Freightliner Columbia Maintenance Manual

®COLUMBIA STI-409-2 A24-01033-000 Maintenance Manual Freightliner Columbia Maintenance Manual Full download: http://manualplace.com/download/freightliner-columbia-maintenance-manual/ This is the cut pages sample. Download all 140 page(s) at: ManualPlace.com

DaimlerTrucksNorthAmericaLLC 4747N.ChannelAve.

COLUMBIAMAINTENANCEMANUAL Models:CL112 CL120 STI-409-2(9/12) Publishedby

Portland,OR97217 PrintedinU.S.A.

Foreword

Scheduledmaintenanceprovidesakeyelementforthesafeoperationofyourvehicle.Aproper maintenanceprogramalsohelpstominimizedowntimeandtosafeguardwarranties.Thismaintenancemanualprovidesinformationnecessaryforyearsofsafe,reliable,andcost-efficientvehicle operation.

IMPORTANT:Themaintenanceoperationsinthismanualare notall-inclusive.Alsoreferto othercomponentandbodymanufacturers’instructionsforspeciﬁcinspectionandmaintenanceinstructions.

Performtheoperationsinthismaintenancemanualatscheduledintervals.Performthepretripand post-tripinspections,anddaily/weekly/monthlymaintenance,asoutlinedinthevehicledriver’s manual.Majorcomponents,suchasengines,transmissions,andrearaxles,arecoveredintheirown maintenanceandoperationmanuals,thatareprovidedwiththevehicle.Performanymaintenance operationslistedattheintervalsscheduledinthosemanuals.YourFreightlinerDealershiphasthe qualiﬁedtechniciansandequipmenttoperformthismaintenanceforyou.Theycanalsosetupa scheduledmaintenanceprogramtailoredspeciﬁcallytoyourneeds.Optionally,theycanassistyouin learninghowtoperformthesemaintenanceprocedures.

IMPORTANT:Descriptionsandspeciﬁcationsinthismanualwereineffectatthetimeof printing.FreightlinerTrucksreservestherighttodiscontinuemodelsandtochange speciﬁcationsordesignatanytimewithoutnoticeandwithoutincurringobligation.

Descriptionsandspeciﬁcationscontainedinthispublicationprovidenowarranty,expressed orimplied,andaresubjecttorevisionandeditionswithoutnotice.

Refertowww.Daimler-TrucksNorthAmerica.comandwww.FreightlinerTrucks.comformoreinformation,orcontactDaimlerTrucksNorthAmericaLLCattheaddressbelow.

EnvironmentalConcernsandRecommendations

NOTICE:PartsReplacementConsiderations

Wheneveryouseeinstructionsinthismanualtodiscardmaterials,youshouldattempttoreclaimand recyclethem.Topreserveourenvironment,followappropriateenvironmentalrulesandregulations whendisposingofmaterials.

DaimlerTrucksNorthAmericaLLC ServiceSystemsandDocumentation(POC-SSD) P.O.Box3849 Portland,OR97208–3849

Donotreplacesuspension,axle,orsteeringparts(suchassprings,wheels,hubs,andsteeringgears) withusedparts.Usedpartsmayhavebeensubjectedtocollisionsorimproperuseandhave undetectedstructuraldamage.

Allrightsreserved.Nopartofthispublication,inwholeorinpart,maybetranslated,reproduced, storedinaretrievalsystem,ortransmittedinanyformbyanymeans,electronic,mechanical, photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofDaimlerTrucksNorth AmericaLLC.DaimlerTrucksNorthAmericaLLCisaDaimlercompany.

DescriptionsofServicePublications

DaimlerTrucksNorthAmericaLLCdistributesthefollowingmajorservicepublicationsinpaperandelectronic (viaServicePro®)formats.

Workshop/Service Manual

Workshop/servicemanualscontainserviceandrepairinformationforallvehicle systemsandcomponents,exceptformajorcomponentssuchasengines,transmissions,andrearaxles.Eachworkshop/servicemanualsectionisdividedinto subjectsthatcanincludegeneralinformation,principlesofoperation,removal, disassembly,assembly,installation,andspeciﬁcations.

MaintenanceManual

Maintenancemanualscontainroutinemaintenanceproceduresandintervalsfor vehiclecomponentsandsystems.Theyhaveinformationsuchaslubrication proceduresandtables,fluidreplacementprocedures,fluidcapacities,specifications,andproceduresforadjustmentsandforcheckingthetightnessoffasteners.Maintenancemanualsdonotcontaindetailedrepairorserviceinformation.

Driver’s/Operator’s Manual

Driver’s/operator’smanualscontaininformationneededtoenhancethedriver’s understandingofhowtooperateandcareforthevehicleanditscomponents. Eachmanualcontainsachapterthatcoverspretripandpost-tripinspections, anddaily,weekly,andmonthlymaintenanceofvehiclecomponents.

Driver’s/operator’smanualsdonotcontaindetailedrepairorserviceinformation.

ServiceBulletins

Servicebulletinsprovidethelatestservicetips,ﬁeldrepairs,productimprovements,andrelatedinformation.Someservicebulletinsareupdatestoinformationintheworkshop/servicemanual.Thesebulletinstakeprecedenceover workshop/servicemanualinformation,untilthelatterisupdated;atthattime,the bulletinisusuallycanceled.Theservicebulletinsmanualisavailableonlyto dealers.Whendoingserviceworkonavehiclesystemorpart,checkforavalid servicebulletinforthelatestinformationonthesubject.

IMPORTANT:Beforeusingaparticularservicebulletin,checkthecurrent servicebulletinvaliditylisttobesurethebulletinisvalid.

PartsTechnicalBulletins

Partstechnicalbulletinsprovideinformationonparts.Thesebulletinscontain listsofpartsandBOMsneededtodoreplacementandupgradeprocedures.

Web-basedrepair,service,andpartsdocumentationcanbeaccessedusingthefollowingapplicationsonthe AccessFreightliner.comwebsite.

ServicePro

ServicePro® providesWeb-basedaccesstothemostup-to-dateversionsofthe publicationslistedabove.Inaddition,theServiceSolutionsfeatureprovidesdiagnosticassistancewithSymptomsSearch,byconnectingtoalargeknowledge basegatheredfromtechniciansandservicepersonnel.Searchresultsforboth documentsandservicesolutionscanbenarrowedbyinitiallyenteringvehicle identiﬁcationdata.

PartsPro

EZWiring

PartsPro® isanelectronicpartscatalogsystem,showingthespeciﬁedvehicle’s buildrecord.

Introduction

EZWiring™ makesFreightliner,Sterling,WesternStar,ThomasBuiltBuses,and FreightlinerCustomChassisCorporationproducts’wiringdrawingsandﬂoating pinlistsavailableonlineforviewingandprinting.EZWiringcanalsobeaccessedfromwithinPartsPro.

ColumbiaMaintenanceManual,February2010 I–1

Introduction

DescriptionsofServicePublications

Warranty-relatedserviceinformationavailableontheAccessFreightliner.comwebsiteincludesthefollowing documentation.

RecallCampaigns

Recallcampaignscoversituationsthatinvolveserviceworkorreplacementof partsinconnectionwitharecallnotice.Thesecampaignspertaintomattersof vehiclesafety.Allrecallcampaignsaredistributedtodealers;customersreceive noticesthatapplytotheirvehicles.

FieldServiceCampaigns

Fieldservicecampaignsareconcernedwithnon-safety-relatedserviceworkor replacementofparts.Allﬁeldservicecampaignsaredistributedtodealers;customersreceivenoticesthatapplytotheirvehicles.

I–2 ColumbiaMaintenanceManual,February2010

Foranexampleofa ColumbiaMaintenanceManual page,see Fig.1 f020127 A B C D E Cooling 11/28/2001 Columbia Maintenance Manual, December 2001 20−01 Coolant Replacement 20−02 Cooling Fan Inspection 20 A.MaintenanceOperationNumberconsistsoftheGroupNumberfollowedbytheSequenceNumber B.GroupTitle C.GroupNumber D.ReleaseDate E.GroupNumber/PageNumber Fig.1,ExampleofaColumbiaMaintenanceManualPage Introduction PageDescription ColumbiaMaintenanceManual,February2010 I–3

GroupNo.GroupTitle 00...................... GeneralInformation 01................................ Engine 09..............................Air Intake 13.........................Air Compressor 15................... AlternatorsandStarters 20................... EngineCooling/Radiator 25................................ Clutch 26...........................Transmission 31............. FrameandFrameComponents 32............................ Suspension 33............................. FrontAxle 35............................. RearAxle 40........................ WheelsandTires 41.............................. Driveline 42................................ Brakes 46............................... Steering 47................................. Fuel 49............................... Exhaust 60..................................Cab 72................................ Doors 83................. HeaterandAirConditioner 88.............. Hood,Grille,andCabFenders Introduction MaintenanceManualContents I–4 ColumbiaMaintenanceManual,February2010

TitleofMaintenanceOperation(MOP)MOPNumber

DeterminingScheduledMaintenanceIntervals 00–01

InitialMaintenance(IM)Operations 00–05

LubricationandFluidLevelCheck 00–04

M1MaintenanceIntervalOperations 00–06

M2MaintenanceIntervalOperations.................................................... 00–07

M3MaintenanceIntervalOperations 00–08

MaintenanceOperationSetsTable ..................................................... 00–09

Metric/U.S.CustomaryConversionTables 00–12

NoiseEmissionControlsMaintenance 00–10

ServiceScheduleTable 00–02

TorqueSpeciﬁcationsTables 00–13

VehicleMaintenanceScheduleTables................................................... 00–03

VeriﬁcationofInspectionsLog 00–11

00

ColumbiaMaintenanceManual,September2012

GeneralInformation

Index,Alphabetical

DeterminingScheduled MaintenanceIntervals

PerformingregularmaintenanceonyourFreightliner willhelpensurethatyourFreightlinerdeliverssafe reliableserviceandoptimumperformanceforyears tocome.Failuretofollowaregularmaintenanceprogramcanresultininefficientoperationandunscheduleddowntime.

Todeterminethecorrectmaintenanceintervalsfor yourvehicleyoumustﬁrstdeterminethetypeofserviceorconditionsthevehiclewillbeoperatingin. Generally,mostvehiclesoperateunderconditions thatfallwithinoneofthefourtypesofservicedescribed.Beforeplacingyournewvehicleinservice, determinethetypeofservice(ServiceScheduleI,II, III,orIV)thatappliestotheintendeduseofthevehicle.Afterdeterminingthevehicle’stypeofservice, refertotheservicescheduletableorthevehicle maintenancescheduletable,todeterminehowoften maintenanceshouldbeperformed.

Whenthevehiclereachesthedistancegivenfora maintenanceinterval,seetheMaintenanceInterval OperationTableforalistofthemaintenanceoperationstobeperformedatthatmaintenanceinterval. Usethemaintenanceoperationreferencenumbersto ﬁnddetailedinstructionsinthemanualoneachoperation.

TypesofService

ServiceScheduleI (severeservice)appliestovehiclesthatannuallytravellessthan6000miles(10 000kilometers) or thatoperateundersevereconditions.Examplesofsevereservice,ScheduleIusage include:operationonextremelypoorroadsorwhere thereisheavydustaccumulation;constantexposure toextremehot,cold,salt-air,orotherextremeclimates;frequentshort-distancetravel;constructionsiteoperation;cityoperation(ﬁretruck);orfarm operation.

ServiceScheduleII (short-haultransport)appliesto vehiclesthatannuallytravellessthan60,000miles (100000kilometers)andoperateundernormalconditions.ExamplesofScheduleIIusageare:operationprimarilyincitiesanddenselypopulatedareas; localtransportwithinfrequentfreewaytravel;orhigh percentageofstop-and-gotravel.

ServiceScheduleIII (long-haultransport)isforvehiclesthatannuallytravel morethan 60,000miles

(100000kilometers)withminimalcityorstop-and-go operation.ExamplesofScheduleIIIusageare:regionaldeliverythatismostlyfreewaymiles;interstate transport;oranyroadoperationwithhighannual mileage.

ServiceScheduleIV (longhaultransportforOptimizedVehicleConﬁguration)isforvehiclesthatannuallytravel over 60,000miles(100000km) and meetthefollowingqualiﬁcations:

• Meritor15-1/2inchdampened/ceramicLite PedalLTDclutchwithsealedreleasebearing.

• Synthetictransmissionﬂuidusedintransmission.

• MeritorFF–961orFF–981frontaxle(12,000lb. capacity)withsyntheticlubricant.

• Frontsuspensionwithmaintenance-freerubber bushingsfor12,000lb.capacitysuspension.

• MeritorRPLseries,orDanaSpicerSPLseries drivelineU-joints.

• Syntheticlubricantusedinrearaxle.

• EquippedwithanyFreightlinerAirLinersuspension.

• EquippedwithMeritorQ-Plusextended-lube cambrakesandautomaticslackadjusters,front andrear.

• StandardbrakesystempackageincludingBendixAD-9airdryer—mountedontheright-hand framerail,locateddirectlybehindthefront bumper—withheater,andaBendixaircompressor.

• TRWTAS65powersteering.

NOTE:Maintenanceinstructionsinthismanual arebasedonaveragevehicleuseandnormal operatingconditions.Unusualvehicleoperating conditionsmayrequireserviceatmorefrequent intervals.

GeneralInformation 00 DeterminingScheduledMaintenanceIntervals:00–01 ColumbiaMaintenanceManual,September2012 00/1

ScheduleI* (SevereService) vehiclesthatannuallytravelless than6000miles(10000km)

ScheduleII† (Short-HaulTransport) vehiclesthatannuallytravelless than60,000miles(100000km)

ScheduleIII† (Long-HaulTransport) vehiclesthatannuallytravelover 60,000miles(100000km)

ScheduleIV† (Long-HaulTransportfor OptimizedVehicleConﬁguration) vehiclesthatannuallytravelover 60,000miles(100000km)

MaintenanceInterval

FrequencyMileskmHours

InitialMaintenance(IM)ﬁrst1000160050 Maintenance1(M1)every1000160050 Maintenance2(M2)every50008000500 Maintenance3(M3)every15,000240001500

InitialMaintenance(IM)ﬁrst10,00016000 Maintenance1(M1)every10,00016000 Maintenance2(M2)every50,00080000 Maintenance3(M3)every150,000240000

InitialMaintenance(IM)ﬁrst25,00040000 Maintenance1(M1)every25,00040000 Maintenance2(M2)every100,000161000 Maintenance3(M3)every300,000483000

* ForScheduleI(severeservice)vehiclesequippedwithanhourmeter,usemaintenanceintervalsbasedonhoursofoperationratherthandistancetraveled.

† UseScheduleI(severeservice)maintenanceintervalsforvehiclesthatoperateundersevereconditions,suchasextremelypoorroads,heavydustaccumulation,extremeclimate,frequentshortdistancetravel,construction-siteoperation,cityoperation(garbagetruck),orfarmoperation.

Table1,ServiceSchedule

ServiceScheduleMaintenanceIntervalOperation

00 ServiceScheduleTable:00–02 ColumbiaMaintenanceManual,September2012 00/2 Freightliner Columbia Maintenance Manual Full download: