Freightliner Columbia Maintenance Manual
COLUMBIA
®
STI-409-2
A24-01033-000
Maintenance Manual
COLUMBIA MAINTENANCE MANUAL
Models: CL112
CL120
STI-409-2 (9/15)
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.
© 2001–2015 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 Maintenance manuals contain routine maintenance procedures and intervals for
Driver’s/Operator’s
Manual
Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-
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.
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.
ments, 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.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins 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 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 PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
™
EZWiring EZWiring
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.
makes Freightliner, Sterling, Western Star, Thomas Built Buses, and
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 Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles.
I–2 Columbia Maintenance Manual, February 2010
Page Description
For an example of a Columbia Maintenance Manual page, see Fig. 1.
A
B C
Introduction
Cooling
20−01 Coolant Replacement
20
20−02 Cooling Fan Inspection
Columbia Maintenance Manual, December 2001
D
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
Columbia Maintenance Manual, February 2010 I–3
E
f020127
Introduction
Group No. Group Title
00...................... General Information
01................................ Engine
09.............................. AirIntake
13 ......................... AirCompressor
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
60.................................. Cab
72 ................................ Doors
83................. Heater and Air Conditioner
88.............. Hood, Grille, and Cab Fenders
Maintenance Manual Contents
I–4 Columbia Maintenance Manual, February 2010
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
M2 Maintenance Interval Operations ....................................................00–07
M3 Maintenance Interval Operations ....................................................00–08
Maintenance Operation Sets Table .....................................................00–09
Noise Emission Controls Maintenance...................................................00–10
Service Schedule Table ............................................................. 00–02
Vehicle Maintenance Schedule Tables...................................................00–03
Verification of Inspections Log.........................................................00–11
Columbia Maintenance Manual, September 2015
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 suspen-
sion.
• 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.
Columbia Maintenance Manual, September 2015 00/1
Service Schedule Table: 00–02
General Information00
Service Schedule Maintenance Interval Operation
Schedule I
*
(Severe Service)
vehicles that annually travel less
than 6000 miles (10 000 km)
Schedule II
†
(Short-Haul Transport)
vehicles that annually travel less
than 60,000 miles (100 000 km)
Schedule III
†
(Long-Haul Transport)
vehicles that annually travel over
60,000 miles (100 000 km)
Schedule IV
†
(Long-Haul Transport for
Optimized Vehicle Configuration)
vehicles that annually travel over
60,000 miles (100 000 km)
*
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 accumu-
lation, extreme climate, frequent short distance travel, construction-site operation, city operation (garbage truck), or farm operation.
Initial Maintenance (IM) first 1000 1600 50
Maintenance 1 (M1) every 1000 1600 50
Maintenance 2 (M2) every 5000 8000 500
Maintenance 3 (M3) every 15,000 24 000 1500
Initial Maintenance (IM) first 10,000 16 000
Maintenance 1 (M1) every 10,000 16 000
Maintenance 2 (M2) every 50,000 80 000
Maintenance 3 (M3) every 150,000 240 000
Initial Maintenance (IM) first 25,000 40 000
Maintenance 1 (M1) every 25,000 40 000
Maintenance 2 (M2) every 100,000 161 000
Maintenance 3 (M3) every 300,000 483 000
Initial Maintenance (IM) first 25,000 40 000
Maintenance 1 (M1) every 25,000 40 000
Maintenance 2 (M2) every 100,000 161 000
Maintenance 3 (M3) every 300,000 483 000
Frequency Miles km Hours
Maintenance Interval
—
—
—
Table 1, Service Schedule
Columbia Maintenance Manual, September 201500/2
General Information 00
Vehicle Maintenance Schedule Tables: 00–03
1st through 30th Maintenance for Service Schedules I and II
Maint. No.
1st IM and M1 1000 1600 100 10,000 16 000
2nd M1 2000 3200 200 20,000 32 000
3rd M1 3000 4800 300 30,000 48 000
4th M1 4000 6400 400 40,000 64 000
5th M1 and M2 5000 8000 500 50,000 80 000
6th M1 6000 9600 600 60,000 96 000
7th M1 7000 11 200 700 70,000 112 000
8th M1 8000 12 800 800 80,000 128 000
9th M1 9000 14 400 900 90,000 144 000
10th M1 and M2 10,000 16 000 1000 100,000 160 000
11th M1 11,000 17 600 1100 110,000 176 000
12th M1 12,000 19 200 1200 120,000 192 000
13th M1 13,000 20 800 1300 130,000 208 000
14th M1 14,000 22 400 1400 140,000 224 000
15th M1, M2, and M3 15,000 24 000 1500 150,000 240 000
16th M1 16,000 25 600 1600 160,000 256 000
17th M1 17,000 27 200 1700 170,000 272 000
18th M1 18,000 28 800 1800 180,000 288 000
19th M1 19,000 30 400 1900 190,000 304 000
20th M1 and M2 20,000 32 000 2000 200,000 320 000
21st M1 21,000 33 600 2100 210,000 336 000
22nd M1 22,000 35 200 2200 220,000 352 000
23rd M1 23,000 36 800 2300 230,000 368 000
24th M1 24,000 38 400 2400 240,000 384 000
25th M1 and M2 25,000 40 000 2500 250,000 400 000
26th M1 26,000 41 600 2600 260,000 416 000
27th M1 27,000 43 200 2700 270,000 432 000
28th M1 28,000 44 800 2800 280,000 448 000
29th M1 29,000 46 400 2900 290,000 464 000
30th M1, M2, and M3 30,000 48 000 3000 300,000 480 000
Maintenance
Interval
Table 2, 1st through 30th Maintenance for Service Schedules I and II
Service
Date
Miles km Hours Miles km
Service Schedule I Service Schedule II
Columbia Maintenance Manual, September 2015 00/3
General Information00
Vehicle Maintenance Schedule Tables: 00–03
31st through 60th Maintenance for Service Schedules I and II
Maint. No.
31st M1 31,000 49 600 3100 310,000 496 000
32nd M1 32,000 51 200 3200 320,000 512 000
33rd M1 33,000 52 800 3300 330,000 528 000
34th M1 34,000 54 400 3400 340,000 544 000
35th M1 and M2 35,000 56 000 3500 350,000 560 000
36th M1 36,000 57 600 3600 360,000 576 000
37th M1 37,000 59 200 3700 370,000 592 000
38th M1 38,000 60 800 3800 380,000 608 000
39th M1 39,000 62 400 3900 390,000 624 000
40th M1 and M2 40,000 64 000 4000 400,000 640 000
41st M1 41,000 65 600 4100 410,000 656 000
42nd M1 42,000 67 200 4200 420,000 672 000
43rd M1 43,000 68 800 4300 430,000 688 000
44th M1 44,000 70 400 4400 440,000 704 000
45th M1, M2, and M3 45,000 72 000 4500 450,000 720 000
46th M1 46,000 73 600 4600 460,000 736 000
47th M1 47,000 75 200 4700 470,000 752 000
48th M1 48,000 76 800 4800 480,000 768 000
49th M1 49,000 78 400 4900 490,000 784 000
50th M1 and M2 50,000 80 000 5000 500,000 800 000
51st M1 51,000 82 000 5100 510,000 820 000
52nd M1 52,000 83 700 5200 520,000 837 000
53rd M1 53,000 85 300 5300 530,000 853 000
54th M1 54,000 86 900 5400 540,000 869 000
55th M1 and M2 55,000 88 500 5500 550,000 885 000
56th M1 56,000 90 100 5600 560,000 901 000
57th M1 57,000 91 700 5700 570,000 917 000
58th M1 58,000 93 300 5800 580,000 933 000
59th M1 59,000 94 900 5900 590,000 949 000
60th M1, M2, and M3 60,000 96 500 6000 600,000 965 000
Maintenance
Interval
Table 3, 31st through 60th Maintenance for Service Schedules I and II
Service
Date
Miles km Hours Miles km
Service Schedule I Service Schedule II
Columbia Maintenance Manual, September 201500/4
General Information 00
Vehicle Maintenance Schedule Tables: 00–03
61st through 90th Maintenance for Service Schedules I and II
Maint. No.
61st M1 61,000 98 200 6100 610,000 982 000
62nd M1 62,000 99 800 6200 620,000 998 000
63rd M1 63,000 101 400 6300 630,000 1 014 000
64th M1 64,000 103 000 6400 640,000 1 030 000
65th M1 and M2 65,000 104 600 6500 650,000 1 046 000
66th M1 66,000 106 200 6600 660,000 1 062 000
67th M1 67,000 107 800 6700 670,000 1 078 000
68th M1 68,000 109 400 6800 680,000 1 094 000
69th M1 69,000 111 000 6900 690,000 1 110 000
70th M1 and M2 70,000 112 700 7000 700,000 1 127 000
71st M1 71,000 114 300 7100 710,000 1 143 000
72nd M1 72,000 115 900 7200 720,000 1 159 000
73rd M1 73,000 117 500 7300 730,000 1 175 000
74th M1 74,000 119 100 7400 740,000 1 191 000
75th M1, M2, and M3 75,000 120 700 7500 750,000 1 207 000
76th M1 76,000 122 300 7600 760,000 1 223 000
77th M1 77,000 123 900 7700 770,000 1 239 000
78th M1 78,000 125 500 7800 780,000 1 255 000
79th M1 79,000 127 100 7900 790,000 1 271 000
80th M1 and M2 80,000 128 700 8000 800,000 1 287 000
81st M1 81,000 130 400 8100 810,000 1 304 000
82nd M1 82,000 132 000 8200 820,000 1 320 000
83rd M1 83,000 134 000 8300 830,000 1 340 000
84th M1 84,000 135 200 8400 840,000 1 352 000
85th M1 and M2 85,000 137 000 8500 850,000 1 370 000
86th M1 86,000 138 400 8600 860,000 1 384 000
87th M1 87,000 140 000 8700 870,000 1 400 000
88th M1 88,000 141 600 8800 880,000 1 416 000
89th M1 89,000 143 200 8900 890,000 1 432 000
90th M1, M2, and M3 90,000 144 800 9000 900,000 1 448 000
Maintenance
Interval
Table 4, 61st through 90th Maintenance for Service Schedules I and II
Service
Date
Miles km Hours Miles km
Service Schedule I Service Schedule II
Columbia Maintenance Manual, September 2015 00/5
General Information00
Vehicle Maintenance Schedule Tables: 00–03
91st through 100th Maintenance for Service Schedules I and II
Maint. No.
91st M1 91,000 146 500 9100 910,000 1 465 000
92nd M1 92,000 148 100 9200 920,000 1 481 000
93rd M1 93,000 150 000 9300 930,000 1 500 000
94th M1 94,000 151 300 9400 940,000 1 513 000
95th M1 and M2 95,000 153 000 9500 950,000 1 530 000
96th M1 96,000 155 000 9600 960,000 1 550 000
97th M1 97,000 156 100 9700 970,000 1 561 000
98th M1 98,000 157 700 9800 980,000 1 577 000
99th M1 99,000 159 300 9900 990,000 1 593 000
100th M1 and M2 100,000 160 900 10,000 1,000,000 1 609 000
Maintenance
Interval
Table 5, 91st through 100th Maintenance for Service Schedules I and II
Service
Date
Miles km Hours Miles km
Service Schedule I Service Schedule II
1st through 20th Maintenance for Service Schedules III and IV
Maint. No. Maintenance Interval
1 IM and M1 25,000 40 000
2 M1 50,000 80 000
3 M1 75,000 121 000
4 M1 and M2 100,000 161 000
5 M1 125,000 201 000
6 M1 150,000 241 000
7 M1 175,000 281 000
8 M1 and M2 200,000 322 000
9 M1 225,000 362 000
10 M1 250,000 402 000
11 M1 275,000 443 000
12 M1, M2, and M3 300,000 483 000
13 M1 325,000 523 000
14 M1 350,000 563 000
15 M1 375,000 604 000
16 M1 and M2 400,000 644 000
17 M1 425,000 684 000
18 M1 450,000 724 000
19 M1 475,000 764 000
Service
Date
Service Schedules III and IV
Miles km
Columbia Maintenance Manual, September 201500/6
General Information 00
Vehicle Maintenance Schedule Tables: 00–03
1st through 20th Maintenance for Service Schedules III and IV
Maint. No. Maintenance Interval
20 M1 and M2 500,000 805 000
Table 6, 1st through 20th Maintenance for Service Schedules III and IV
21st through 40th Maintenance for Service Schedules III and IV
Maint. No. Maintenance Interval
21 M1 525,000 845 000
22 M1 550,000 885 000
23 M1 575,000 925 000
24 M1, M2, and M3 600,000 966 000
25 M1 625,000 1 005 800
26 M1 650,000 1 046 000
27 M1 675,000 1 086 000
28 M1 and M2 700,000 1 127 000
29 M1 725,000 1 167 000
30 M1 750,000 1 207 000
31 M1 775,000 1 248 000
32 M1 and M2 800,000 1 287 000
33 M1 825,000 1 328 000
34 M1 850,000 1 368 000
35 M1 875,000 1 408 000
36 M1, M2, and M3 900,000 1 448 000
37 M1 925,000 1 490 000
38 M1 950,000 1 529 000
39 M1 975,000 1 569 000
40 M1 and M2 1,000,000 1 609 000
Table 7, 21st through 40th Maintenance for Service Schedules III and IV
Service
Date
Service
Date
Service Schedules III and IV
Miles km
Service Schedules III and IV
Miles km
Columbia Maintenance Manual, September 2015 00/7
Lubrication and Fluid Level Check: 00–04
General Information00
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
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.
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.
Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV
Maint.
Operation
Number
25–01 Eaton Fuller Clutch Release Bearing Lubrication •
25–02 Clutch Release Cross-Shaft Lubrication •
25–03 Sleeve Assembly Bronze Bushing Lubrication •
26–02 Transmission Fluid Level Inspection •
31–02 Fifth Wheel Lubrication •
31–04 Trailer Electrical Connector Lubrication •
32–02 Suspension Lubrication •
33–01 Knuckle Pin Lubrication, Meritor Axles •
33–03 Tie Rod Lubrication, Meritor Axles •
33–05 Knuckle Pin Lubrication, Dana Spicer Axles •
33–06 Tie Rod Lubrication, Dana Spicer Axles •
33–09 Kingpin Lubrication, Detroit™Axles
33–10 Tie Rod Lubrication, Detroit™Axles
35–02 Axle Breather and Axle Lubricant Level Inspection •
41–02 Driveline Lubrication • •
42–05 Dana Spicer Camshaft Bracket Lubrication •
42–06 Dana Spicer, Haldex, and Gunite Slack Adjuster
42–07 Meritor Camshaft Bracket Lubrication • •
46–03 Power Steering Fluid Level Inspection •
46–04 Power Steering Gear Lubrication •
46–05 Drag Link Lubrication •
46–06 Rack and Pinion Inspection •
72–01 Door Seal, Door Latch, and Door Hinge Lubrication •
88–01 Hood Rear Support Lubrication •
*
For Schedule II vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
Table 8, Maintenance Operation 00-04, Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV
Lubrication
Operation Description
Maintenance Operation 00–04
Schedules I, II,
and III (at M1)
*
*
Service
•
Service
Schedule IV
(at M2)
•
•
Check
Columbia Maintenance Manual, September 201500/8
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 main-
Maintenance
Operation Number
00–06 Perform all M1 Operations
31–03 Frame Fastener Torque Check
31–05 Premier 690 Coupling Inspection
32–03 Suspension U-Bolt Torque Check
33–04 All-Axle Alignment Check
40–01 Wheel Nut Check
47–03 Fuel Tank Band-Nut Tightening
Table 9, Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV
Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV Check
tenance operations to be performed. All operations
listed in the table, along with the operations listed in
the applicable M1 maintenance interval table, must
be performed to complete the initial maintenance
(IM).
Columbia Maintenance Manual, September 2015 00/9
M1 Maintenance Interval Operations: 00–06
General Information00
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.
Maintenance
Operation Number
00–04 Lubrication and Fluid Level Check (includes the following)
13–01 Air Compressor Inspection
20–03 Fan Clutch Check (noise emission control)
31–01 Fifth Wheel Inspection
31–05 Premier 690 Coupling Inspection
40–02 Tire Check
41–01 Driveline Inspection
42–07 Meritor Camshaft Bracket Lubrication
42–10 Brake Inspection
49–01 Exhaust System Inspection (noise emission control)
Table 10, M1 Maintenance Interval Operations for Service Schedules I, II, and III
M1 Maintenance Interval Operations for Service Schedules I, II, and III Check
• Eaton Fuller Clutch Release Bearing Lubrication
• Fifth Wheel Lubrication
• Trailer Electrical Connector Lubrication
• Suspension Lubrication
• Knuckle Pin Lubrication, Dana Spicer Axles
• Tie Rod Lubrication, Dana Spicer Axles
• Driveline Lubrication
• Dana Spicer Camshaft Bracket Lubrication
• Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
• Door Seal, Door Latch, and Door Hinge Lubrication
• Hood Rear Support Lubrication
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
Operation Number
13–01 Air Compressor Inspection
20–03 Fan Clutch Check (noise emission control)
31–01 Fifth Wheel Inspection
31–02 Fifth Wheel Lubrication
31–04 Trailer Electrical Connector Lubrication
31–05 Premier 690 Coupling Inspection
40–02 Tire Check
M1 Maintenance Interval Operations for Service Schedule IV Check
Columbia Maintenance Manual, September 201500/10
General Information 00
M1 Maintenance Interval Operations: 00–06
Maintenance
Operation Number
42–07 Meritor Camshaft Bracket Lubrication
42–10 Brake Inspection
49–01 Exhaust System Inspection (noise emission control)
72–01 Door Seal, Door Latch, and Door Hinge Lubrication
88–01 Hood Rear Support Lubrication
Table 11, M1 Maintenance Interval Operations for Service Schedule IV
M1 Maintenance Interval Operations for Service Schedule IV Check
Columbia Maintenance Manual, September 2015 00/11
M2 Maintenance Interval Operations: 00–07
General Information00
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
Maintenance
Operation Number
00–06 Perform All M1 Operations
01–01 Engine Support Fasteners Check (noise emission control)
01–02 Engine Drive Belt Inspection
15–01 Alternator, Battery, and Starter Check
20–01 Pressure Relief Cap Check
25–02 Clutch Release Cross-Shaft Lubrication
25–03 Sleeve Assembly Bronze Bushing Lubrication
25–04 Meritor Clutch Release Bearing Lubrication
26–02 Transmission Fluid Level Inspection
26–03 Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
32–01 Suspension Inspection
32–03 Suspension U-Bolt Torque Check
33–01 Knuckle Pin Lubrication, Meritor Axles
33–02 Tie Rod Inspection
33–03 Tie Rod Lubrication, Meritor Axles
33–07 Basic Inspection, Meritor Unitized Wheel Ends
33–08 End-Play Check, Meritor Unitized Wheel Ends
33–09 Kingpin Lubrication, Detroit™Axles
33–10 Tie Rod Lubrication, Detroit™Axles
35–02 Axle Breather and Axle Lubricant Level Inspection
40–01 Wheel Nut Check
42–01 Air Brake System Valve Inspection
42–03 Air Dryer Inspection
42–04 Alcohol Evaporator Cleaning and Inspection
42–08 Meritor Slack Adjuster Lubrication
46–01 Drag Link Inspection
46–03 Power Steering Fluid Level Inspection
46–04 Power Steering Gear Lubrication
46–05 Drag Link Lubrication
46–06 Rack and Pinion Steering Gear Inspection
47–01 Fuel Filter Replacement
47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement
60–01 Mirror Folding Check
M2 Maintenance Interval Operations for Service Schedules I, II, and III Check
you find detailed instructions in this manual on the
maintenance operations to be performed. Perform all
M1 maintenance interval operations at the M2 main-
tenance interval.
*
*
Columbia Maintenance Manual, September 201500/12
General Information 00
M2 Maintenance Interval Operations: 00–07
Maintenance
Operation Number
M2 Maintenance Interval Operations for Service Schedules I, II, and III Check
83–01 Air Conditioner Inspection
83–02 Air Filter Replacement
*
For Schedule II vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
†
Replace the HVAC filters every 6 months regardless of mileage.
†
Table 12, M2 Maintenance Interval Operations for Service Schedules I, II, and III
Maintenance
Operation Number
M2 Maintenance Interval Operations for Service Schedule IV Check
00–04 Lubrication and Fluid Level Check (includes the following)
• Clutch Release Cross-Shaft Lubrication
• Sleeve Assembly Bronze Bushing Lubrication
• Transmission Fluid Level Inspection
• Knuckle Pin Lubrication, Meritor Axles
• Tie Rod Lubrication, Meritor Axles
™
• Kingpin Lubrication, Detroit
• Tie Rod Lubrication, Detroit
Axles
™
Axles
• Axle Breather and Axle Lubricant Level Inspection
• Driveline Lubrication
• Power Steering Fluid Level Inspection
• Power Steering Gear Lubrication
• Drag Link Lubrication
00–06 Perform All M1 Operations
01–01 Engine Support Fasteners Check (noise emission control)
01–02 Engine Drive Belt Inspection
15–01 Alternator, Battery, and Starter Check
20–01 Pressure Relief Cap Check
26–03 Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
32–01 Suspension Inspection
32–03 Suspension U-Bolt Torque Check
33–02 Tie Rod Inspection
33–07 Basic Inspection, Meritor Unitized Wheel Ends
33–08 End-Play Check, Meritor Unitized Wheel Ends
40–01 Wheel Nut Check
41–01 Driveline Inspection
42–01 Air Brake System Valve Inspection
42–03 Air Dryer Inspection
42–04 Alcohol Evaporator Cleaning and Inspection
Columbia Maintenance Manual, September 2015 00/13
M2 Maintenance Interval Operations: 00–07
General Information00
Maintenance
Operation Number
46–01 Drag Link Inspection
46–06 Rack and Pinion Steering Inspection
47–01 Fuel Filter Replacement
47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement
60–01 Mirror Folding Check
83–01 Air Conditioner Inspection
83–02 Air Filter Replacement
*
Replace the HVAC filters every 6 months regardless of mileage.
Table 13, M2 Maintenance Interval Operations for Service Schedule IV
M2 Maintenance Interval Operations for Service Schedule IV Check
*
Columbia Maintenance Manual, September 201500/14
General Information 00
M3 Maintenance Interval Operations: 00–08
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
Maintenance
Operation Number
00–06 Perform All M1 Operations
00–07 Perform All M2 Operations
09–01 Air Cleaner Element Inspection and Replacement
20–02 Radiator Pressure-Flushing and Coolant Change
26–01 Manual Transmission Fluid Change, and Magnetic Plug Cleaning (synthetic lubricant)
35–01 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (synthetic lubricant)
42–02 Air Dryer Desiccant Replacement
42–09 Bendix E–6 Foot Control Valve Inspection and Lubrication
46–02 Power Steering Fluid and Filter Change
46–07 Bellows Replacement, Rack and Pinion Steering Gear
49–02 CAT CGI Bellows Replacement
Table 14, M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV
M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV Check
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.
Columbia Maintenance Manual, September 2015 00/15
General Information00
Maintenance Operation Sets Table: 00–09
Maintenance Operation Sets for Groups 00 through 83
Maint.
No.
00–04 Lubrication and Fluid Level Check •••• ••
01–01 Engine Support Fasteners Check (noise emission control) • • • •
01–02 Engine Drive Belt Inspection • • • •
01–03 Pacbrake Inspection and Lubrication
09–01 Air Cleaner Element Inspection and Replacement • •
13–01 Air Compressor Inspection •••• ••••
15–01 Alternator, Battery, and Starter Check • • • •
20–01 Pressure Relief Cap Check • • • •
20–02 Radiator Pressure-Flushing and Coolant Change • •
20–03 Fan Clutch Check (noise emission control) •••• ••••
25–01 Eaton Fuller Clutch Release Bearing Lubrication ••••
25–02 Clutch Release Cross-Shaft Lubrication • • • •
25–03 Sleeve Assembly Bronze Bushing Lubrication • • • •
25–04 Meritor Clutch Release Bearing Lubrication • •
26–01 Manual Transmission Fluid Change, and Magnetic Plug Cleaning
(Synthetic Lubricant)
26–02 Transmission Fluid Level Inspection • • • •
26–03 Manual Transmission Air Filter/Regulator Check, Cleaning, or
Replacement
31–01 Fifth Wheel Inspection •••• ••••
31–02 Fifth Wheel Lubrication •••• ••••
31–03 Frame Fastener Torque Check • •
31–04 Trailer Electrical Connector Lubrication •••• ••••
31–05 Premier 690 Coupling Inspection • •
32–01 Suspension Inspection • • • •
32–02 Suspension Lubrication ••••
32–03 Suspension U-Bolt Torque Check • • • • • •
33–01 Knuckle Pin Lubrication, Meritor Axles • • • •
33–02 Tie Rod Inspection • • • •
33–03 Tie Rod Lubrication, Meritor Axles • • • •
33–04 All-Axle Alignment Check • •
33–05 Knuckle Pin Lubrication, Dana Spicer Axles ••••
33–06 Tie Rod Lubrication, Dana Spicer Axles ••••
33–07 Basic Inspection, Meritor Unitized Wheel Ends
33–08 End-Play Check, Meritor Unitized Wheel Ends
Operation Description
*
†
‡
Service Schedules
I, II, and III
IM M1 M2 M3 IM M1 M2 M3
•• ••
•• ••
•• ••
Service Schedule
IV
••
Columbia Maintenance Manual, September 201500/16
General Information 00
Maintenance Operation Sets Table: 00–09
Maintenance Operation Sets for Groups 00 through 83
Maint.
No.
33–09 Kingpin Lubrication, Detroit™Axles
33–10 Tie Rod Lubrication, Detroit™Axles
35–01 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning
(synthetic lubricant)
35–02 Axle Breather and Axle Lubricant Level Inspection • • • •
40–01 Wheel Nut Check • • • • • •
40–02 Tire Check • • • • • • • •
41–02 Driveline Lubrication • • • • • •
42–01 Air Brake System Valve Inspection • • • •
42–02 Air Dryer Desiccant Replacement • •
42–03 Air Dryer Inspection • • • •
42–04 Alcohol Evaporator Cleaning and Inspection • • • •
42–05 Dana Spicer Camshaft Bracket Lubrication • • • •
42–06 Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication • • • •
42–07 Meritor Camshaft Bracket Lubrication • • • • • • • •
42–08 Meritor Slack Adjuster Lubrication • •
42–09 Bendix E–6 Foot Control Valve Inspection and Lubrication • •
42–10 Brake Inspection • • • • • • • •
46–01 Drag Link Inspection • • • •
46–02 Power Steering Fluid and Filter Change • •
46–03 Power Steering Fluid Level Inspection • • • •
46–04 Power Steering Gear Lubrication • • • •
46–05 Drag Link Lubrication • • • •
46–06 Rack and Pinion Steering Gear Inspection • • • •
46–07 Bellows Replacement, Rack and Pinion Steering Gear • •
47–01 Fuel Filter Replacement • • • •
47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement • • • •
47–03 Fuel Tank Band-Nut Tightening • •
49–01 Exhaust System Inspection (noise emission control) • • • • • • • •
49–02 CAT CGI Bellows Replacement • •
60–01 Mirror Folding Check • • • •
72–01 Door Seal, Door Latch, and Door Hinge Lubrication • • • • • • • •
83–01 Air Conditioner Inspection • • • •
83–02 Air Filter Replacement
Operation Description
§
§
¶
Service Schedules
I, II, and III
IM M1 M2 M3 IM M1 M2 M3
•• ••
•• ••
Service Schedule
IV
••
Columbia Maintenance Manual, September 2015 00/17
General Information00
Maintenance Operation Sets Table: 00–09
Maintenance Operation Sets for Groups 00 through 83
Maint.
No.
Operation Description
88–01 Hood Rear Support Lubrication •••• ••••
*
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).
§
For Schedule II vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
¶
Replace the HVAC filters every 6 months regardless of mileage.
Table 15, Maintenance Operation Sets for Groups 00 through 83
Service Schedules
I, II, and III
Service Schedule
IV
IM M1 M2 M3 IM M1 M2 M3
Columbia Maintenance Manual, September 201500/18
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.
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 noise-
deadening panels.
C. Removal of, or rendering inoperative, the en-
gine 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, ex-
haust 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.
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
Columbia Maintenance Manual, September 2015 00/19
General Information00
Verification of Inspections Log: 00–11
Verification of Inspections Log
Verification of Inspections Log, Group 01
Verification of Inspections Log — Group 01 — Engine Mounts
Date Mileage Item Cost Maintenance Facility
Verification of Inspections Log, Group 20
Verification of Inspections Log — Group 20 — Fan Clutch
Date Mileage Item Cost Maintenance Facility
Columbia Maintenance Manual, September 201500/20
General Information 00
Verification of Inspections Log: 00–11
Verification of Inspections Log, Group 49
Verification of Inspections Log — Group 49 — Exhaust System Components
Date Mileage Item Cost Maintenance Facility
Columbia Maintenance Manual, September 2015 00/21
Engine 01
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Engine Drive Belt Inspection..........................................................01–02
Engine Support Fasteners Check ......................................................01–01
Pacbrake Inspection and Lubrication....................................................01–03
Safety Precautions......................................................................
Columbia Maintenance Manual, September 2015
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