freightliner CL112 2015 Maintenance Manual Download

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Title of Maintenance Operation (MOP)

MOP Number

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

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

Lubricant)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–00

Rear Axle

Index, Alphabetical

Columbia Maintenance Manual, July 2017

Summary of Contents for CL112 2015

Page 1: ...COLUMBIA MAINTENANCE MANUAL Models CL112 CL120 STI 409 2 7 17 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A ...

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Page 3: ...nting 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 ...

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Page 5: ...a tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a par...

Page 6: ...ns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles Field Service Campaigns Field service campaigns are concerned with non safety related service work or replacement of parts All field service campaigns are distributed to dealers cus tomers receive notices that apply to their vehicles Introduction Descriptio...

Page 7: ... 01 Coolant Replacement 20 02 Cooling Fan Inspection 20 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 Introduction Page Description Columbia Maintenance Manual February 2010 I 3 ...

Page 8: ...tor 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 Introduction Maintenance Manual Contents I 4 Columbia Maintenance Manual February 2010 ...

Page 9: ...tenance 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 General Information 00 Index Alphabetical Columbia Maintenance Manual July 2017 ...

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Page 11: ... Service Schedule II short haul transport applies to vehicles that annually travel less than 60 000 miles 100 000 kilometers and operate under normal con ditions Examples of Schedule II usage are opera tion primarily in cities and densely populated areas local transport with infrequent freeway travel or high percentage of stop and go travel Service Schedule III long haul transport is for ve hicles...

Page 12: ...e 1 M1 every 25 000 40 000 Maintenance 2 M2 every 100 000 161 000 Maintenance 3 M3 every 300 000 483 000 Schedule IV Long Haul Transport for Optimized Vehicle Configuration vehicles that annually travel over 60 000 miles 100 000 km 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 For Schedu...

Page 13: ...40 000 224 000 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 23...

Page 14: ...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 ...

Page 15: ...4 000 119 100 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 8...

Page 16: ... 100 000 160 900 10 000 1 000 000 1 609 000 Table 5 91st through 100th Maintenance for Service Schedules I and II 1st through 20th Maintenance for Service Schedules III and IV Maint No Maintenance Interval Service Date Service Schedules III and IV Miles km 1 IM and M1 25 000 40 000 2 M1 50 000 80 000 3 M1 75 000 121 000 4 M1 and M2 100 000 161 000 5 M1 125 000 201 000 6 M1 150 000 241 000 7 M1 175...

Page 17: ... 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...

Page 18: ...1 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 Driveli...

Page 19: ...erval table must be performed to complete the initial maintenance IM Maintenance Operation Number Initial Maintenance IM Operations for Service Schedules I II III and IV Check 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 Tight...

Page 20: ...ation 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 13 01 Air Compressor Inspection 20 03 Fan Clutch Check noise emission control 31 01 Fifth Wheel Inspection 31 05 Premier 690 Coupling Inspection 33 11 Steer Axle Hub Cap Vent Plu...

Page 21: ...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 General Information 00 M1 Maintenance Interval Operations 00 06 Columbia Maintenance Manual July 2017 00 11 ...

Page 22: ...anual 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 Lu...

Page 23: ...or Axles Kingpin Lubrication Detroit Axles Tie Rod Lubrication Detroit 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 Sta...

Page 24: ...t 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 General Information 00 M2 Maintenance Interval Operations 00 07 Columbia Maintenance Manual July 2017 00 14 ...

Page 25: ...orm 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 Lubricat...

Page 26: ...tor 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 69...

Page 27: ...djuster 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 Steeri...

Page 28: ...les 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 thr...

Page 29: ... with Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 The...

Page 30: ...roup 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 General Information 00 Verification of Inspections Log 00 11 Columbia Maintenance Manual July 2017 00 20 ...

Page 31: ... Log Group 49 Verification of Inspections Log Group 49 Exhaust System Components Date Mileage Item Cost Maintenance Facility General Information 00 Verification of Inspections Log 00 11 Columbia Maintenance Manual July 2017 00 21 ...

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Page 33: ...ion MOP MOP Number Engine Drive Belt Inspection 01 02 Engine Support Fasteners Check 01 01 Pacbrake Inspection and Lubrication 01 03 Safety Precautions 01 00 Engine 01 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 35: ...elt 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 bel...

Page 36: ...ult to distinguish the location of a supposed bearing noise place a stetho scope on the component being checked not the pulley to isolate the area from outside interfer ence 8 Inspect all pulleys for foreign objects oil or grease in the grooves Belt Tension Inspection Threaded Adjustment Type 1 Apply the parking brakes and chock the tires 2 Install a belt tension gauge at the center of the belt s ...

Page 37: ...ke will operate maintenance free If the vehicle is used in consistently or seasonally it will be necessary to per form preventative maintenance If the vehicle is ex posed to excess moisture or is used only for periodic or seasonal use perform the following steps 1 With the engine off use any oil free or non petroleum based high heat lubricant and spray or coat a sufficient amount on the restrictor...

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Page 39: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement 09 01 Air Intake 09 Index Alphabetical Columbia Maintenance Manual November 2014 ...

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Page 41: ...lements After market air cleaner elements may not seal the housing correctly which can lead to engine dam age and potentially the loss of warranty When re placing an air cleaner element use only the part listed in PartsPro for the serial number of the ve hicle 2 If necessary replace the air cleaner element For air cleaner element replacement instructions see Group 09 of the vehicle Workshop Manual...

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Page 43: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 45: ...ious personal injury or death 13 01 Air Compressor Inspection 1 Inspect the air compressor intake hoses and connections at the air intake and air compressor for physical damage If needed change the hoses and or tighten or replace the connections 2 Inspect the coolant supply and return lines for tight connections Tighten the connections and replace the lines and fasteners if needed 3 For the air go...

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Page 47: ...f Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 49: ...equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension inspection 4 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections including the connections at the starter B terminal and ground terminal and where the alternator charg ing cable terminates 5 Inspect the batt...

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Page 51: ...r Fan Clutch Check Noise Emission Control 20 03 Pressure Relief Cap Check 20 01 Radiator Pressure Flushing and Coolant Change 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 53: ...d On vehicles with screw on caps with O rings make sure that the O ring is not cracked or deteriorated Replace the cap if the gasket shows deterioration or dam age 20 02 Radiator Pressure Flushing and Coolant Change NOTE For additional instructions on cleaning and flushing the engine cooling system see the applicable engine manufacturer s maintenance and operation manual 1 Park the vehicle and app...

Page 54: ...lug 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 diam eter greater than 2 inches 51 mm f5002...

Page 55: ...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 Refer to the engine manufacturer s service literature for specific coolant information 14 Replace the surge tank cap s 15 Return the hood to the operating position 16 Start the engin...

Page 56: ... 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 proce dures 9 1 Check for a leak ...

Page 57: ...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 f200194a 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 22 24 03 30 95 1 Mounting Bracket 2 Rear Sheave Bearing 3 Inner and Outer Bearing Space...

Page 58: ... the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filter if equipped 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment 3 2 Clean the filter element with cleaning sol vent 3 3 Using a clean lint free cloth wipe off any excess solvent 3 4 Reassemble the clutch valve sole...

Page 59: ...heck 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 b...

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Page 61: ...aft Lubrication 25 02 Eaton Fuller Clutch Release Bearing Lubrication 25 01 Meritor Clutch Release Bearing Lubrication 25 04 Safety Precautions 25 00 Sleeve Assembly Bronze Bushing Lubrication 25 03 Clutch 25 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 63: ...ot 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 high temperature grease that meets the NLGI grade one or two specification 3 Wipe any dirt away from the grease fitting See Fig 1 Using a pressure type grease gun equipped with the recommended grease lubri cate the bearing unti...

Page 64: ... the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Remove the clutch inspection plate NOTE Some clutch release bearings are equipped with a lubrication extension that ex tends outside of the clutch housing It is not necessary to remove the clutch inspection plate when the lubrication extension is used NOTE For lubrication of the release bearing Meritor recommends a...

Page 65: ...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 Clutch 25 Columbia Maintenance Manual September 2015 25 3 ...

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Page 67: ...ulator Check Cleaning or Replacement 26 03 Manual and Automated Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant 26 01 Safety Precautions 26 00 Transmission Fluid Level Inspection 26 02 Transmission 26 Index Alphabetical Columbia Maintenance Manual July 2017 ...

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Page 69: ...teel 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 be tween 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...

Page 70: ...ransmission Model Refill Capacity qt L 7 Speed T Series All Models 18 0 17 0 All 9 Speed Series All Models 13 5 12 8 All 10 Speed Manual except deep reduction FR and FRO Series 11 75 11 0 RT and RTX Series 13 0 12 3 RTLO Series 14 0 13 2 10 Speed Deep Reduction RTO 14908LL 14 0 13 2 RTO 16908LL 10 Speed Automated Lightning Top 2 all 13 5 12 8 10 Speed Autoshift AS2 all 13 0 12 3 13 Speed RTLO Seri...

Page 71: ...e fill opening See Table 1 for approved transmission lubricants For more information and a complete listing of Eaton approved lubricants refer to the Eaton website www roadranger com For more infor mation and a complete listing of Meritor ap proved lubricants refer to the ZF Meritor web site www zf com 5 Clean the fill plug then install it Tighten the plug as follows 25 to 35 lbf ft 34 to 48 N m f...

Page 72: ...NOTE This procedure does not apply to FreedomLine transmissions 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Remove the element from the air filter regulator assembly Inspect the O rings in the end cap replace worn or damaged O rings Inspect the element for fluid contamination If fluid is present replace the element Inspect the air supply sys tem for th...

Page 73: ...n 31 01 Fifth Wheel Lubrication 31 02 Frame Fastener Torque Check 31 03 Premier 690 Coupling Inspection 31 05 Safety Precautions 31 00 Trailer Electrical Connector Lubrication 31 04 Frame and Frame Components 31 Index Alphabetical Columbia Maintenance Manual July 2017 ...

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Page 75: ...heel com 6 Check the jaw and stationary jaw for mushroom ing and check that the serrations at the jaw and wedge are in good condition 7 Test the secondary safety lock latch for ease of operation 8 Check for loose nuts or bolts on the fifth wheel and the mounting Set a torque wrench to the maximum torque value for the bolt being checked and confirm that the torque is to speci fication Do not loosen...

Page 76: ...6 Bracket Pin 7 Bracket Retainer Pin 8 Cotter Pin 3 16 x 1 9 Bumper Spring 10 Handle Spring 11 Bolt Secondary Safety Lock 12 Flat Washer 13 Secondary Safety Lock 14 Bushing Secondary Safety Lock 15 Hex Locknut 16 Pull Handle 17 Bolt Bumper 18 Bushing 19 Bumper 20 Timer Spring 21 Timer 22 Operating Handle 23 Bolt Operating Handle 24 Bushing Operating Handle 25 Hair Pin Cotter 26 Wedge 27 Step Jaw F...

Page 77: ...v ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions Holland FW35 1 Disconnect the tractor from the trailer For in structions see the Columbia Driver s Manual 2 Thoroughly steam clean all fifth wheel compo nents before inspection 3 Check for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Check the fastener torques on the fifth whee...

Page 78: ...n boss and measure the vertical move ment Ref 5 The bracket connection provides a 9 32 inch 7 mm vertical clearance to provide cushioning and to avoid downward pin loading while retaining minimum plate lift If the plate lift Ref A exceeds 5 16 inch 8 mm as a result of wear or rubber deterioration install new stan dard or oversized bracket shoe rubber pads see Group 31 of the Columbia Workshop Manu...

Page 79: ...ring bolts It is normal for out side edges of the plate to pucker slightly this does not affect performance 7 Check the fifth wheel adjustment Using a lock tester lock and unlock the fifth wheel several times Make sure that the locking mechanism works properly The lock is properly adjusted if the wheel locks and unlocks easily each time and the lock tester rotates freely The lock is too loose if y...

Page 80: ...ly requires no adjustment If the plungers are loose in spect and replace locking mechanism parts as needed 9 5 The inboard slider is adjustable for frame width and plunger engagement For ad justment refer to the fifth wheel installa tion instructions 09 01 2009 f311099 A B C D E F G H A Checking for fore aft play B Rotating tester in lock C Engage hook D Pull push handle fore aft E Check for movem...

Page 81: ...l is down and repeat the greasing pro cedure Rock the top plate back and forth sev eral times to spread the grease over the bearing surface 2 Inspect the trailer kingpin plate and top surface of the fifth wheel to make sure each is properly greased A liberal coating of grease should be applied to the complete surfaces of both the trailer kingpin plate and the top surface of the fifth wheel NOTE Do...

Page 82: ...e MOP 31 01 Apply a light oil to all mov ing parts For sliding fifth wheels spray diesel fuel on the slide path of the base plate NOTICE Do not use a power grease gun The pressure will damage the lube line If the fifth wheel is not equipped with low lube plates apply a lithium based grease with extreme pressure EP additive to the trailer contact surface of the fifth wheel NOTE If the fifth wheel i...

Page 83: ... Deck Plates Engine Trunnion Supports Equalizer Brackets Exhaust Brackets Fifth Wheel Legs Fifth Wheel Mountings Frame Crossmembers and Gussets Front Frame Brackets 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 ...

Page 84: ...been replaced In addition carefully inspect the 690 coupling drawbar drawbar eye front end as sembly and tail board for damage Failure to do so may result in trailer separation from the truck while in use resulting in serious personal injury or property damage The time in service of the 294 bolt located in the 690 coupling must be monitored and maintenance per formed as follows See Fig 14 For a ne...

Page 85: ...e Operation MOP MOP Number Safety Precautions 32 00 Suspension Inspection 32 01 Suspension Lubrication 32 02 Suspension U Bolt Torque Check 32 03 Suspension 32 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 87: ...ce 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 assem blies Section 9 Suspension Pages 44 to 45 Inspect the Liteflex spring for cracks that result in an out of service condition as follows see Fig 1 a side to side crac...

Page 88: ...ssmember and gussets for wear cracks and other damage If any of these conditions exist replace the dam aged parts See Group 32 of the Columbia Workshop Manual for instructions 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 rad...

Page 89: ... bly could cause an accident resulting in property damage serious personal injury or death Inspect the forward and rear spring brackets for wear cracks and other damage If any of these con 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...

Page 90: ...a fixed lev eling valve see Group 32 of the Columbia Workshop Manual for the overtravel lever length for the rear axle installed in your vehicle 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 dual drive rear axle configurations measure the dis tance from the bottom of the forwardmost left axle stop to the...

Page 91: ...for cracks severe corrosion and distortion If any of these conditions are present or the restrictor can is missing replace the re strictor can WARNING Replace all cracked or missing restrictor cans Failure to do so could lead to loss of vehicle con trol which could result in property damage seri ous personal injury or death 32 02 Suspension Lubrication Front Suspension Wipe all dirt away from the ...

Page 92: ... on 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 re move the pin and clean the lubrication channels where lubricant may have hardened ...

Page 93: ... 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 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 7 8 14 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 1 14 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 520 to 600 707 to 816 Tighten in a diagonal patt...

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Page 95: ...troit Axles 33 09 Knuckle Pin Lubrication Dana Spicer Axles 33 05 Knuckle Pin Lubrication Meritor Axles 33 01 Safety Precautions 33 00 Steer Axle Hub Cap Vent Plug Inspection 33 11 Tie Rod Inspection 33 02 Tie Rod Lubrication Dana Spicer Axles 33 06 Tie Rod Lubrication Detroit Axles 33 10 Tie Rod Lubrication Meritor Axles 33 03 Front Axle 33 Index Alphabetical Columbia Maintenance Manual July 2017...

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Page 97: ...ttings The grease seal will accept grease pres sure without damage and is designed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate gasket continue pumping until new grease is seen at the bushing seal opposite the grease fitting See Fig 1 33 02 Tie Rod Inspection Inspect the tie rod ends as follows 1 Shake the cross tube A loose fit or...

Page 98: ...r 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 ti...

Page 99: ...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 park ing brakes shut ...

Page 100: ...all 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 th...

Page 101: ...0 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 re place it with a new one 24 Remove the chocks from the tires 33 09 Kingpin Lubrication Detroit Axles 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires When lubricating the kingpin do not raise the front axle 2 ...

Page 102: ... there is water con taminated oil in the hub pressure washing is the most likely cause 06 07 2012 f330272 A B 1 1 A Upper View LH Side B Lower View LH Side 1 Grease Fitting Fig 7 Kingpin Grease Fittings Detroit Axles 09 13 2012 f330275 Fig 8 Kingpin Grease Exit Points Detroit Axles 06 12 2012 f330273 1 2 NOTE No grease should emit from the tie rod boot If grease emits from the tie rod boot the boo...

Page 103: ...pe the hub cap and vent plug clean with a rag 4 Remove the vent plug and check the oil for evi dence of water contamination If there is evidence of water contaminated oil in the hub disassemble the effected axle end clean inspect and reassemble the axle end For instructions refer to Group 33 of the vehicle s Workshop Manual If there is evidence of excessive leakage re move the damaged part and rep...

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Page 105: ...ber Axle Breather and Axle Lubricant Level Inspection 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Lubricant 35 01 Safety Precautions 35 00 Rear Axle 35 Index Alphabetical Columbia Maintenance Manual July 2017 ...

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Page 107: ...shift unit also change the shift unit lubricant See under the heading Two Speed Axles With Shift Unit All Axle Models Detroit IMPORTANT On Detroit axles the oil change interval for long haul vehicles can be 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 if a lubricant analysis shows adequate quality Oil must b...

Page 108: ...oil fill hole Lubri cant should be level with the bottom of the oil fill hole To check fluid level see Fig 2 5 2 Install and tighten the fill plug 30 lbf ft 41 N m Detroit Drive Axle Lubricants IMPORTANT Lubricant used in Detroit rear axles must meet Mercedes Benz specification 235 20 mineral or 235 8 synthetic Mobil Delvac Gear Oil A 80W 90 and Mobilube HD A Plus 80W 90 meet specification 235 20 ...

Page 109: ...that lubricant 3 If equipped with an oil pump remove the axle oil filter Use a suitable filter strap wrench See Fig 3 Discard the old filter 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 filte...

Page 110: ... 2 RT 44 145 RT 44 145P Forward 29 3 13 9 Rear 25 1 11 9 RT 46 160 RT 46 160P Forward 39 1 18 5 Rear 34 4 16 3 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground See Traction Equalizer Additives in the text Table 4 Meritor Drive Axle Lubricant Capacities 6 2 Install and tighten the fill plug 35 lbf ft 47 N m 7 Whenever the in...

Page 111: ... magnetic strainer from the power divider cover WARNING Always wear eye protection when using com pressed air to clean parts as flying debris could cause permanent damage to unprotected eyes Do not point the air stream in the direction of other persons 4 2 Wash the strainer in solvent and blow it dry with compressed air to remove oil and metal particles 4 3 Install and tighten the magnetic straine...

Page 112: ...ximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground Add 2 pints 1 L of additional lubricant to the power divider Table 6 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 us...

Page 113: ...arking brake Chock the tires 2 If the vehicle has just been driven allow a few minutes for the lubricant to settle IMPORTANT On Detroit axles the oil change interval for long haul vehicles can be 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 if a lubricant analysis shows adequate quality Oil must be changed a...

Page 114: ...ted wheel bearings check the oil level at the wheels and add oil if low Use the same lubricant recom mended for the drive axle NOTE When adding to or checking the oil level make certain the hub cap and plug are clean before removing the plug this will minimize the possibility of dirt and road grime entering the assembly Dana Spicer NOTICE Failure to keep the rear axle filled to the proper level wi...

Page 115: ...level The lubricant should be level with the bottom of the fill hole If low add the recommended lubricant NOTICE 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 en gine oil API service classification ...

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Page 117: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Check 40 01 Wheels and Tires 40 Index Alphabetical Columbia Maintenance Manual July 2017 ...

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Page 119: ...oted Disc Wheel With Inner and Outer Nuts Front Wheel Nut 1 1 8 16 All 450 500 610 678 Rear Wheel Inner Nut 3 4 16 All 450 500 610 678 Rear Wheel Outer Nut 1 1 8 16 All 450 500 610 678 Torque values for hub piloted wheels are given for lubricated threads Lubricate threads with SAE 30W engine oil Do not apply thread lubricant to ball seats of the nuts and wheels Wipe it off if it is applied acciden...

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Page 121: ...Title of Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 123: ...ws 125 lbf ft 169 N m See Fig 3 3 Check the driveline yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes If any end yoke can be moved in or out on its shaft or can be rocked on its shaft disconnect the driveshaft and U joint from the yoke then check the drive component s shaft seal for leak age or other visible damage that may have been caused by the loose yoke Repl...

Page 124: ...ends twists or other damage If any tube ap pears to be damaged refer to Group 41 of the Columbia Workshop Manual for repair and re placement instructions 8 Examine the driveshaft for evidence of missing balance weights and for build up of foreign ma terial Remove any foreign material If there is f410067b 10 06 2016 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NOTE Not all fasteners are shown 1 Transmi...

Page 125: ...ipped 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 d...

Page 126: ... 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 wit...

Page 127: ...ection 42 04 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 09 Brake Inspection 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 Safety Precautions 42 00 Brakes 42 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 129: ...unt ing 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 installa tion 7 Remove the upper mounting bracket strap cap screw and remove the air dryer from the vehicle 8 Place the air dryer on a bench and remove the remaining 6 capscrews 12 washers 6 Nylok nuts and...

Page 130: ...et Install the two previously marked cap screws four washers and two new Nylok nuts 08 09 95 f421383 1 2 3 4 5 9 10 11 12 13 14 15 17 18 19 21 22 23 24 25 10 10 10 10 10 10 6 7 8 8 8 20 16 1 5 16 x 4 1 2 Upper Mounting Bracket Capscrew 2 Upper Mounting Bracket Strap 3 5 16 Lockwasher 4 5 16 Nylok Nut 5 Upper Mounting Bracket 6 Housing 7 Nylok Nut 8 3 8 Special Washer 9 Desiccant Cartridge 10 O Rin...

Page 131: ...ean the inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge sealing rings 6 Inspect the end cover for physical damage then inspect all air line fittings for corrosion replace as necessary 7 Clean and inspect the bolt paying attention to the threads and O ring grooves IMPORTANT Use only the grease suppl...

Page 132: ...s and Twin air dryers NOTICE The WABCO System Saver air dryers can use ei ther a standard or oil coalescing desiccant car tridge When replacing the desiccant cartridge it is very important to use the same type of car tridge that was originally installed on the dryer Oil coalescing cartridges can be used in any applica tion but require more frequent service intervals every 1 to 2 years instead of e...

Page 133: ...dication of poor air dryer per formance 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 Workshop Manual for mounting instructions 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...

Page 134: ...om 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 m...

Page 135: ...l grease appears on the camshaft or flows from the grease relief See Fig 8 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 8 42 07 Meritor Camshaft Bracket...

Page 136: ...m whichever comes first The extended maintenance slack adjusters are lubricated dur ing the brake reline service interval For service and lubrication instructions see Group 42 of the Columbia Workshop Manual For slack adjusters with grease fittings and for oper ating temperatures above 40 F 40 C use a NLGI Grade 1 clay base grease or a NLGI Grade 1 or 2 lithium base grease For slack adjusters with...

Page 137: ...returning the vehicle to service 42 10 Brake Inspection IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold the vehicle per sonal injury or property damage may result 1 With the engine running and air pressure at cut out pressure set th...

Page 138: ...roke is too long Check the foundation brake components for wear or damage and repair as needed See Group 42 of the Columbia Workshop Manualfor inspection troubleshooting and repair procedures 4 Measure the applied chamber stroke See Table 1 for the proper stroke for the type of chamber being used If the stroke is too short the brakes may drag or will not fully apply Check for im proper operation o...

Page 139: ...Less than 1 3 4 44 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Dana Spicer Long Stroke 16L 2 51 20L 24L 24LS 2 1 2 64 30LS Long stroke design is indicated by a tag or embossing on the brake chamber Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers If type 36 chamber is used slack length should be les...

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Page 141: ...pection 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 Gear Inspection 46 06 Safety Precautions 46 00 Steering 46 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 143: ...ng 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 acci dent resulting in personal injury or property dam age Wear eye protection when changing the fluid and filter 1 Park the vehicle on a level surface shut down the e...

Page 144: ... 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 Remove the dipstick and check that power steering fluid is between ADD HOT and FULL HOT If necessary add enough ATF fluid that meets Dexron III or TES 389 specifications to bring the level up to the FULL HO...

Page 145: ...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 See Group 46 of the Columbia Workshop Man...

Page 146: ... leak age f462151 11 17 12 13 14 1 6 7 5 5 9 9 4 4 3 3 18 19 20 21 23 2 10 22 15 16 07 24 2009 8 8 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 Yok...

Page 147: ...e down the housing with brake cleaner to remove all remain ing dirt and debris IMPORTANT Only apply grease to the rack shaft on the driver side Do not apply grease to the teeth of the rack shaft Do not apply grease to the shaft on the passenger side 10 Turn the wheels all the way to the right to fully expose the driver side rack Without applying grease to the teeth of the rack shaft evenly apply a...

Page 148: ...t be engaged If all three barbs are not engaged after crimping re move and discard the clamp and install a new clamp Oetiker clamps must be adequately crimped and the bellows must be tightly secured to the gear housing to prevent moisture intrusion and corrosion 14 3 Using an Oetiker clamp tool like the one shown in Fig 8 crimp the small and large Oetiker bellows clamp ears until the 05 30 2012 f4...

Page 149: ...ice technician to complete the following steps If this type of tool is not ac cessible the alignment procedure must be done by a facility that has the appropriate tool When the alignment process requires that the steering wheel be pointed straight ahead align the steering rack on center pointers instead See Fig 11 20 1 Loosen the driver side tie rod jam nut If necessary hold the inner tie rod in p...

Page 150: ... there must be at least 1 2 inch 13 mm clearance between the wheels and stationary components and at least 3 4 inch 19 mm clearance between the wheels tires and moving components If this is not the case back out the stop bolts and adjust the jam nuts to limit the turning angles and to prevent possible contact with components 20 9 Tighten the stop bolt jam nuts 80 to 120 lbf ft 108 to 163 N m NOTIC...

Page 151: ...MOP Number Fuel Filter Replacement 47 01 Fuel Separator Sight Bowl Cleaning and Element Replacement 47 02 Fuel Tank Band Nut Tightening 47 03 Safety Precautions 47 00 Fuel 47 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 153: ...fuel system have a fire extinguisher within easy reach 1 Drain the fuel separator 2 Unscrew the sight bowl from the fuel separator 3 Wipe the sight bowl clean using a soft cloth 4 Lubricate the gasket with a film of oil and rein stall it on the sight bowl If the gasket appears dry rotted or damaged replace the gasket 5 Lightly lubricate the threads on the sight bowl with oil then thread the sight ...

Page 154: ...Mounting Brackets 4 O Ring when equipped with heater 5 Stainless Steel V Clamp when equipped with heater 6 Heater Assembly 7 Gasket 8 Sight Bowl Heater Rod 9 Sight Bowl Assembly 10 Vacuum Breaker Drain Valve Fig 1 ConMet Fuel Separator Fuel 47 Columbia Maintenance Manual September 2015 47 2 ...

Page 155: ...nance Operation MOP MOP Number CAT CGI Bellows Replacement 49 02 Exhaust System Inspection Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 157: ... installed on the vehicle See Group 49 of the Columbia Workshop Manual for replace ment procedures 2 Inspect the exhaust flex hose see Fig 1 for leakage wear or damage Replace with new parts if replacement is needed 3 Check for leakage at the V band coupling which attaches the exhaust pipe to the turbocharger exhaust outlet See Fig 2 4 If leakage exists tighten the nut on the V band coupling 85 lb...

Page 158: ... 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 the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leaka...

Page 159: ...ousing 7 DPF Outlet Temperature Sensor 8 Exhaust Outlet Marmon Fitting 9 DPF Outlet Pressure Sensor Fig 4 Typical After Treatment Device 02 24 2011 f490456 1 1 2 3 4 5 6 5 3 7 8 9 3 10 1 Clamp 2 Inlet Pipe 3 U Clamp 4 Forward Pipe Support Brace 5 Slip Clamp 6 CGI Bellows 7 Center Pipe Support Brace 8 Center Pipe 9 Clamp 10 Outlet Pipe Fig 5 CAT EPA07 Exhaust Installation with CGI Bellows Exhaust 4...

Page 160: ... Fig 6 5 On the workbench remove the CGI bellows from the exhaust piping Do not damage the piping NOTE The following step and its substeps is to be done without the bellows installed This will align the pipes so that the bellows can be installed correctly 6 Install the CGI piping without CGI bellows and align piping 6 1 Attach the aft CGI pipe to the ATD 6 2 Attach the forward CGI pipe to the en g...

Page 161: ...ipe See Fig 10 for proper installation 14 Slide the end of the forward CGI pipe into the bellows and properly align the pipe 15 Secure the forward CGI pipe to the engine and any CGI pipe support brackets 02 24 2011 f490456 1 1 2 3 4 5 6 5 3 7 8 9 3 10 1 Clamp 2 Inlet Pipe 3 U Clamp 4 Forward Pipe Support Brace 5 Slip Clamp 6 CGI Bellows 7 Center Pipe Support Brace 8 Center Pipe 9 Clamp 10 Outlet P...

Page 162: ...1 lbf ft 15 N m 18 Start the engine and check for exhaust leaks Tighten any clamps as needed 02 23 2011 f490458 A A 2 1 3 A At least 7 16 inch 10 mm 1 Forward CGI Pipe 2 CGI Bellows 3 Aft CGI Pipe Fig 9 CGI Bellows Installation 02 08 2010 f490417 5 4 3 2 1 1 CGI Bellows 2 Slip Clamp 3 Retaining Ring 4 Graphite Gasket 5 Forward CGI Pipe Fig 10 Forward Facing Slip Clamp Installation Exhaust 49 Colum...

Page 163: ...Title of Maintenance Operation MOP MOP Number Mirror Folding Check 60 01 Cab 60 Index Alphabetical Columbia Maintenance Manual December 2011 ...

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Page 165: ...in mirrors make sure that the mirrors fold freely on the pivot points Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold away feature of the mirror Cab 60 Columbia Maintenance Manual December 2011 60 1 ...

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Page 167: ...Title of Maintenance Operation MOP MOP Number Door Seal Door Latch Door Hinge and Door Check Lubrication 72 01 Doors 72 Index Alphabetical Columbia Maintenance Manual December 2011 ...

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Page 169: ...t on or after 8 1 2005 the door hinge center pin is recessed in the top loop of the hinge bracket There is a dimple in the top and bot tom loop of the hinge bracket See Ref A of Fig 1 Do not lubricate this type of hinge Lubrication could adversely affect the performance of the bushings In addition some lubricants may not be compatible with the hinge bushings Door Hinges on Vehicles Built Before 8 ...

Page 170: ...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 Doors 72 Columbia Maintenance Manual December 2011 72 2 ...

Page 171: ...intenance Operation MOP MOP Number Air Conditioner Inspection 83 01 Air Filter Replacement 83 02 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical Columbia Maintenance Manual September 2015 ...

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Page 173: ...umbia Workshop Manual 4 On a Sanden A C compressor use a feeler gauge to check that the drive plate clutch clear ance is 0 016 to 0 030 inch 0 4 to 0 8 mm See Fig 1 If the drive plate clutch requires adjust ment see Group 83 of the Columbia Work shop Manual On a Climate Control A C compressor place a feeler gauge between the air conditioner com pressor clutch and the pulley to check the com presso...

Page 174: ... See Fig 3 3 Note the direction of the arrow on the air filter cover then remove the cover and the attached filter 4 Remove the air filter from the air filter cover Dis card the air filter 5 Attach a new air filter to the air filter cover Make sure the arrow on the filter is pointing in the same direction as the arrow on the cover 6 Install the air filter and air filter cover in the HVAC air intak...

Page 175: ...acement 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 1 Turn off the engine apply the brakes and ch...

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Page 177: ...Title of Maintenance Operation MOP MOP Number Hood Rear Support Lubrication 88 01 Hood Grille and Cab Fenders 88 Index Alphabetical Columbia Maintenance Manual December 2011 ...

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Page 179: ...sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Grease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Shell Retinax LC Grease Texaco Starplex 2 Table 1 Approved Suppliers of Multi Purpose Lithium Grease Hood Grille and Cab Fenders 88 Colu...

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