 50 lbf·ft (68

N·m), may be necessary to remove the desiccant 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.

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 lbf·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 pattern 270 to 385 lbf·in (3060 to 4340 N·cm). See

Fig. 2

.

17. Install the air dryer on the lower mounting bracket. Install the two previously marked capscrews, four washers, and two new Nylok nuts.

Torque the two remaining capscrews 270 to 385


42/1

42

Brakes

1

2

11

5

3

4

6

7

8

10

9

10

12

8

13

10

14

15

18

17

10

10

10

10

23

22

21

20

19

25

8

24

16

08/09/95

1.

5/16 x 4-1/2-Inch Upper

Mounting Bracket Capscrew

2.

Upper Mounting Bracket Strap

3.

5/16-Inch Lockwasher

4.

5/16-Inch Nylok ® Nut

5.

Upper Mounting Bracket

6.

Housing

7.

Nylok Nut

8.

3/8-Inch Special Washer

9.

Desiccant Cartridge

10. O-Ring

11. Safety Valve

12. Lower Mounting Bracket

13. 3/8-Inch Capscrew (long)

14. Check Valve Assembly

15. Purge Valve Assembly

16. Purge Valve Bolt

17. Exhaust Diaphragm

Fig. 1, AD-9 Air Dryer (exploded view)

18. Purge Valve

19. 1/4-Inch Tapping Screw

20. Purge Valve Housing

21. Heater and Thermostat

Housing

22. Return Spring

23. Purge Piston

24. 3/8-Inch Capscrew

25. End Cover lbf·in (3060 to 4340 N·cm). Install the capscrew, two washers, and a new Nylok nut in the upper mounting bracket strap. Torque the upper mounting bracket strap capscrew 80 to 120 lbf·in (904 to 1356 N·cm).

18. Connect and tighten the three air lines. Connect the harness connector to the heater and thermostat assembly until the lock tab snaps in place.

19. Start the engine, build the air pressure, and check the air brake system for leaks. If any air leaks are present, see Group 42 of the f421383

Columbia ® Workshop Manual for diagnosis and repair information.


42/2


Brakes

42

4

1 & 9

6

2

5

3

7

8

09/20/94 f420544a

Fig. 2, End Cover to Housing Torque Pattern

42–03 Air Dryer Inspection

1.


2.

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 indicates excessive moisture is present in the air system and the desiccant cartridge needs to be replaced. See Group 42 of the Columbia

®

Workshop Manual for troubleshooting procedures. The following conditions could cause small amounts of moisture to be found in the air system:

•

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 unload in a normal fashion. Check for air system leaks.

•

The air dryer has been installed on a system 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.

•

The temperature range in your area fluctuates 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 considered an indication of poor air dryer performance.

3.

Inspect the air dryer for external damage, and check that the unit is tightly mounted on the frame. If the air dryer mounting is loose, See

Group 42 of the

Columbia for mounting instructions.

® Workshop Manual

4.

Turn on the ignition switch, but do not start the engine.

5.

Disconnect the harness connector from the air dryer.

6.

Connect a voltmeter to circuit 94 on the air dryer’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.

7.

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.

8.

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 resistance will be infinite ohms. If the measured resistance is less than infinity, replace the heater/thermostat.

9.

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 resistance 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) measured resistance should be infinite ohms. If the heater/thermostat does not operate as outlined, replace it. If it does operate as outlined, install it, then remove the chocks from the tires.


42/3

42

Brakes

1

2

06/04/96

1.

End Cover Assembly

2.

Heater/Thermostat Terminals f421384

Fig. 3, End Cover Terminals Location

42–04 Alcohol Evaporator

Cleaning and Inspection

Midland

Maintenance is required during both the freeze season and the off season to keep the alcohol evaporator 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. Before reactivating the evaporator for the next freeze season, drain, disassemble, inspect, and steamclean the unit of any sludge that may have accumulated. It is advisable to replace any rubber parts when assembling the alcohol evaporator. Perform this service just before the freeze season.

Freeze Season Reactivation

1.


2.

Remove the filler cap, and check the cap tetraseal.

3.

Remove the capscrews and reservoir from the cover.

4.

Remove the cover tetraseal.

5.

Drain the air tank, and disconnect the line from the evaporator outlet. Remove the check-valve retainer, spring, and disc.

6.

Install the disc, spring, and check-valve retainer, and connect the line to the evaporator outlet.

7.

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.


42–05 Dana Spicer Camshaft

Bracket Lubrication

IMPORTANT: Perform

MOP 42–11

before lubricating the camshaft bracket.

Pump grease into the camshaft bracket until it appears at the slack adjuster end of the bracket. See

Fig. 4

.

Use an NLGI Grade 1 or Grade 2 multipurpose chassis grease. If grease leaks out under the camhead, the camshaft bracket grease seal is worn or damaged; 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 lubricating the slack adjusters.

42/4


Brakes

42

1

1

3

2

A

05/28/93

A. Grease Exit

1.

2.

Brake Chamber

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.

WARNING

Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure, resulting in property damage, personal injury, or death.

Dana Spicer and Haldex

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 synthetic 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.

2

02/01/2001

1.

Grease Fitting 2.

Slack Adjuster f421649a

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 lubricating the camshaft bracket.

NOTE: If equipped with an extendedmaintenance Q Plus

™ brake system, the camshaft bracket will not have a grease fitting.

These camshafts use a special NLGI grade synthetic polyurea grease and do not require lubrication for 3 years or 500,000 miles (800 000 km), whichever comes first. The extendedmaintenance camshaft bushings are lubricated


42/5

42

Brakes

2

1

3

4

8

7

6

10

5

9

10/27/93

1.

7/16-Inch Adjusting

Nut

2.

Grease Fitting

3.

Boot

4.

Link

5.

Brake Chamber Piston

Rod

Fig. 6, Gunite Automatic Slack Adjuster

f420653a

6.

Clevis

7.

1/2-Inch Clevis Pin

8.

1/4-Inch Clevis Pin

9.

Grease Relief

Opening

10. Slack Adjuster Spline during the brake reline service interval. For service 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

WARNING

If grease leaks out under the camhead, the camshaft 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 lubricating the slack adjusters.

NOTE: If equipped with an extendedmaintenance Q Plus

™ brake system, the slack adjuster will not have a grease fitting. These slack adjusters use a special NLGI grade synthetic polyurea grease and do not require lubrication for 3 years or 500,000 miles (800 000 km), whichever comes first. The extendedmaintenance slack adjusters are lubricated during 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 operating 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 operating 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.


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


Brakes

42

1

2

3

4

5

7

10/20/93

6 f420012a

1.

Brake Chamber

2.

Clevis

3.

Actuator Rod

4.

Boot

5.

Pressure-Relief Capscrew, Gasket, Pawl Spring, and Pawl

6.

Manual Adjusting Nut

7.

Grease Fitting (or plug)

Fig. 7, Meritor Automatic Slack Adjuster

IMPORTANT: Only use the silicone grease supplied 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.


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 ®


2.

Remove the roll pin from the brake pedal pivot pin. See

Fig. 9

.

2

5

6

1

3

4

7

8

1

2

3

04/16/98

1.

Desiccant Cartridge

2.

Cartridge Sealing Ring

3.

Threaded Base Post

Fig. 8, Desiccant Cartridge Replacement

f421910

4.

On the new desiccant cartridge, lubricate the sealing rings with silicone grease.

09/10/2004

1.

2.

3.

4.

E-6 Foot Control Valve

Mounting Plate

Nut and Washer

Pivot Pin

5.

Roll Pin

6.

Roller

7.

Roller Pin

8.

Pedal

Fig. 9, Brake Pedal and Valve Assembly

f430405

3.

Remove the brake pedal pivot pin.

4.

Remove the brake pedal.

5.

Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses (the


42/7

42

area from which the pivot pin was removed). Replace 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 alcohol, 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.

Brakes

42/8


Steering

46



Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01

Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05

Power Steering Fluid Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03

Power Steering Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02

Power Steering Gear Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04

Rack and Pinion Steering Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–06


Steering

46

46–01 Drag Link 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 personal injury and property damage.

Have someone turn the steering wheel from left to right. Check for movement between the ball stud end at both the pitman arm and the steering arm. Also check if the ball stud nut is loose.

If the ball stud end is loose, replace the drag link. If the ball stud nut is loose, replace the nut and cotter key. See

Group 00

for proper torque specifications.

Inspect the boot of the drag link at both the pitman arm and the steering arm end for cracks, splits, or other damage. Replace the boot as needed. See

Group 46 of the Columbia ® Workshop Manual for drag link removal and installation instructions.

Grasp the drag link near the pitman arm end, then push and pull laterally to check for axial movement in the ball stud 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 (3mm) movement or more, do not drive the vehicle until the drag link is replaced.

46–02 Power Steering Fluid and Filter Changing

WARNING

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 accident resulting in personal injury or property damage. 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 reservoir, and remove the steering gear-to-reservoir return hose at the reservoir. Drain the power steering fluid into the drain pan and dispose of the fluid properly. Plug the return line fitting on the reservoir.

3.

Loosen the clamp and remove the cover along with the filter spring and the filter top plate.

NOTE: Always replace the power steering reservoir 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.

5.

Place the disconnected end of the steering gearto-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.

6.

With the larger opening at the top, install a new filter in the reservoir.

7.

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.

8.

Install the reservoir cover along with the spring and the top plate. Make sure the center of the top plate fits into the opening at the top of the filter.

9.

Place the clamp over the flanges of the cover and shell assembly, then tighten 25 to 30 lbf·ft

(35 to 40 N·m).

10. Fill the power steering reservoir with approved power steering fluid to the FULL COLD mark.

See

Table 1

.

11. 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


46/1

46

Steering 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

Fluid

Dexron ® II

Dexron ® III

Heavy-Duty Engine Oil

IMPORTANT: Do not use heavy-duty engine oil on vehicles built from

November 4, 2002.

Shell Rotella T

Shell Rotella T

Chevron

Chevron Custom

Mobil Super

Texaco

Union

Union

Unocal Guardol

30W

SAE 30

10W-40

10W-40

10W-40

10W-40

10W-40

15W-40

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

1.

Apply the parking brakes and chock the tires.

2.

With the engine cool, use a shop towel or a clean rag to clean the area around the power steering reservoir fill cap. Twist the cap counterclockwise 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 recommended 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.

46–04 Power Steering Gear

Lubrication

Sheppard

Sheppard power steering gears manufactured without grease fittings are maintenance-free. If the power steering gear has no grease fitting, then it requires no periodic lubrication.

Sheppard power steering gears with grease fittings must be lubricated periodically.

1.

Wipe off debris from the bearing cap grease fitting. See

Fig. 1

.

1

05/28/93 f460296a

1.

Bearing Cap Grease Fitting

Fig. 1, Sheppard Bearing Cap Lubrication

2.

Using a hand-type grease gun, apply multipurpose 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 handtype grease gun. See

Fig. 2 . Use of a high-

pressure power grease gun will supply grease too quickly and could affect the high pressure seal, contaminating the hydraulic fluid.

Using a hand-type grease gun, apply NLGI Grade 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal.

46/2


Steering

46

1

11/28/95

1.

Sector Shaft Grease Fitting f461071

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 (8% 12-hydroxy lithium stearate grease) or NLGI Grade 1 (6% 12-hydroxy lithium stearate grease). Grade 2 is preferred.

11/27/95

1

1.

Grease Fitting at Pitman Arm

2.

Grease Fitting at Axle Steering Arm

Fig. 3, Drag Link

2 f461072

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 personal injury and property damage.

The rack and pinion steering system is designed to be maintenance-free. Inspect the system as described below, and repair or replace any components that are worn or damaged.

Figure 4

shows the components of the rack and pinion steering system.

1.

Park the vehicle on a level surface, and chock the rear tires.

2.

Check the steering I-Shaft U-joints for evidence of looseness or binding. If any is found, replace the I-Shaft.

3.

Check the steering I-Shaft slip joint for evidence of lateral movement, looseness, or binding. If any is found, replace the I-Shaft.

4.

Jack up one axle end at a time, and move the tire in and out by hand to check the tie rod ends for free play. No free play is allowed. If the outer tie rod ends are damaged or worn, replace them.

For repair procedures, see Group 46 of the

Columbia Workshop Manual .

5.

Check the rack and pinion 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 pinion 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 evidence of leakage from the bellows. If hydraulic


46/3

46

Steering

16

11

6

7

8

9

10

12

13

14

15

17

2

5

4

3

19

9

8

20

21

22

23

18

5

1

3

4

07/24/2009

1.

Steering Tie Rod Arm

2.

Power Steering Fluid Lines

3.

Large Bellows Clamp

4.

Bellows

5.

Small Bellows Clamp

6.

Driver-Side Outer Tie Rod

7.

Tie Rod Jam Nut

8.

Inner Tie Rod Flat

9.

Inner Tie Rod Ball Joint

10. Input Shaft Seal Cover

11. I-Shaft Upper Yoke

12. I-Shaft Lower Yoke Boot Clamp

13. I-Shaft Lower Yoke Boot

14. I-Shaft Lower End Yoke

15. Transfer Line Tube Fittings

16. Power Steering Fluid Line

Fittings f462151

17. I-Shaft Slip Joint

18. Transfer Lines

19. Rack and Pinion Gear

20. Pinch Bolt

21. Tie Rod Clamp

22. Tie Rod Clamp Nut

23. Passenger-Side Outer Tie Rod

Fig. 4, Rack and Pinion Steering System

fluid is found to be leaking from within the bellows, replace the rack and pinion unit.

9.

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 oncenter 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 hoses. Repair or replace lines, hoses, and fittings as necessary.

10. 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


Fuel

47



Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01

Fuel Separator Sight Bowl Cleaning and Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02

Fuel Tank Band-Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–03


Fuel

47

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

.

WARNING

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, possibly resulting in personal injury or property damage. 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 reinstall it on the sight bowl. If the gasket appears dry-rotted or damaged, replace the gasket.

5.

Lightly lubricate the threads on the sight bowl with oil, then thread the sight bowl into the bottom 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 fitting when the unit is full of fuel.

1

6

2

8

7

4

5

3

3

9

10

08/25/95

1.

Vacuum Breaker/Drain

Valve

2.

Reducer Bushing

3.

Mounting Brackets

4.

O-Ring (when equipped with heater)

5.

Stainless Steel

V-Clamp (when equipped with heater)

Fig. 1, ConMet Fuel Separator

f470146

6.

Heater Assembly

7.

Gasket

8.

Sight Bowl Heater

Rod

9.

Sight Bowl Assembly

10. Vacuum Breaker/Drain

Valve

IMPORTANT: The fitting must be air-tight and the valve closed.


47/1

47

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 retention nuts 30 to 35 lbf·ft (41 to 46 N·m). After the retention nuts have been tightened, hold each retention nut with a wrench while tightening its jam nut 30 lbf·ft

(41 N·m).

IMPORTANT: Do not overtighten.

Fuel

47/2


Exhaust

49



Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01


Exhaust

49

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 increased. Replace parts that show leakage, wear, or damage, with genuine Freightliner parts.

Pre-EPA07 Exhaust System

Inspecting

1.

On all vehicles, check the condition of the muffler body and the top stack. Check the inlet/outlet 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 replacement 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

.

4.

If leakage exists, tighten the nut on the V-band coupling 85 lbf·in (940 N·cm). If leakage persists, install a new V-band coupling.

5.

Inspect the turbo outlet pipe, and replace it as needed.

6.

Check the U-bolt clamps for tightness, and tighten as needed.

7.

Check the isolator at the base of the exhaust stack elbow(s) (see

Fig. 2

), for cracking, dam-

age, and dry rot. Replace as needed.

1

2

3

4

06/01/93

1.

Flex Hose

2.

V-Band Coupling

3.

Exhaust Pipe

Fig. 1, V-Band Coupling and Flex Hose

f490024a

4.

Turbocharger Exhaust

Outlet

1

2

3

08/25/95

1.

Exhaust Pipe

2.

Exhaust Elbow Isolator

3.

Mounting Nut

Fig. 2, Exhaust Elbow Isolator

f490127

8.

Check for leakage at all wide-band exhaust clamps. See

Fig. 3

.

If leakage exists, tighten the nuts 40 to 60 lbf·ft

(54 to 81 N·m). If leakage persists, inspect the sealclamps. If necessary, install a new wide-band exhaust clamp.

EPA07 Exhaust System

Inspecting

IMPORTANT: The Environmental Protection

Agency’s 2007 regulations require lower exhaust 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


49/1

49

Exhaust maintenance inspections. If any discrepancies are discovered, refer to the engine manufacturer’s service literature for repair instructions.

05/28/93 f490025a

Fig. 3, Donaldson Sealclamp Wide-Band Exhaust

Clamp

1

2

3

4

2

5

Definitions of ATS Components

Refer to the following list of definitions of ATS components.

•

After-Treatment System (ATS)—the entire exhaust system from the turbocharger to the exhaust stack or tail pipe.

•

After-Treatment Device (ATD)—a muffler-like canister that houses a DPF, DOC, and sensors.

•

Diesel Particulate Filter (DPF)—a filter that collects and holds particulate matter (soot and ash).

•

Diesel Oxidation Catalyst (DOC)—oxidizes hydrocarbons and reduces NOx.

•

Sensors—detect temperatures and pressures in the ATS.

Inspection

1.

Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet.

If leakage exists, tighten the nut on the clamp to

6

5

7

8

9

3

10/20/2006

A. Inspect this area of the canister for dents.

1.

Marmon Fitting at Inlet from Turbocharger

2.

DOC Temperature Sensor

3.

ATD Mounting Band

4.

DPF Intake Pressure Sensor

5.

DPF V-Band Mounting Clamps

6.

7.

8.

9.

A

Sensor Housing

DPF Outlet Temperature Sensor

Exhaust Outlet Marmon Fitting

DPF Outlet Pressure Sensor

Fig. 4, Typical After-Treatment Device

49/2

f490283


Exhaust the required torque. If leakage persists, install a new clamp.

2.

Check the exhaust pipe, bellows, and each exhaust seal clamp for leakage, wear, cracks, or damage. Replace damaged components as needed. If leakage exists at a clamp, tighten the nuts to the required torque. If leakage persists, install a new exhaust seal clamp. Do not reuse seal clamps. Once a seal clamp is loosened or removed, it must be replaced.

3.

If present, check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD.

4.

Check the ATD mounting bands for tightness.

Tighten to 30 lbf·ft (41 N·m) if needed. Do not overtighten.

5.

Check for leaks around the clamps that attach the ATD in the ATS, and around the clamps that retain the DPF in the ATD. No leaks are allowed anywhere in the system.

6.

Check all sensors attached to the ATD for leaks or damaged wires. No leaks are allowed.

7.

Check the DPF exterior surface for dents or other damage. See Item A of

Fig. 4

. A dent over

3 inches (76 mm) in diameter and 1/4-inch (6mm) deep could cause internal damage to the

DPF, causing it to malfunction.

8.

Check for heat discoloration on the surface of the ATD. Heat discoloration may indicate internal damage; especially around the DPF.

9.

Check any wires, lines, or hoses within 4 inches

(10 cm) of the exhaust system for heat damage.

Repair or reroute as needed.


49

49/3

Doors

72



Door Seal, Door Latch, Door Hinge, and Door Check Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72–01


Doors

72

72–01 Door Seal, Door Latch,

Door Hinge, and Door

Check Lubrication

Door Seals

Lightly coat the door seals with a lubricant that is safe for rubber.

Door Latches

Approved NLGI grade 2 greases or products for lubricating door latches are:

•

Mobilgrease Moly 52

•

Chemtool Alpha 2000

•

Unirex Moly H

•

Conoco Moly Poly

•

Conoco Tachna 2000

Apply liberal amounts of an approved NLGI grade 2 grease to each moving joint of all door latch assemblies. Use an appropriate applicator that will not leave material behind. Chemtool Alpha 2000 is the preferred product for this application because it has superior properties and it is white, unlike the molyimpregnated greases.

In general, light penetrating oils, such as WD–40, should not be used because they wash out beneficial factory-installed grease, and they evaporate.

Door Hinges

The door hinges on 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 lubricated, first identify the hinge by checking the top loop of the hinge bracket. See

Fig. 1

.

Door Hinges on Vehicles Built on or After 8/1/2005

On vehicles built on or after 8/1/2005, the door hinge center pin is recessed in the top loop of the hinge bracket. There is a dimple in the top and bottom loop of the hinge bracket. See Ref. A of

Fig. 1

.

Do not lubricate this type of hinge. Lubrication could adversely affect the performance of the bushings. In addition, some lubricants may not be compatible with the hinge bushings.

Door Hinges on Vehicles Built

Before 8/1/2005

On vehicles built before 8/1/2005, the door hinge center pin is flush with the top of the top loop of the hinge bracket. There is no dimple in the top or bottom loop of the hinge bracket. See Ref. B of

Fig. 1

.

Lubricate this type of hinge with approved NLGI grade 2 greases or products, such as:

•

Mobilgrease Moly 52

•

Chemtool Alpha 2000

•

Unirex Moly H

•

Conoco Moly Poly

•

Conoco Tachna 2000

Lubricate external hinges every six months. Using an appropriate applicator, force a moly-impregnated

NLGI grade 2 grease into the hinge components.

Wipe off any excess grease.

In general, light penetrating oils, such as WD–40, should not be used because they wash out beneficial factory-installed grease, and they evaporate.

Door Checks

Lubricate door checks at installation and every six months thereafter, with moly-impregnated NLGI grade 2 grease.


72/1

72

Doors

A

B

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

f720613

72/2


Heater and Air Conditioner

83



Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01

Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–02



83

83–01 Air Conditioner

Inspection

WARNING

Wear eye protection, gloves, and protective clothing 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 surface 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 fasteners. For instructions and torque values, see

Group 01 of the Columbia ® Workshop Manual .

3.

Inspect the drive plate. If the friction surface of the drive plate shows visible signs of damage due to excessive heat, replace the drive plate and pulley assembly. For removal and installation procedures, see Group 83 of the Columbia

®

Workshop Manual .

4.

On a Sanden A/C compressor, use a feeler gauge to check that the drive plate clutch clearance 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 compressor clutch and the pulley to check the compressor 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. Replace the wire if it is damaged.

6.

Check the overall condition of the air conditioning hoses. Look for cracks, cuts, and abrasions on

08/25/94 f830641

Fig. 1, Drive Plate Clearance Inspection

the hoses. Replace damaged hoses. For replacement instructions, see Group 83 of the

Columbia

®

Workshop Manual . Also check for loose fittings on all of the air conditioning components.

7.

Check for a buildup of road debris on the condenser fins. For cleaning instructions, see Group

83 of the Columbia

®

Workshop Manual .

Refrigerant Checking

Check the color of the moisture indicator on the receiver-drier. See

Fig. 2

.

If the indicator is blue, the refrigerant charge is dry.

If the indicator is not blue, the system is contaminated 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.

CAUTION

If equipped with a fresh air filter, it should be replaced every six months. If the fresh air filter is


83/1

83


1

1

2

11/21/95

1.

Moisture Indicator

Fig. 2, Receiver-Drier

f830746

not replaced every six months, damage to the heater and air conditioner components could occur.

IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter.

1.

Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires.

2.

Lift the wire retainer on the air filter cover up and over the upper edge of the cover and pull the wire retainer down. See

Fig. 3

.

3.

Note the direction of the arrow on the air filter cover, then remove the cover and the attached filter.

4.

Remove the air filter from the air filter cover. Discard 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.

02/26/2002

1.

Air Filter Cover 2.

Wire Retainer

Fig. 3, HVAC Air Intake Plenum

f831493

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.


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.

CAUTION

If the recirculation 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.

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



83

3.

Remove the retainer that holds the recirculation air filter in place. See

Fig. 4

.

1

2

1.

Turn off the engine, apply the brakes, and chock the tires.

2.

Access the sleeper HVAC assembly by raising the mattress and bunk panel to the locked position. If there is a baggage compartment, the sleeper HVAC assembly may be accessed through the baggage door on the right side of the vehicle.

3.

Slide the air filter out of the sleeper HVAC assembly. See

Fig. 5

.

1

02/26/2002

1.

Retainer

2.

Recirculation Air Filter

Fig. 4, Cab Recirculation Air Filter

f831491

4.

Remove and discard the recirculation air filter.

5.

Install a new recirculation air filter in the HVAC assembly.

6.

Install the retainer to hold the recirculation air filter in place.

7.

Install the heater and air conditioner cover and 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.

02/26/2002

1.

Air Filter

Fig. 5, Sleeper HVAC Assembly

f831492

4.

Discard the air filter.

5.

Place a new air filter in the sleeper HVAC assembly. The edge of the filter should be flush with the HVAC assembly.

6.

Lower the bunk panel and mattress.

7.



83/3

Maintenance Manual

COLUMBIA MAINTENANCE MANUAL

Models: CL112

CL120

Published by

Daimler Trucks North America LLC

4747 N. Channel Ave.

Portland, OR 97217

Printed in U.S.A.

Foreword

Environmental Concerns and Recommendations

NOTICE: Parts Replacement Considerations

Descriptions of Service Publications

Descriptions of Service Publications

Page Description

Maintenance Manual Contents

Index, Alphabetical

Determining Scheduled Maintenance Intervals: 00–01

Determining Scheduled

Maintenance Intervals

Types of Service

Service Schedule Table: 00–02

Vehicle Maintenance Schedule Tables: 00–03

Vehicle Maintenance Schedule Tables: 00–03

Vehicle Maintenance Schedule Tables: 00–03

Vehicle Maintenance Schedule Tables: 00–03

Vehicle Maintenance Schedule Tables: 00–03

Lubrication and Fluid Level Check: 00–04

Initial Maintenance (IM) Operations: 00–05

M1 Maintenance Interval Operations: 00–06

M2 Maintenance Interval Operations: 00–07

M2 Maintenance Interval Operations: 00–07

M2 Maintenance Interval Operations: 00–07

M3 Maintenance Interval Operations: 00–08

Maintenance Operation Sets Table: 00–09

Maintenance Operation Sets Table: 00–09

Noise Emission Controls Maintenance: 00–10

Noise Emission Control

Maintenance

Federal Law, Part 205:

Transportation Equipment Noise

Emission Controls

Recommendations for

Replacement Parts

Freightliner Noise Emission

Controls Warranty

Tampering with Noise Controls is

Prohibited

Maintenance Instructions

Verification of Inspections Log: 00–11

Verification of Inspections Log

Verification of Inspections Log: 00–11

Metric/U.S. Customary Conversion Tables: 00–12

Torque Specifications Tables: 00–13

Torque Specifications Tables: 00–13

Torque Specifications Tables: 00–13

Index, Alphabetical

01–01 Engine Support

Fasteners Check

01–02 Engine Drive Belt

Inspection

Visual Inspection

Belt Tension Inspection

Threaded-Adjustment Type

Spring-Tension Type

01–03 Pacbrake Inspection and

Lubrication

Index, Alphabetical

09–01 Air Cleaner Element

Inspection and

Replacement

Method 1

Method 2

Index, Alphabetical

13–01 Bendix Air Compressor

Inspection

Index, Alphabetical

15–01 Alternator, Battery, and

Starter Connections

Check