Checklist B – 5,000 to 100,000 Miles
When service is completed, write date in the box in the column for that mileage.
Miles in Thousands
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100Level A - Every day
1 / Check engine lube oil level
2 / Check engine coolant level
3 / Check Allison WTB500 transmission fluid level
4 / Check power steering fluid level
5 / Check engine air intake piping for loose clamps, cracked hoses, etc.(visually)
6 / Check drive belts condition and tension (visually)
7 / Check pipes and hoses for security, damage and chaffing
8 / Check fluid leaks in engine compartment, wheel hubs etc.
9 / Check tire inflation, use "tire thumper"
10 / Check tire condition
11 / Check tire pressure (visually)
12 / Check wheel nuts for tightness (visually)
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
13 / Check wheel rims for cracks and deformation
14 / Check suspension ride height (visually)
15 / Check fuel level
16 / Check that emergency windows are closed and locked
17 / Check air cleaner restriction indicator
18 / Check Cummins engine crankcase breather tube (visually)
19 / Drain Cummins engine fuel filter
20 / Drain Caterpillar engine primary fuel filter
Level B - Every 5,000 miles
1 / Check axle oil levels
2 / Check batteries electrolyte level
3 / Check windshield washer liquid level
4 / Check tire pressure (with gauge)
5 / Check dashboard gauges and warning lights operation
6 / Check drive belts wear and tension
7 / Check suspension ride height (measure)
8 / Check screen in air intake for radiator
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
9 / Check engine rear mounts adjustment
10 / Check that emergency exits (windows and roof hatches) open, close and latch properly
11 / Drain air tanks
12 / Lubricate steering king-pins unless "non-lubricate" type knuckle
13 / Lubricate intermediate lever of steering system
14 / Lubricate HVAC compressor pivot bushings
15 / Torque check security of axles and suspension components
16 / Torque check wheel nuts (with torque wrench)
17 / Check acceleration/deceleration performance (2.4K)
18 / Check engine exhaust system (2.4K)
19 / Clean out sediment in fuel pre-filter
20 / Check brake pedal free play
21 / Clean the front and rear axles as well as the wheel assembly
22 / Check free play of the steering wheel
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
23 / Check torque of the battery terminals and add distilled water to batteries as needed
24 / Check torque of the connecting bolts on the chassis frame
25 / Clean/replace the core of the air cleaner/filter.
26 / Inspect complete brake system operation
27 / Lubricate slack adjusters, if applicable
28 / Transmission and wet clutch service. See manufacturer’s manual at for additional information.
29 / Replace fuel filter and oil-water separator
30 / Check lubricant level of the reduction final drive and clean the ventilation plug
31 / Check for any loosening or damage of connecting components of steering gear
32 / Check tightness of the various components in the hydraulic system
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
33 / Check tightness and operation of cross-shaft bearings on the transmission shaft and on the flange nuts
34 / Check Eaton transmission fluid level and leakage
Level C - Every 10,000 miles
1 / Check ZF Astronic transmission fluid level
2 / Check engine coolant SCA (supplemental coolant additives) concentration level
3 / Check engine coolant antifreeze concentration level
4 / Check engine air cleaner restriction indicator operation
5 / Check Caterpillar engine automatic belt tensioner position
6 / Check Caterpillar engine cylinder head grounding stud (clean/tighten)
7 / Check steering ball-joints for excessive play
8 / Check electric cable connections for corrosion and tightness
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
9 / Check general condition of the brake assemblies for damage corrosion
10 / Check brake lining wear
11 / Check brake chamber condition and leaks
12 / Check brake system valves, lines and fittings for leaks
13 / Check suspension air bellows external condition/leaks
14 / Check shock absorbers for external damage and leakage
15 / Check air dryer operation
16 / Check all lights, interior and exterior
17 / Check headlight beam settings
18 / Check windshield wiper and washer condition and operation
19 / Check automatic passenger door operation and adjustment
20 / Check lavatory operation, toilet, sink etc.
21 / Check foot brake valve operating mechanism
22 / Clean Caterpillar engine crankcase breather
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
23 / Change Cummins engine fuel filter (at least every 6 months)
24 / Change Caterpillar engine primary and secondary fuel filters
25 / Change lube oil and filter
26 / Lubricate all body components such as door locks, latches and linkages (with oil)
27 / Lubricate windshield wiper linkage pivot points (with oil)
28 / Torque check security of all steering components
29 / Torque check all hose clamps
30 / Torque check security of exhaust system
31 / Check driveshaft U-joint and slip-joint for wear
32 / Replenish First-Aid kit
Level D - Every 20,000 miles
1 / Perform air brake system functional check
2 / Check throttle control
3 / Check toe of front wheels
4 / Check drive axle breather for freedom of obstruction
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
5 / Check air suspension leveling valves for wear and damage
6 / Check emergency window release tension (20 lbs)
7 / Check all hoses (thoroughly)
8 / Check Caterpillar engine electronic unit injector (adjust)
9 / Check Caterpillar engine valve lash (adjust)
10 / Check Caterpillar engine valve actuators (adjust)
11 / Clean cooling radiator and intercooler
12 / Change CAT CX31 transmission fluid (at least every year)
13 / Change CAT CX31 transmission fluid filters (main and lube) (at least every year)
14 / Lubricate propeller shaft universal joints
15 / Lubricate throttle control pivot points (with oil)
16 / Lubricate automatic passenger door pillar (requires needle tip grease gun adapter)
17 / Lubricate automatic passenger door guide rod end
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
18 / Lubricate automatic passenger door locking cams with Vaseline
19 / Lubricate passenger door(s) rubber seals with silicone spray
20 / Lubricate emergency window release handle, cable and latches
21 / Torque check security of engine
22 / Torque check security of transmission
23 / Torque check security of air compressor
Level E - Every 45,000 miles
1 / Change Allison WTB500 transmission fluid filters (main and lube) (at least every 2 years)
Level F - Every 60,000 miles
1 / Perform minor inspection of propeller shaft
2 / Check front axle axial clearance between steering knuckle and carrier center
3 / Check alternator voltage regulator brushes
4 / Check air system pressure protection valve settings
Level / Description / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 55 / 60 / 65 / 70 / 75 / 80 / 85 / 90 / 95 / 100
5 / Check automatic passenger door locking cams for wear
6 / Adjust engine valves and injectors
7 / Change drive axle oil
8 / Change power steering filter
9 / Change air dryer cartridge(at least every year)
10 / Clean pressure wash engine compartment
11 / Clean crankcase breather assembly
12 / Torque check security of turbocharger and exhaust system
Level G - Every 100,000 miles
1 / Change drive axle oil (ok to 240K mi with Dana-approved synth lubricant)
Page 1 of 11
LZ Bus Falcon 45 Maintenance Schedule Rev Draft 1/11/11
Page 1 of 11
LZ Bus Falcon 45 Maintenance Schedule Rev Draft 1/11/11