FREIGHTLINER CORONADO Trucks Service Repair Manual

CORONADO WORKSHOP MANUAL Models: Coronado 122 Coronado SD122 Coronado 132 STI-495, S2 (12/10P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword The purpose of this manual is to assist the service technician when the vehicle is serviced. Major drivetrain component service information is not included in this manual, but is located in each manufacturer’s service manual. For service and repair information of major components, refer to the OEMs website. A listing of many OEM websites can be found in Section 00.02. The list also includes OEM websites for a number of other vehicle component or system providers. Instructions and procedures are those recommended by Freightliner Trucks or the component manufacturer. Maintenance schedules and additional service information are included in the Coronado ® Maintenance Manual. 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. IMPORTANT: 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. © 2010 Daimler Trucks North America LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a Daimler company. Daimler Trucks North America LLC Service Systems and Documentation (CVI-SSD) P.O. Box 3849 Portland, OR 97208-3849

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro ® ) formats. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, trans- missions, and rear axles. For service and repair information of major components, refer to the OEMs website. A listing of many OEM websites can be found in Section 00.02. Each workshop/service manual section is divided into sub- jects that can include general information, principles of operation, removal, dis- assembly, assembly, installation, and specifications. Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information. Driver’s/Operator’s Manual 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 pre-trip and post-trip inspections, and daily, weekly, and monthly maintenance of vehicle components. Driver’s/ operator’s manuals do not contain detailed repair or service information. Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve- 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 di- agnostic 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 ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro. Introduction Descriptions of Service Publications Coronado Workshop Manual, Supplement 1, June 2010 I–1

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. Introduction Descriptions of Service Publications I–2 Coronado Workshop Manual, Supplement 1, June 2010

For an example of a Coronado ® Workshop Manual page, see Fig. 1. B C A F G D E f020174 Fastener Replacement When replacing fasteners, use only identical bolts, washers, and nuts; they must be the same size, strength, and finish as originally specified. When replacing graded (or metric class) bolts and capscrews, use only fasteners that have the manufacturer’ s trademark or identification on the bolt head; do not use substandard bolts. Inferior , counterfeit fasteners are difficult to identify; buy your fasteners from a reputable supplier . Fastener Selection and Installation When using nuts with bolts, use a grade (or class) of nut that matches the bolt. When installing non-flanged fasteners, use hardened steel flatwashers under the bolt (capscrew) head, and under the hexnut or locknut. For bolts 4 inches (100 mm) or less in length, make sure that at least 1-1/2 threads and no more than 5/8-inch(16-mm) bolt length extends through the nut after it has been tightened. For bolts longer than 4 inches (100 mm), allow a minimum of 1-1/2 threads and a maximum of 3/4-inch(19-mm) bolt length. Never hammer or screw bolts into place. Align the holes of the parts being attached, so that the nut and bolt surfaces are flush against the washers, and the washers are flush against the parts. When installing fasteners in aluminum or plastic parts with threaded holes, start the fasteners by hand, to ensure straight starting and to prevent damaged threads. Do not use lockwashers (split or toothed) next to aluminum surfaces. When installing studs that do not have an interfer- ence fit, install them with thread locking compound, as instructed in this subject. When installing parts that are mounted on studs, use free-spinning(non-locking) nuts and helical-spring (split) lockwashers or internal-tooth lockwashers. Do not use locknuts, because they tend to loosen the studs during removal. Do not use plain washers (flatwashers). Do not use lockwashers and flatwashers in combination (against each other); each defeats the other’ s purpose. Use stainless steel fasteners against chrome plating, unpainted aluminum, or stainless steel. Fastener Tightening Before installing fasteners, clean all fastener (and parts) threads, and all surfaces being clamped. To ensure they are always torqued accurately , Freightliner recommends that all fasteners be lubricated with oil (unless specifically instructed to install them dry), then torqued to the values for lubricated- and plated-thread fasteners. When locking compound or antiseize compound is recommended for a fastener , the compound acts as a lubricant, and oil is not needed. Bring parts and fasteners into contact, with no gaps between them, before using a torque wrench to tighten fasteners to their final torque values. Tighten the nut, not the bolt head. This will givea truer torque reading by eliminating bolt body friction. Always use a torque wrench to tighten fasteners, and use a slow, smooth, even pull on the wrench. Do not overtorque fasteners; overtightening causes perma- nent stretching of the fasteners, which can result in breakage of the parts or fasteners. If specific torque values are not given for counter- sunk bolts, use the torque value for the corresponding size and grade of regular bolt, as given in Speci- fications 400. . Always follow the torque sequence or torque interval when provided, to ensure that clamping forces are even, and parts and fasteners are not distorted. Thread Locking Compound Application When the use of thread locking compound is recommended or desired, for studs, capscrews, and bolts with a thread diameter of 1 inch (25 mm) or less, use Loctite 271 or Perma-Lok HM-128. For thread diameters over 1 inch (25 mm), use Loc- tite 277. Threaded Fasteners 00.04 General Instructions 100/1 Coronado Workshop Manual, Supplement 0, January 2010 07/20/2009 A. Section Title B. Section Number (made up of the Group Number—first two digits, followed by a sequence number—last two digits) C. Subject Title D. Manual Title E. Release (Supplement) Date F. Subject Number G. Subject Page Number Fig. 1, Example of a Cascadia Workshop Manual Page Introduction Page Description Coronado Workshop Manual, Supplement 1, June 2010 I–3

Group No. Group Title 00 ...................... General Information 01 ................................ Engine 09 .............................. Air Intake 13 .......................... Air Compressor 20 ................... Engine Cooling/Radiator 25 ................................. Clutch 26 ........................... Transmission 30 .......................... Throttle Control 32 ............................. Suspension 33 .............................. Front Axle 35 .............................. Rear Axle 40 ........................ Wheels and Tires 41 ............................... Driveline 42 ................................ Brakes 46 ............................... Steering 47 .................................. Fuel 49 ............................... Exhaust 54 .......... Electrical, Instruments, and Controls 60 .................................. Cab 72 ................................. Doors 82 .............. Windshield Wipers and Washer 83 ................. Heater and Air Conditioner 88 .............. Hood, Grille, and Cab Fenders 91 ................ Seats and Restraint Systems 98 ................................. Paint Introduction Workshop Manual Contents I–4 Coronado Workshop Manual, Supplement 1, June 2010

Federal Motor Vehicle Safety Standard 115 specifies that all vehicles sold in the U.S. be assigned a 17- character Vehicle Identification Number (VIN). Using a combination of letters and numerals, the VIN de- fines the manufacturer, model, and major characteris- tics of the vehicle. See Table 1 for the character positions of a typical Freightliner VIN, 1FUPABAV11PA12345. The VIN can be found on the Vehicle Specification Decal (see the Driver’s Manual for decal location), and the last six digits (designating the chassis serial number) are stamped into the metal frame. Each product line has its own model list; that is, positions 5 and 6 are product-specific. For example, the code AB in positions 5 and 6 for a Freightliner vehicle indicates an FLD112 conventional truck. Code AB in the same position for a FCCC chassis vehicle represents and MB45 chassis. For all vehicles, a check digit (9th character) is deter- mined by assignment of weighted values to the other 16 characters. These weighted values are processed through a series of equations designed to check validity of the VIN and to detect VIN alteration. NOTE: Always specify the VIN when ordering parts. Seventeen-Character Vehicle Identification Number (VIN) Typical VIN 1FU P AB AV 1 1 P A12345 Character Position 1, 2, 3 4 5, 6 7, 8 9 10 11 12–17 Code Description World Manufacturer Identification Chassis Configuration Model, Cab, GVWR Engine, Brakes Check Digit Calculation Model Year Build Location Production Serial Number Decoding Table * Table 2 Table 3 Table 4 Table 5 — Table 6 Table 7 — * For corresponding decoding information, see the applicable tables in this subject. Table 1, Seventeen-Character Vehicle Identification Number (VIN) VIN Positions 1, 2, and 3 (World Manufacturer Identification) Code Vehicle Manufacturer Vehicle Make Vehicle Type 1FU Freightliner, U.S.A. Freightliner Truck-Tractor 1FV Freightliner, U.S.A. Freightliner Incomplete Vehicle 3AK Daimler AG, Mexico Freightliner Truck-Tractor 3AL Daimler AG, Mexico Freightliner Incomplete Vehicle RSA NAI, Saudi Arabia Freightliner Incomplete Vehicle RSB NAI, Saudi Arabia Freightliner Truck-Tractor Table 2, VIN Positions 1, 2, and 3 (World Manufacturer Identification) VIN Position 4 (Chassis Configuration) Code Chassis A 4 x 2 Truck B 4 x 2 Truck-Tractor C 8 x 8 Truck D 4 x 4 Truck E 4 x 4 Truck-Tractor VIN Position 4 (Chassis Configuration) Code Chassis F 6 x 2 Truck G 6 x 2 Truck-Tractor H 6 x 4 Truck J 6 x 4 Truck-Tractor K 6 x 6 Truck Vehicle Identification Numbering System 00.01 VIN Information Coronado Workshop Manual, Supplement 5, June 2012 050/1

VIN Position 4 (Chassis Configuration) Code Chassis L 6 x 6 Truck-Tractor M 8 x 4 Truck N 8 x 4 Truck-Tractor P 8 x 6 Truck R 8 x 6 Truck-Tractor S 10 x 4 Truck T 10 x 4 Truck-Tractor U 10 x 6 Truck VIN Position 4 (Chassis Configuration) Code Chassis V 10 x 6 Truck-Tractor W 12 x 4 Truck X Glider Y 8 x 2 Truck Z 14 x 4 Truck 1 12 x 6 Truck Table 3, VIN Position 4 (Chassis Configuration) VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model Cab GVWR AA FLB Glider COE Glider AB FLD112 Conventional Class 7 AC FLD112 Conventional Class 8 AD FLD112 Glider Conventional Glider AE FLD112 SD Conventional Class 8 AF FLD112 SD Glider Conventional Glider AG FLD120 Conventional Class 7 AH FLD120 Conventional Class 8 AJ FLD120 Glider Conventional Glider AK FLD120 SD Conventional Class 7 AL FLD120 SD Conventional Class 8 AM FLD120 SD Glider Conventional Glider AN FLD132 XL Classic Conventional Class 7 AP FLD132 XL Classic Conventional Class 8 AR FLD132 XL Glider Conventional Glider AS FLD120 Military Conventional Class 7 AT FLD120 Military Conventional Class 8 AU FLD120 Military Glider Conventional Glider AV Argosy COE Class 7 AW Argosy COE Class 8 AX Argosy Glider COE Glider AY C112 Conventional Class 7 AZ C112 Conventional Class 8 A1 C112 Glider Conventional Glider A2 C120 Conventional Class 7 Vehicle Identification Numbering System 00.01 VIN Information Coronado Workshop Manual, Supplement 5, June 2012 050/2

VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model Cab GVWR A3 C120 Conventional Class 8 A4 C120 Glider Conventional Glider A5 Columbia 120 Conventional Class 7 A6 Columbia 120 Conventional Class 8 A7 Columbia 120 Glider Conventional Glider A8 CST112 Conventional Class 7 A9 CST112 Conventional Class 8 A0 CST112 Glider Conventional Glider BA CST120 Conventional Class 7 BB CST120 Conventional Class 8 BC CST120 Glider Conventional Glider BD FLD120 Classic Legacy Conventional Class 8 BE FLS112 Legacy Conventional Class 8 BF FL112 Conventional Class 7 BG FL112 Conventional Class 8 BH FL112 Glider Conventional Glider BJ FL50 Conventional Class 4 BK FL50 Conventional Class 5 BL FL50 Conventional Class 6 BM FL50 Conventional Class 7 BN FL60 Conventional Class 5 BP FL60 Conventional Class 6 BR FL60 Conventional Class 7 BS FL70 Conventional Class 6 BT FL70 Conventional Class 7 BU FL70 Conventional Class 8 BV FL80 Conventional Class 6 BW FL80 Conventional Class 7 BX FL80 Conventional Class 8 BY FL106 Conventional Class 6 BZ FL106 Conventional Class 7 B1 FL106 Conventional Class 8 B2 FC70 Cargo COE Class 6 B3 FC70 Cargo COE Class 7 B4 FC70 Cargo COE Class 8 B5 FC80 Cargo COE Class 6 Vehicle Identification Numbering System 00.01 VIN Information Coronado Workshop Manual, Supplement 5, June 2012 050/3

FREIGHTLINER CORONADO Trucks Service Repair Manual

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