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4 - Freightliner Trucks

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1. 1 2 3 XE XE GEO OG 2 2 09 22 2009 611065 1 Cab Recirculation Air Filter 2 Torx Screw 3 Dash Lower Console Fig 3 Cab Recirculation Air Filter Location 1 2 Z ki 1 02 26 2002 1831492 1 Air Filter Fig 5 Sleeper HVAC Assembly 02 26 2002 831491 1 Retainer 2 Recirculation Air Filter Fig 4 Cab Recirculation Air Filter Coronado Maintenance Manual January 2010 83 3 Hood Grille and Cab Fenders 88 Index Alphabetical Title of Maintenance Operation MOP MOP Number Hood Rear Support EUDFCASUDFE cues c co aga Enn Race ER o ox bU dat ve dra ut db rade teca S teehee nee 88 01 Coronado Maintenance Manual June 2010 Hood Grille and Cab Fenders 88 01 Hood Rear Support Lubrication Apply the parking brakes and chock the tires 2 Open the hood 3 Clean both the hood and cab mounted hood rear support components with a soapy water so lution 4 Cover all contact surfaces of the hood rear 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
2. 02 27 2007 1320033a NOTE Shown without pinch bolt to provide clarity 1 Cross Tube Split Freightliner For any Freightliner axle that requires lubrication of the tie rod ends wipe the grease fittings clean then pump multipurpose chassis grease NLGI Grade 1 696 12 hydroxy lithium stearate grease or NLGI Fig 4 Tie Rod End Adjustment Grade 2 896 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 Dana Spicer For any Dana Spicer axle that requires lubrication of the tie rod ends wipe the grease fittings clean then pump multipurpose chassis grease NLGI Grade 2 896 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 NOTE For operation in very cold climates use NLGI Grade 1 696 12 hydroxy lithium stearate grease 33 05 Tie Rod Lubrication Meritor Axles For any Meritor axle that requires lubrication of the tie rod 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 33 2 Coronado Maintenance Manual January 2010 Front Axle into the tie rod ends until all used grease is forced out and fresh grease is seen at the bal
3. 13 01 Bendix Air Compressor Inspection 25 01 Eaton Fuller Heavy Duty Clutch Release Bearing Lubrication 26 04 Allison Transmission Fluid and Filter Change TES 389 or Dexron VI 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 04 Trailer Electrical Connector Lubrication 31 05 Premier 690 Coupling Inspection 32 02 Suspension Lubrication 33 01 Knuckle Pin Lubrication Freightliner and Dana Spicer Axles 33 04 Tie Rod Lubrication Freightliner and Dana Spicer Axles 41 01 Driveline Inspection 41 02 Driveline Lubrication 42 02 Bendix Air Dryer Desiccant Replacement with an oil coalescing desiccant cartridge 42 05 Brake Inspection 42 08 Dana Spicer Camshaft Bracket Lubrication 42 09 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 49 01 Exhaust System Inspection noise emission control 72 01 Door Seal and Door Latch Lubrication 88 01 Hood Rear Support Lubrication If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwise use the M3 maintenance interval Table 6 M1 Maintenance Interval Operations for Service Schedules Il and III Maintenance M1 Maintenance Interval Operations for Service Schedule IV Chack Operation Number e Schedule IV every 25 000 miles 40 000 km 13 01 Bendix Air Compressor Inspection 31 01 Fifth Wheel Inspection 31 02 Fifth W
4. Meritor Drive Axle Lubricant Capacities Axle Model Capacity pt L Single Drive Single Reduction RS 21 160 39 5 18 7 RS 23 160 39 5 18 7 RS 23 161 37 2 17 6 RS 23 185 47 3 22 4 RS 23 186 47 3 22 4 RS 26 185 46 0 22 0 Tandem Drive Single Reduction Forward 30 2 14 3 MT 40 143MA N Rear 25 8 12 2 RT 40 145 RT 40 145A Forward 30 2 14 3 RT 40 145P Rear 25 8 12 2 Forward 39 1 18 5 RT 40 160 Rear 39 4 16 3 Forward 29 3 13 9 RT 44 145 RT 44 145P Rear 25 1 11 9 Forward 39 1 18 5 RT 46 160 RT 46 160P Rear 34 4 16 3 Forward 38 0 18 0 RT 46 164EH P Rear 33 0 15 0 Forward 38 0 18 0 RT 50 160 Rear 33 0 15 0 Forward 56 1 26 5 RT 52 185 Rear 36 1 17 1 Forward 56 1 26 5 RT 58 185 Rear 36 1 17 1 Forward 54 4 25 7 RT 70 380 Rear 53 1 25 1 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground Table 2 Meritor Drive Axle Lubricant Capacities Freightliner IMPORTANT On Freightliner axles the oil change interval for Schedule Ill and IV vehicles is extended to 500 000 miles 800 000 km for 35 2 Coronado Maintenance Manual January 2010 Rear Axle 08 17 2009 A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole f350061a Fig 2 Axle Lubricant Level Inspection axles with weight ratings of 34 000
5. Mali No Maintenance Service Service Schedule I Service Schedule Il Interval Date Miles km Hours Miles km 36 M1 36 000 57 600 3600 360 000 576 000 37 M1 37 000 59 200 3700 370 000 592 000 38 M1 38 000 60 800 3800 380 000 608 000 39 M1 39 000 62 400 3900 390 000 624 000 40 M1 and M2 40 000 64 000 4000 400 000 640 000 41 M1 41 000 65 600 4100 410 000 656 000 42 M1 42 000 67 200 4200 420 000 672 000 43 M1 43 000 68 800 4300 430 000 688 000 44 M1 44 000 70 400 4400 440 000 704 000 45 M1 M2 and M3 45 000 72 000 4500 450 000 720 000 46 M1 46 000 73 600 4600 460 000 736 000 47 M1 47 000 75 200 4700 470 000 752 000 48 M1 48 000 76 800 4800 480 000 768 000 49 M1 49 000 78 400 4900 490 000 784 000 50 M1 and M2 50 000 80 000 5000 500 000 800 000 51 M1 51 000 82 000 5100 510 000 820 000 52 M1 52 000 83 700 5200 520 000 837 000 53 M1 53 000 85 300 5300 530 000 853 000 54 M1 54 000 86 900 5400 540 000 869 000 55 M1 and M2 55 000 88 500 5500 550 000 885 000 56 M1 56 000 90 100 5600 560 000 901 000 57 M1 57 000 91 700 5700 570 000 917 000 58 M1 58 000 93 300 5800 580 000 933 000 59 M1 59 000 94 900 5900 590 000 949 000 60 M1 M2 and M3 60 000 96 500 6000 600 000 965 000 61 M1 61 000 98 200 6100 610 000 982 000 62 M1 62 000 99 800 6200 620 000 998 000 63 M1 63 000 101 400 6300 630 000 1 014 000 64 M1 64 000 103 000 6400 640 000 1 030 000 65 M1 and M2 65 000 104 600 6500 650 000 1 046 000 66 M1 66 000 106 200 6600 660 000 1 062 000 67 M1 67 000
6. Inspect the air intake line oil supply and return lines and coolant supply and return hoses for tight connec tions and general condition Tighten the connections and replace the lines and hoses as needed If equipped with a governor adaptor attached to the air compressor check the adaptor bolts and the gov ernor bolts If the bolts are loose tighten them 14 to 16 Ibf ft 19 to 22 N m then confirm that there are no leaks at the connection If a leak is present re place the gaskets See Fig 1 09 11 2009 130141 1 Adaptor Bolt 2 Governor Bolt Fig 1 Governor Adaptor 13 Coronado Maintenance Manual January 2010 13 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check ees 15 01 Coronado Maintenance Manual January 2010 Alternators and Starters 15 01 Alternator Battery and Starter Connections Check WARNING Batteries generate explosive gas as a by product of their chemical process Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment Make sure the battery compartment has been completely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective cloth
7. 5 Remove the filter and dispose of it in an environ mentally acceptable manner 6 Clean all threads and sealing surfaces very thor oughly Even a small amount of dirt will prevent the fuel water separator from sealing and an air leak may result Ensure that the drain valve is closed 8 Remove the filter grommet from the filter stud if equipped 9 Fill the housing to the top with clean diesel fuel 10 Install a standard engine spin on filter part num ber FF105 or equivalent on the filter stud 11 Install the cover O ring clear cover and the col lar Hand tighten the collar 12 Install and hand tighten the vent cap O ring and vent cap 13 Start the engine When the lubricating oil reaches its normal operating pressure increase engine speed to high idle for one to two minutes to purge air from the system 14 Check for leaks and shut down the engine 47 03 Fuel Tank Band Nut Tightening Hold each fuel tank band retention nut with a wrench while backing off its jam nut Then tighten the reten tion nuts 30 to 35 Ibf ft 41 to 46 N m After the re tention nuts have been tightened hold each retention nut with a wrench while tightening its jam nut 30 Ibf ft 41 N m IMPORTANT Do not overtighten 47 4 Coronado Maintenance Manual January 2010 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspection Noise Emission Control
8. Emergency Temporary Filter Replacement Fuel Pro 382 Fluid circulated through the fuel water separator to heat the fuel may be diesel fuel returned from the engine or engine coolant Drain the fuel water separator only when the engine and fluids have cooled Draining it when the engine is hot could cause severe personal injury due to scalding If returning fuel is released into the atmosphere its vapors can ignite in the presence of any igni tion source Do not expose the fuel to or work with the fuel system near open flame or intense heat To do so could cause fire possibly resulting in serious personal injury or property damage 1 Shut down the engine apply the parking brake and chock the tires 2 Puta clean receptacle under the fuel water sepa rator and attach a piece of hose to the drain valve to direct fuel into the receptacle The drain valve has a 1 2 inch 12 7 mm pipe use a hose with a 1 2 inch pipe thread to fit cor rectly Fuel 3 Remove the vent cap Fig 2 Item 4 and open the drain valve Fig 2 Item 1 to drain the fuel completely then close the drain valve 4 Using a DAVCO Oollar Wrench Fig 3 remove the clear cover and collar NOTE Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVCO Oollar Wrench part number 380134 is used for removal During installation the vent cap and collar are to be hand tightened only not tightened with a wrench
9. Service Schedule i Maintenance Interval Service Schedule iE be Interval peration Frequency Miles km Hours Initial Maintenance IM first 1000 1600 50 Schedule Maintenance 1 M1 every 1000 1600 50 Severe Service Maintenance 2 M2 every 5000 8000 500 Maintenance 3 M3 every 15 000 24 000 1500 Initial Maintenance IM first 10 000 16 000 Schedule Il Maintenance 1 M1 every 10 000 16 000 Ba Short Haul Transport Maintenance 2 M2 every 50 000 80 000 Maintenance 3 M3 every 150 000 240 000 Schedule Ill Initial Maintenance IM first 25 000 40 000 ad o LL Maintenance 1 M1 every 25 000 40 000 Schedule IV Maintenance 2 M2 every 100 000 161 000 o Long Haul Transport for Optimized Vehicle Configuration Maintenance 3 M3 every 300 000 483 000 Table 2 Service Schedule 00 2 Coronado Maintenance Manual August 2010 General Information 00 Vehicle Maintenance Schedule Tables 00 02 Maintenance for Service Schedules and lI Maint No Maintenance Service Service Schedule I Service Schedule Il Interval Date Miles km Hours Miles km 1 IM and M1 1000 1600 100 10 000 16 000 2 M1 2000 3200 200 20 000 32 000 3 M1 3000 4800 300 30 000 48 000 4 M1 4000 6400 400 40 000 64 000 5 M1 and M2 5000 8000 500 50 000 80 000 6 M1 6000 9600 600 60 000 96 000 7 M1 7000 11 200 700 70
10. 10 05 2009 A Front View 1 Axle Breather 2 Breather Hose 1350509 B Rear View 3 Temperature Sensor Port 4 Oil Fill Plug 05 27 93 1 Oil Fill Plug f350018a 2 Oil Drain Plug Fig 4 Dana Spicer Axle Housing Drain and Fill Plugs temperature the oil will run more freely and en sure that the axle is flushed Fig 3 Freightliner Tandem Axle forward axle shown NOTE Some tandem drive axles are equipped with a cylindrical magnetic strainer located below the lube pump on the front of the power divider cover All rear axles are fitted with mag netic drain and fill plugs 4 Ateach axle oil change remove and clean the magnetic strainer if equipped as follows see Fig 5 4 1 Remove the 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 strainer 40 to 60 Ibf ft 54 to 81 Nm 35 4 Coronado Maintenance Manual January 2010 Rear Axle 35 05 27 93 1350017a Dana Spicer Drive Axle Recommended Lubricant 2 Power Divider 1 Magnetic Strainer Fig 5 Dan
11. 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar Fig 5 Top View of the Equalizer ditions exist replace the damaged bracket s See Group 32 of the Coronado Workshop Manual for instructions Replace worn cracked or damaged spring brackets Failure to do so could result in bracket breakage possibly leading to loss of vehicle con trol and resulting in personal injury or property damage Inspect the crossmember s and gussets for wear cracks and other damage If any of these conditions exist replace the damaged parts See Group 32 of the Coronado Workshop Manual for instructions Visually check the air spring piston for cracks chips and broken areas Check the air bag for rips tears and holes Verify that the air spring assembly does not leak If any of these conditions exist replace the damaged parts See Group 32 of the Coronado Workshop Manual for instructions IMPORTANT Before checking the AirLiner sus pension height make sure there is no load on the chassis and the trailer is unhitched IMPORTANT To prevent voiding the warranty on Barksdale height control valves note the fol lowing Coronado Maintenance Manual August 2010 32 3 32 Do not overtighten the bolts in the Barksdale height control valve housing The bolts should not be loose and should not require tightening Only if necessary tighten the valve housing bolts 45 Ibf in 500 N cm Any damage
12. 18 C use SAE 10 heavy duty en gine oil API service classification SD sulfated ash content must not exceed 1 85 When the ambient temperature is below 0 F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures do not mix it with kerosene 35 8 Coronado Maintenance Manual January 2010 Rear Axle 3 Coat the threads of the fill plug with a small amount of Loctite 242 or equivalent sealant Install the fill plug finger tight in the rear axle shift unit housing Using a wrench tighten it an addi tional 1 1 2 turns 35 Coronado Maintenance Manual January 2010 35 9 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel Nut XSITBOK sia raras pi ad Reece b A Le Shore NE 40 01 Coronado Maintenance Manual January 2010 Wheels and Tires 40 01 Wheel Nut Check IMPORTANT After a wheel has been installed the wheel nut torque must be rechecked after 50 to 100 miles 80 to 160 km of operation See Table 1 for disc wheel nut torque specifications and see Fig 1 for the wheel nut tightening se quence NOTICE Insufficient wheel
13. 60 81 a Stage 3 200 271 Stage 4 520 to 600 707 to 816 Tighten in a diagonal pattern as shown in Fig 10 Table 1 Spring Assembly U Bolt High Nut Torque Values 32 6 Coronado Maintenance Manual August 2010 Suspension 32 03 10 2011 2 3 1320783 Fig 10 Tightening Pattern for U Bolt High Nuts Coronado Maintenance Manual August 2010 32 7 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AIFAxIG Alignment Check ama usta doa acere t dig dence ee E DEAD KP xe e oce d RT oco d diga o d bo ie 33 06 Knuckle Pin Lubrication Freightliner and Dana Spicer Axles 2 liliis 33 01 Knuckle Pin Lubrication Meritor Axles RRRRRRRRRR Rh 33 02 1e Rod AA e e E N a S 33 03 Tie Rod Lubrication Freightliner and Dana Spicer Axles 000 eee 33 04 Tie Rod Lubrication Meritor AXIS diria og eode C Kok des e e P Ee e etd et ge ds 33 05 Coronado Maintenance Manual January 2010 Front Axle 33 01 Knuckle Pin Lubrication Freightliner and Dana Spicer Axles NOTICE Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps Freightliner Park the vehicle on a level surface apply the parking brakes and chock the tires When lubricating upper and lower knuckle assemblies do not raise the front axle Wipe the fittings clean then apply multipurpose
14. Apply multi purpose chassis grease with a pressurized grease gun until old grease is forced out NOTE Service Schedule IV vehicles equipped with a 12 000 Ib 5452 kg front axle are fitted with maintenance free rubber bushings and do not require lubrication Hear Suspension Chalmers No lubrication is required on the Chalmers rear suspension Freightliner Spring Single Axle No lubrication is required on Freightliner single axle rear suspensions Tandem Axle Lubricate the equalizer cap and tube assembly bush ings by applying multipurpose chassis grease at the grease fitting until old grease is forced out from the cap and tube assembly see Fig 8 Hendrickson The Hendrickson RS Series suspension does not require lubrication Coronado Maintenance Manual August 2010 32 5 32 Suspension 05 27 93 A Lubricate here 1 Cap and Tube Assembly Bushing 320020a Fig 8 Equalizer Assembly Lubrication For Hendrickson RT2 and RTE2 Series lubricate the bronze ball indented bushings in the spring eye as follows 1 Park the vehicle on a level surface apply the parking brakes and chock the front tires 2 Raise the rear of the vehicle until the rear wheels are suspended in the air then support the ve hicle with safety stands This relieves the load on the bushings and pins to allow the proper flow of lubricant around them 3 Usea multipurpose chassis grease and lubricate the b
15. Do not expose the fuel to or work with the fuel system near open flame or intense heat To do so could cause fire possibly resulting in serious personal injury or property damage 1 Drain off some fuel by loosening the vent plug and opening the drain valve 2 Disconnect the water sensor and heater connec tions if equipped 3 Remove the element and bowl together by turn ing counterclockwise 4 Remove the bowl from the element and clean the O ring land 5 Apply a coating of clean fuel or motor oil to the new O ring and element seal 6 Spin the bowl onto the new element then spin them both onto the filter head snugly by hand only IMPORTANT Do not use tools to tighten the bowl and element 47 7 Connect the water sensor and heater connectors if equipped 8 If equipped with a primer pump prime the fuel water separator as follows 8 1 Loosen the vent plug Then operate the primer pump until the fuel purges at the vent plug See Fig 1 8 2 Close the vent plug 2 1 M 3 4 11 E d 5 9 TI 6 Eum 8 06 25 97 1470147 1 Mounting Head 7 Water Sensor Probe 2 Fuel Primer Pump 8 Heater Connector 3 Vent Plug 9 Drain Plug 4 Bowl O Ring 10 Sight Bowl 5 Bowl Gasket 11 Filter Element 6 Bowl Probe Plug Fig 1 Alliance Fuel Water Separator 9 Start the engine and check for fuel leaks 10 Shut down the engine and correct any fuel leaks Davco Fuel Pro 382 and 482 Fluid circul
16. 000 112 000 8 M1 8000 12 800 800 80 000 128 000 9 M1 9000 14 400 900 90 000 144 000 10 M1 and M2 10 000 16 000 1000 100 000 160 000 11 M1 11 000 17 600 1100 110 000 176 000 12 M1 12 000 19 200 1200 120 000 192 000 13 M1 13 000 20 800 1300 130 000 208 000 14 M1 14 000 22 400 1400 140 000 224 000 15 M1 M2 and M3 15 000 24 000 1500 150 000 240 000 16 M1 16 000 25 600 1600 160 000 256 000 17 M1 17 000 27 200 1700 170 000 272 000 18 M1 18 000 28 800 1800 180 000 288 000 19 M1 19 000 30 400 1900 190 000 304 000 20 M1 and M2 20 000 32 000 2000 200 000 320 000 21 M1 21 000 33 600 2100 210 000 336 000 22 M1 22 000 35 200 2200 220 000 352 000 23 M1 23 000 36 800 2300 230 000 368 000 24 M1 24 000 38 400 2400 240 000 384 000 25 M1 and M2 25 000 40 000 2500 250 000 400 000 26 M1 26 000 41 600 2600 260 000 416 000 27 M1 27 000 43 200 2700 270 000 432 000 28 M1 28 000 44 800 2800 280 000 448 000 29 M1 29 000 46 400 2900 290 000 464 000 30 M1 M2 and M3 30 000 48 000 3000 300 000 480 000 31 M1 31 000 49 600 3100 310 000 496 000 32 M1 32 000 51 200 3200 320 000 512 000 33 M1 33 000 52 800 3300 330 000 528 000 34 M1 34 000 54 400 3400 340 000 544 000 35 M1 and M2 35 000 56 000 3500 350 000 560 000 Coronado Maintenance Manual August 2010 00 3 00 General Information Vehicle Maintenance Schedule Tables 00 02 Maintenance for Service Schedules and Il
17. 1 2 Park the vehicle on a level surface apply the parking brakes and chock the tires Check for moisture in the air brake system by opening the reservoir drain cocks Examine the discharge Some trace of water in the discharge is normal A discharge of a milky gray liquid indi cates excessive moisture is present in the air System and the desiccant cartridge needs to be Brakes replaced The following conditions could cause small amounts of moisture to be found in the air system e An outside air source has been used to charge the air brake system This air did not pass through the drying bed Air usage is unusually high and not normal This may be due to accessory air demands or some unusual air requirement that does not allow the compressor to load and un load in a normal fashion Check for air sys tem leaks The air dryer has been installed on a sys tem that had previously been operated without an air dryer This type of system will be saturated with moisture and several weeks of operation may be needed to fully dry the system The temperature range in your area fluctu ates more than 30 degrees in one day Small amounts of water can accumulate in the air brake system due to condensation Under these conditions the presence of moisture is normal and should not be con sidered an indication of poor air dryer per formance Inspect the air dryer for external damage and check that the unit is tightly mounted
18. 20 Fan Clutch Date Mileage Item Cost Maintenance Facility 00 16 Coronado Maintenance Manual August 2010 General Information Verification of Inspections Log Group 49 00 Verification of Inspections Log 00 08 Verification of Inspections Log Group 49 Exhaust System Components Date Mileage Item Cost Maintenance Facility Coronado Maintenance Manual August 2010 00 17 00 General Information Metric U S Customary Conversion Tables 00 09 dk iha US E To Get Metric Balls ede ii To Get U S Customary Length inches in 25 4 millimeters mm 0 03937 inches in inches in 2 54 centimeters cm 0 3937 inches in feet ft 0 3048 meters m 3 281 feet ft yards yd 0 9144 meters m 1 094 yards yd miles mi 1 609 kilometers km 0 6215 miles mi Area square inches in 645 16 square millimeters mm 0 00155 square inches in square inches in 6 452 square centimeters cm 0 155 square inches in square feet ft 0 0929 square meters m 10 764 square feet ft Volume cubic inches in3 16387 0 cubic millimeter mm3 0 000061 cubic inches in3 cubic inches in3 16 387 cubic centimeters cm3 0 06102 cubic inches in3 cubic inches in3 0 01639 liters L 61 024 cubic inches in3 fluid ounces fl oz 29 54 mil
19. 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance camshaft bushings are lubricated during the brake reline service interval For ser vice and lubrication instructions see Group 42 of the Coronado Workshop Manual For camshaft brackets with grease fittings use an NLGI Grade 1 or Grade 2 multipurpose chassis grease Lubricate the camshaft bushings through the grease fitting on the camshaft bracket or the spider until new grease flows from the inboard seal See Fig 5 If grease leaks out under the camhead the cam shaft bracket grease seal is worn or damaged See Coronado Maintenance Manual January 2010 42 7 42 05 28 93 A Grease Exit 1 Brake Chamber 2 Slack Adjuster f420011a 3 Non Pressure Relief Grease Fitting Fig 5 Camshaft Bracket Lubrication Group 42 in the Coronado Workshop Manual for grease seal replacement instructions If this seal is not replaced the brake linings could become contaminated with grease The stopping distance of the vehicle will be increased which could result in personal injury or property damage 42 07 Meritor Slack Adjuster Lubrication IMPORTANT Perform MOP 42 05 before lubri cating the camshaft bracket Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death NOTE If equipped with an extended maintenance Q Plus bra
20. Fig 2 Components of a Basic Driveline Manual for torque specifications Replace the midship bearing assembly if the rubber cushion is deteriorated or oil soaked Check slip joints for spline wear by moving the sleeve yoke and splined shaft back and forth see Fig 5 If the slip joint can be twisted in a clockwise or counterclockwise movement greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft Examine the driveshaft tubes for dents bends twists or other damage If any tube appears to be damaged refer to Section 41 00 of the Coro nado Workshop Manual for repair and replace ment instructions Examine the driveshaft for evidence of missing balance weights and for build up of foreign ma terial Remove any foreign material If there is any evidence that balance weights are missing remove the driveshaft and have it balanced For driveshafts with slip joints check to be sure the yoke plug is not loose or missing see Fig 6 Ref 2 Repair or replace the yoke plug as 41 2 Coronado Maintenance Manual January 2010 Driveline 41 E 4 gt 4 2 05 27 93 y f410012a Attempt to move the sleeve yoke and splined shaft back and forth Fig 5 Slip Joint Spline Wear Checking 04 13 98 f410155a 1 Self Locking Capscrew 2 Adhesive Band Fig 3 Meritor U Joint Fasteners for Full Round Yokes 12 09 97 1410182 Fig 4 Meritor RPL Series U Joint needed If
21. 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 88 Coronado Maintenance Manual June 2010 88 1
22. 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 00 6 Coronado Maintenance Manual August 2010 General Information 00 Vehicle Maintenance Schedule Tables 00 02 Maintenance for Service Schedules Ill and IV Maint No Maintenance Interval Service Ee Date Miles km 36 M1 M2 and M3 900 000 1 448 000 37 M1 925 000 1 490 000 38 M1 950 000 1 529 000 39 M1 975 000 1 569 000 40 M1 and M2 1 000 000 1 609 000 Table 4 Maintenance for Service Schedules lll and IV Coronado Maintenance Manual August 2010 00 7 00 General Information Initial Maintenance IM Operations 00 03 The Initial Maintenance table lists all maintenance tenance operations to be performed All operations operations that are to be performed at the initial listed in the table along with the operations listed in maintenance IM interval Maintenance operation the applicable M1 maintenance interval table must numbers are reference numbers used to help you be performed to complete the initial maintenance find detailed instructions in this manual on the main IM Maintenance Operation Number Initial Maintenance IM Operations for Serv
23. Release Cross Shaft 2 Grease Fitting f250048a Fig 4 Cross Shaft Grease Fitting Left Side 05 27 93 f260146a Fig 5 Cross Shaft Grease Fitting Right Side 25 03 Meritor LitePedal Clutch Release Bearing Lubrication If the clutch is equipped with an optional sealed clutch release bearing lubricate the bronze bushing located between the clutch bearing housing and the transmission input shaft Use a pressure type grease Clutch gun with Meritor Specification 0 661 Lithium Complex Grease NLGI Grade 3 and lubricate until grease flows from the release bearing housing Depress the clutch pedal a couple of times before starting the engine If the clutch is equipped with a standard non sealed clutch release bearing with a grease fitting lubricate the bearing as follows 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 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 2 Remove the clutch inspection plate if necessary See Fig 1 NOTE For lubrication of the release bearing use Meritor Specification 0 661 Lithium Complex Grease NLGI Grade 3 3 Wipe any dirt from the grease fitting See Fig 2 Using a pressure type grease gun equipped with recommended grease lubricate the bearing u
24. Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD 6 Check all sensors attached to the ATS for leaks or damaged wires No leaks are allowed See Coronado Maintenance Manual January 2010 49 1 49 Fig 1 Fig 2 or Fig 3 for Detroit Diesel ATS sensor locations 7 Check the DPF exterior surface for dents or other damage A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to mal function 8 Check the SCR catalyst for dents and other damage 9 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF Exhaust NOTE Diesel exhaust fluid creeps causing white crystals to form around the line fittings The presence of crystals does not mean the system has a leak Replacing fittings or trouble shooting components is not necessar
25. Seal 12 13 Fig 5 Allison Transmission Filter Location and Components Replace the drain plug O ring then install the drain plug Tighten the drain plug 18 to 24 Ibf ft 25 to 32 N m Refill the transmission with fresh automatic trans mission fluid and check the fluid level See Table 3 for transmission lubricant capacities and Coronado Maintenance Manual January 2010 26 5 26 Transmission Table 4 for approved transmission lubricants Allison 4000 Series Transmission Lubricant Capacities Sump Size Refill Capacity qt L 4 Inch 39 37 t 2 Inch 31 30 f Quantities listed are approximate Add listed amount of fluid then perform a hot check and add fluid as needed Do not overfill t Add 3 qt 2 8 L for transmissions with PTO Table 3 Allison 4000 SeriesTransmission Lubricant Capacities Allison Approved Automatic Transmission Lubricants Transmission Lubricant Type Castrol TranSynd synthetic or other Allison Approved TES 295 Fluid Allison Approved TES 389 Fluid Allison 4000 Series or Dexron VIt IMPORTANT For TES 389 and Dexron VI use maintenance interval M1 Lubricants listed in order of preference Do not mix fluid types Call 1 800 252 5288 or see www AllisonTransmission com for a complete list of Alli son approved lubricants t Dexron VI may only be used in units beginning with S N 6610220990 Table 4 Allison Appro
26. a a tod Aid Rear Axle AD ois he fat nee Ban EE E Wheels and Tires O a TD Ge Mae sat ag NG Driveline AQ apa diate ie Cae une be Mui ene e Brakes AG es a apa edem tuba etd sov RE ee atte eens Steering A ea fe aah heals ae we ett anaes aie ai dos Fuel Cr Exhaust jj aM 2a eee ett asad Ama ABG ean paa Ana ANG Cab p TEE PET er Doors c PEN a Na ace Heater and Air Conditioner OB ida baka ka Hood Grille and Cab Fenders 4 Coronado Maintenance Manual June 2011 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Determining Scheduled Maintenance Intervals 2 00 01 Initial Maintenance IM OperatiOnS soc apaw a AGA acm Acero S AH str e de a enin a dria on 00 03 M1 Maintenance Interval Operati0MS oooooocooooo rh 00 04 M2 Maintenance Interval Operations lilii 00 05 M3 Maintenance Interval Operations lille nn 00 06 Metric U S Customary Conversion Tables llli 00 09 Noise Emission Controls Malhteriane e 2i iaa dew depu ner CPOE oh beg Ua RS E E a E 00 07 Torque Speciications Tables recrea UA KA AA TA ceed mms pee dems E NU ame d Ae ING 00 10 Vehicle Maintenance Schedule Tables 0 0000 cee eh 00 02 Meriticauort Of INSPSCUONS LOT x aat sodes oO ded d a eda di ded ed 00 08 Coronado Maintenance Manual August 2010 General Information 00 Determining Scheduled Maintenance Intervals 00 01 Determining Scheduled Maintenance In
27. be seen escaping from just one of the U joint seals check the torque on the capscrews at that seal Tighten the bearing cup capscrews 43 Ibf ft 58 N m If the capscrews were already tight or all of the U joint seals still do not purge remove the bearing cup at that seal and examine the seal for damage If the seal is damaged replace the complete U joint If grease does not appear at one seal use a pry ing tool to pry the U joint trunnion away from the non purging seal or tap the driveshaft or yoke with a plastic or rawhide mallet on the side oppo site the dry seal while continuing to lubricate If grease still does not appear loosen the cap screws at the bearing with the dry seal to relieve seal tension Lubricate the U joint until new grease is seen at the seal then tighten the cap Screws to the correct torque specifications If the bearing will not take grease replace the U joint see Group 41 of the Coronado Workshop Manual Check the purged grease If it appears rusty gritty or burned replace the U joint Wipe the purged grease from the seals and any excess grease from the grease fitting Driveline Slip Joint Spline Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines do not require periodic lubrication 1 If equipped with a grease fitting wipe all old grease and dirt from the slip joint grease fitting see Fig 6 Ref 1 Use a hand type grease gun or a high pressure gun
28. breather whenever checking lubricant level Check the breather more frequently under adverse operat ing conditions 5 Check the axle housing breather Make sure that it is open and unclogged If the breather is plugged or damaged clean or replace it as needed See Fig 7 6 On non drive axles using oil lubricated 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 Coronado Maintenance Manual January 2010 35 7 35 Dana Spicer NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock the tires 2 If the vehicle has just been driven allow a few minutes for the lubricant to settle 3 Clean the oil fill plug and the area surrounding it see Fig 8 Remove the plug from the fill hole or standpipe if installed in the oil fill hole PA a 06 07 94 1 Axle Housing Breather 2 Fill Plug f350002a 3 Temperature Indicator Plug Fig 8 Dana Spicer Axle Housing Breather IMPORTANT A lubricant level close enough to be seen or touched is not sufficient It must be level with the b
29. chassis grease NLGI Grade 1 696 12 hydroxy lithium stearate grease or NLGI Grade 2 896 12 hydroxy lithium stearate grease until new grease is seen at the junctions of the axle beam and knuckles See Fig 1 05 31 2005 1320360a Pump lubricant into each grease fitting until fresh grease come out at point A 1 Grease Fitting Fig 1 Freightliner Knuckle Pin Lubrication Dana Spicer Park the vehicle on a level surface apply the parking brakes and chock the tires When lubricating upper and lower knuckle assemblies do not raise the front axle Wipe the fittings clean then apply multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 896 12 33 hydroxy lithium stearate grease until new grease is seen at the junctions of the axle beam and knuckles See Fig 2 Knuckle pins without grease fittings are permanently lubricated 1 11 21 95 1330129 A Grease Exit 1 Grease Fitting Fig 2 Dana Spicer Knuckle Pin Lubrication 33 02 Knuckle Pin Lubrication Meritor Axles NOTICE Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps Park the vehicle on a level surface apply the parking brakes and chock the tires When lubricating knuckle pin bushings do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease NLGI Grade 2 896 12 hydroxy l
30. for fore aft play Rotating tester in lock Engage hook Pull push handle fore aft Check for movement of kingpin in lock Disengage hook Push pull handle inboard outboard Rotate lock tester Fig 6 Jost Fifth Wheel Adjustment nism several times to test Repeat if necessary See Fig 7 If the lock is too loose loosen the jam nut turn the adjustment bolt counterclockwise one full turn then reset the jam nut Lock and unlock the 31 4 Coronado Maintenance Manual June 2011 Frame and Frame Components mechanism several times to test Repeat if nec essary See Fig 7 09 02 2009 1 Jam Nut 2 Adjustment Bolt f311100 3 Grease Zerk Fig 7 Jost Fifth Wheel 9 If the fifth wheel is equipped with a sliding mechanism inspect and adjust it as follows 9 1 Check the bracket for any cracks or miss ing and damaged parts 9 2 Inspect the locking plungers for full en gagement 9 3 Check the locking mechanism for proper operation If the plungers will not release check the air cylinder or plunger adjustment If the plungers are loose check the plunger adjustment and the plunger springs for proper compression Replace if needed 31 9 4 The outboard slider assembly 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
31. new filter and grommet assembly and cover O ring on the housing 47 2 Coronado Maintenance Manual January 2010 Fuel 47 12 05 05 2009 1470531 05 05 2009 1470530 1 Drain Valve 7 Spring 1 Inlet Port Check Valve 8 Vent Cap O Ring 2 Bottom Plate 8 Clear Cover 2 Lower Housing 9 Vent Cap Assembly 9 Vent Cap O Ring 3 Bypass Valve 10 Collar 3 Bottom Plate O Ring 10 Vent Cap 4 Filter Element 11 120VAC Pre Heater 4 Lower Housing 11 Collar 5 Spring 12 12VDC Pre Heater 5 Cover O Ring 12 Inlet Port Check Valve 6 Cover O Ring 13 Drain Valve 6 Filter Element 13 Heat Exchanger 7 Clear Cover Fig 4 DAVCO Fuel Pro 382 Fig 5 DAVCO Fuel Pro 482 Coronado Maintenance Manual January 2010 47 3 47 10 Install the clear cover and the collar Hand tighten the collar 11 Prime the system 11 1 X Ensure that the drain valve is closed 11 2 Fill the housing to the top with clean die sel fuel 11 3 Install and hand tighten the vent cap O ring and vent cap 11 4 Start the engine When the lubricating oil reaches its normal operating pressure increase engine speed to high idle for one to two minutes to purge air from the system 11 5 While the engine is running and after the air is purged from the system loosen the vent cap until the fuel level falls to just above the collar then hand tighten the vent cap 11 6 Check for leaks and shut down the en gine
32. 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 as follows 11 1 11 2 Turn the fan in both directions and feel for worn hub bearings If possible remove the drive belt and check for worn sheave bearings by turn ing the sheave in both directions If either the hub or sheave bearings are worn replace them using a Horton Drive Master Super Kit see Group 20 of the Coronado Workshop Manual 20 4 Coronado Maintenance Manual January 2010 Clutch Title of Maintenance Operation MOP Clutch Release Cross Shaft Lubrication Eaton Fuller Heavy Duty Clutch Release Bearing Lubrication Meritor LitePedal Clutch Release Bearing Lubrication 25 Index Alphabetical MOP Number Coronado Maintenance Manual January 2010 Clutch 25 01 Eaton Fuller Heavy Duty Clutch Release Bearing Lubrication 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires NOTE Some clutch release bearings are equipped with a lubrication extension or lube tube that extends outside of the clutch housing 2 Remove the clutch inspection plate See Fig 1 03 01 94 f250002a 1 Clutch Inspection Plate Fig 1 Clutch Inspection Plate NOTE For lubrication of the release bearing Eaton Fuller
33. recommends NLGI Grade 2 or 3 EP lithium grease with a 325 F 163 C operat ing temperature or Roadranger Grease MP 2 3 Wipe any dirt away from the grease fitting See Fig 2 Using a pressure type grease gun equipped with the recommended grease lubri cate the bearing until excess grease purges from the rear of the release bearing toward the transmission NOTICE Do not over lubricate the clutch release bearing Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature failure Do not use chassis grease or multipurpose lubricants 25 05 27 93 f250081a Fig 2 Release Bearing Grease Fitting 4 Wipe off excess grease and apply to both the yoke finger and sleeve bushing contact points See Fig 3 08 10 2009 f250444 1 Sleeve Bushing Contact Point 2 Yoke Finger Contact Points Fig 3 Grease the Contact Points 5 Install the clutch inspection plate if removed 25 02 Clutch Release Cross Shaft Lubrication The clutch release cross shaft is equipped with two grease fittings on the transmission clutch housing Coronado Maintenance Manual January 2010 25 1 25 See Fig 4 and Fig 5 Wipe any dirt from the grease fittings and lubricate with NLGI Grade 2 or 3 EP lithium grease with a 325 F 163 C operating tem perature or Roadranger Grease MP 2 10 19 93 1 Clutch
34. the equalizer exceeds 1 8 inch 3 mm replace the equalizer bushings See Group 32 of the Coronado Workshop Manual for instructions E 2 05 27 93 A Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer f320022a Fig 4 Side View of the Equalizer 7 With the vehicle unloaded attempt to move the equalizer side to side using a pry bar between the equalizer and frame rail Apply hand pressure only See Fig 5 If clearance between the equal izer assembly and any frame component or fas tener is less than 1 8 inch 3 mm replace the equalizer bushings See Group 32 of the Coro nado Workshop Manual for instructions Freightliner AirLiner Suspension WARNING Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem 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 32 1 jy A Yu A e 3 hd 05 27 93 5 f320023a A 1 8 3 mm Clearance
35. the life of the vehicle Wipe out the filter housing with a clean dry lint free rag Clean and inspect the O rings and end cap Replace any parts that are damaged 5 Install the large O ring then the filter element small end first into the filter housing 6 Install the small O ring in the end cap then in stall the end cap and tighten it until firm NOTICE A leaking air filter or air lines can cause slow or hard shifting of the transmission and eventual transmission damage 7 Start the engine and build pressure in the air System Check for air leaks at the filter housing and air line connections repair any leaks 26 04 Allison Transmission Fluid and Filter Change When draining transmission fluid check for evidence of dirt or water contamination A small amount of condensation will appear in the fluid during operation 26 4 Coronado Maintenance Manual January 2010 Transmission Water contamination is normally characterized as a milky discoloration of the transmission fluid Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the trans mission cooler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers 1 4 If the transmission fluid is not at normal operat ing temperature run the engine until the fluid reaches operating temperature 160 to 200 F 71 to 93 C Park the vehicle on a level surfac
36. the yoke plug is missing the splined shaft may be hitting the plug and knocking it out contact your Regional Service Office for assis tance in determining the correct driveshaft length 10 20 93 f410050a A After grease appears cover the pressure relief hole while continuing to lubricate Slip Joint Grease Fitting with grease gun attached Yoke Plug Grease Half Round Yoke Yoke Plug Pressure Relief Hole Slip Joint Seal Full Round Yoke U Joint Grease Fitting ONDA WM Fig 6 Slip Joint and U Joint Lubrication Coronado Maintenance Manual January 2010 41 3 41 41 02 Driveline Lubrication Universal Joint Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines do not require periodic lubrication 1 Park the vehicle on a flat surface apply the park ing brakes and chock the tires Wipe all old grease and dirt from each U joint grease fitting see Fig 6 Ref 8 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate U joints If a low pressure adapter is not used U joints may not receive enough grease Using lithium 12 Hydroxy stearate grease NLGI Grade 2 with EP additives lubricate until new grease can be seen at all four U joint seals Fresh grease must be seen escaping from all four bearing cap seals of each U joint On full round yokes equipped with a bearing cup if most of the grease being added to a U joint can
37. torque specifications If the yoke is still loose after tightening the yoke nut replace the end yoke and yoke nut Replace the prevailing torque locknut end yoke nut if it was removed for yoke replacement seal replacement or any other reason 4 Check U joint assemblies for wear by moving the driveshaft up and down and from side to side If any movement of the U joint cross in the bear ings can be felt or seen replace the U joint as sembly 5 Check if the midship bearing and mounting are loose or have deteriorated by attempting to move the driveshaft up and down and from side to side If the bearing is loose on its shaft or rattles replace it If the bearing mount is loose on the frame tighten the mounting fasteners to the proper torque value See Section 41 00 Specifications 400 of the Coronado Workshop Coronado Maintenance Manual January 2010 41 1 41 Driveline S N NI N 16 1 2 NG 3 05 01 95 1410067b NOTE Not all fasteners are shown 1 Transmission 6 U Joint Cross 11 Dust Cap 2 Transmission Output Shaft 7 Bearing Cup for half round 12 Splined Stub Shaft End Yoke half round yoke 13 Driveshaft Tube 3 U Joint Assembly 8 Bearing Strap and Bearing 14 Tube Yoke full round 4 Bearing Plate Self Locking Strap Capscrew 15 Axle Input Shaft End Yoke Capscrew 9 Slip Joint Assembly half round 5 Bearing Cup for full round 10 Sleeve Yoke full round 16 Rear Axle yoke
38. unit also change the shift unit lubricant See under the heading Two Speed Axles With Shift Unit All Axle Models Meritor NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground apply the park ing brakes and chock the tires IMPORTANT Oil level must be checked at each M1 interval on Meritor axles 2 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature 35 6 Coronado Maintenance Manual January 2010 Rear Axle NOTE Some Meritor 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 used as a fill or level hole 3 Check that the lubricant is level with the bottom of the fill hole see Fig 2 If low check for oil leaks and correct as needed 4 Install and tighten the fill plug 35 Ibf ft 47 N m IMPORTANT Always check the axle breather whenever checking lubricant level Check the breather more frequently under adverse operat ing conditions 5 Check the axle housing breather Make sure that it is open and unclogged see Fig 7 If the breather is plugged or damaged clean or re place it as needed 06 07 94 1 Axle Housing Breathers 2 Carrier
39. 03 Fan Clutch Check Noise Emission Control Borg Warner Kysor K26RA Fan Clutch 1 Disconnect the batteries at the negative termi nals Drain all air from the air system 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 3 Ref A 3 2 1 4 5 05 27 93 NG f200237a With the fan clutch engaged measure the distance at A measure it again with the fan clutch disengaged 1 Bearing Housing 5 Air Cylinder 2 Retaining Plate 6 Fan 3 Fan Pulley 4 Air Inlet from solenoid valve Fig 3 Kysor K26RA Fan Clutch Lining Wear Check 20 2 Coronado Maintenance Manual January 2010 Engine Cooling R adiator 3 Disconnect the line from the air inlet of the air cylinder Connect a shop air hose to the inlet 4 Apply a minimum of 100 psi 690 kPa air pres sure to the air cylinder the bearing housing will move backwards disengaging the clutch Again measure the distance from the back surface of the retaining plate to the forward most edge of the fan belt pulley 5 Compare the two measurements if the difference between the two measurements exceeds 0 150 inches 3 8 mm the clutch lining is worn and must be replaced See Group 20 of the Coro nado Workshop Manual for clutch lining re placement instructions 6 Release the air pressure then disconnect the shop hose from the air inlet of the air cylinder Co
40. 1 Thoroughly steam clean the fifth wheel Check the mounting for missing or damaged fas teners and broken components Replace or re pair as needed 4 Inspect the bracket pin bolts Make sure the lock ing tabs are properly securing the bolts in place See Fig 5 Frame and Frame Components 09 01 2009 f311101 Fig 5 Bracket Pin Bolt Locking Tabs 5 Check the fifth wheel for bent worn or broken parts Replace as needed 6 If the fifth wheel is equipped with low lube plates check the plates and replace if damaged or worn down to the securing 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 you feel fore aft play when pulling and pushing on the lock tester handle See Fig 6 Ref A The lock is too tight if the lock tester does not rotate freely in the lock See Fig 6 Ref B 8 If the lock is improperly adjusted correct as fol lows If the lock is too tight loosen the jam nut turn the adjustment bolt clockwise one full turn then reset the jam nut Lock and unlock the mecha 09 01 2009 rommoog9 f311099 Checking
41. 107 800 6700 670 000 1 078 000 68 M1 68 000 109 400 6800 680 000 1 094 000 69 M1 69 000 111 000 6900 690 000 1 110 000 70 M1 and M2 70 000 112 700 7000 700 000 1 127 000 00 4 Coronado Maintenance Manual August 2010 General Information 00 Vehicle Maintenance Schedule Tables 00 02 Maintenance for Service Schedules and II Maint No Maintenance Service Service Schedule I Service Schedule II Interval Date Miles km Hours Miles km 71 M1 71 000 114 300 7100 710 000 1 143 000 72 M1 72 000 115 900 7200 720 000 1 159 000 73 M1 73 000 117 500 7300 730 000 1 175 000 74 M1 74 000 119 100 7400 740 000 1 191 000 75 M1 M2 and M3 75 000 120 700 7500 750 000 1 207 000 76 M1 76 000 122 300 7600 760 000 1 223 000 77 M1 77 000 123 900 7700 770 000 1 239 000 78 M1 78 000 125 500 7800 780 000 1 255 000 79 M1 79 000 127 100 7900 790 000 1 271 000 80 M1 and M2 80 000 128 700 8000 800 000 1 287 000 81 M1 81 000 130 400 8100 810 000 1 304 000 82 M1 82 000 132 000 8200 820 000 1 320 000 83 M1 83 000 134 000 8300 830 000 1 340 000 84 M1 84 000 135 200 8400 840 000 1 352 000 85 M1 and M2 85 000 137 000 8500 850 000 1 370 000 86 M1 86 000 138 400 8600 860 000 1 384 000 87 M1 87 000 140 000 8700 870 000 1 400 000 88 M1 88 000 141 600 8800 880 000 1 416 000 89 M1 89 000 143 200 8900 890 000 1 432 000 90 M1 M
42. 11 SCR Outlet NOx Sensor 1490353 Fig 2 2V2 Two Box ATS Sensor Locations Diesel Exhaust Fluid DEF Filter Replacement The Environmental Protection Agency s 2010 regula tions require lower nitrogen oxide NOx exhaust emissions Selective catalytic reduction SCR uses diesel exhaust fluid DEF to lower NOx emissions in the vehicle exhaust A filter in the DEF pump pre vents clogging of the DEF metering unit injection nozzle See the engine manufacturer s maintenance manual for filter replacement instructions and maintenance intervals Coronado Maintenance Manual January 2010 49 3 49 Exhaust 2 3 09 16 2009 1490354 1 DPF Inlet Temperature Sensor 6 DPF Outlet Temperature 9 SCR Outlet Temperature 2 DOC Inlet Temperature Sensor Sensor Sensor 3 DOC Inlet Pressure Sensor 7 DPF Outlet NOx Sensor 10 SCR Sensor Box 4 DPF Sensor Box 8 SCR Inlet Temperature Sensor 11 SCR Outlet NOx Sensor 5 DPF Outlet Pressure Sensor Fig 3 2HV Two Box ATS Sensor Locations 49 4 Coronado Maintenance Manual January 2010 Cab 60 Index Alphabetical Title of Maintenance Operation MOP MOP Number Mitror Folding CheCk Ama cutis ER 221 7 720 e ia E 60 01 Coronado Maintenance Manual August 2010 Cab 60 01 Mirror Folding Check For vehicles with folding main mirrors make sure that the mirrors fold freely on the pivot points Pivot each
43. 13 2007 SAE Cap for coolant overflow pressure relief only Surge Tank Filler Cap Cold Maximum Coolant Level Cold Minimum Coolant Level 1500390 RONA Fig 1 Surge Tank 2 Using a radiator cap tester check the pressure cap to see if it maintains pressure to within 1096 of the pressure rating marked on the cap If it does not replace the cap Make sure that the replacement radiator cap is correctly rated for the cooling system of the vehicle 3 There is a second valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cools Inspect the vacuum relief valve to be sure it is not stuck 20 4 Make sure that the cap seals properly on the coolant filler neck seat and that the radiator cap gasket is not damaged 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 Apply the vehicle parking brakes then chock the tires Tilt the hood 2 Place a suitable container under the elbow of the radiator outlet pipe and the radiator The con tainer should hold at least 60 quarts 57 liters of fl
44. 2 and M3 90 000 144 800 9000 900 000 1 448 000 91 M1 91 000 146 500 9100 910 000 1 465 000 92 M1 92 000 148 100 9200 920 000 1 481 000 93 M1 93 000 150 000 9300 930 000 1 500 000 94 M1 94 000 151 300 9400 940 000 1 513 000 95 M1 and M2 95 000 153 000 9500 950 000 1 530 000 96 M1 96 000 155 000 9600 960 000 1 550 000 97 M1 97 000 156 100 9700 970 000 1 561 000 98 M1 98 000 157 700 9800 980 000 1 577 000 99 M1 99 000 159 300 9900 990 000 1 593 000 100 M1 and M2 100 000 160 900 10 000 1 000 000 1 609 000 Table 3 Maintenance for Service Schedules and Il Coronado Maintenance Manual August 2010 00 5 00 Vehicle Maintenance Schedule Tables 00 02 General Information Maintenance for Service Schedules Ill and IV Maint No Maintenance Interval gena nali pere AA LULA ate 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 175 000 281 000 8 M1 and M2 200 000 322 000 9 M1 225 000 362 000 10 M1 250 000 402 000 11 M1 275 000 443 000 12 M1 M2 and M3 300 000 483 000 13 M1 325 000 523 000 14 M1 350 000 563 000 15 M1 375 000 604 000 16 M1 and M2 400 000 644 000 17 M1 425 000 684 000 18 M1 450 000 724 000 19 M1 475 000 764 000 20 M1 and M2 500 000 805 000 21 M1 525 000 845 000 22 M1 550 000 885 000 23 M1 575 000 925 000 24 M1 M2 and
45. 4 A 8 Stud Disc Wheel B 10 Stud Disc Wheel Fig 1 Wheel Nut Tightening Sequence Fastener Torques Coronado Maintenance Manual January 2010 40 1 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveiie Inepe6llO Nama Regine eae cet BHB A Steere A A a 41 01 OKVE INS EW OMCAUOM sasa rdc Roc S ANA EAS o are ded item dU lu oder d Er e cate a dome QR 41 02 Coronado Maintenance Manual January 2010 Driveline 41 01 Driveline Inspection 1 Park the vehicle on a flat level surface apply the parking brakes and chock the tires 4h WARNING Self locking bearing cup or bearing strap cap Screws must not be reused replace the cap screws with new ones Also do not undertighten or overtighten any bearing cup or bearing strap capscrews A loose or broken fastener at any point in the driveline weakens the driveline con nection which could cause serious vehicle dam age or could result in a driveshaft separating from the vehicle possibly causing loss of vehicle control that could result in serious personal injury or death 2 Check the torque of the bearing cup or bearing strap capscrews see Table 1 for installed torque values Remove and discard any loose capscrews Do not reuse any loosened self locking capscrews they are designed for one time installation only Replace all loosened and removed capscrews with new ones Tighten the new capscrews as specified in
46. 57 Long Stroke 16 2 51 20 24 2 1 2 inch rated stroke 24 3 inch rated 2 1 2 64 stroke 30 42 6 Coronado Maintenance Manual January 2010 Brakes 42 Brake Chamber Stroke Specifications Chamber z Max Applied Stroke inch mm Manufacturer Type Size 1 Haldex Standard Stroke 12 1 3 8 35 16 1 3 4 44 20 24 2 1 2 Inch Extended Stroke 24 2 51 3 Inch Extended Stroke 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke 30 2 1 2 64 Meritor Standard Stroke 9 Less than 1 1 2 38 12 16 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 t Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers t If type 36 chamber is used slack length should be less than 6 inches Table 1 Brake Chamber Stroke Specifications 42 06 Meritor Camshaft Bracket Lubrication IMPORTANT Perform MOP 42 05 before lubri cating the camshaft bracket NOTE If equipped with an extended maintenance Q Plus brake system the cam shaft bracket will not have a grease fitting These camshafts use a special NLGI Grade synthetic polyurea grease and do not require lubrication for
47. 777207773 y Run Smart CORONADO MAINTENANCE MANUAL Models Coronado 122 Coronado 122SD Coronado 132 Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle A proper maintenance program also helps to minimize downtime and to safeguard warranties This maintenance manual provides information necessary for years of safe reliable and cost efficient vehicle operation IMPORTANT The maintenance operations in this manual are not all inclusive Also refer to other component and body manufacturers instructions for specific inspection and maintenance instructions A listing of many OEM websites of vehicle component or system providers can be found in the Coronado Workshop Manual Section 00 02 Perform the operations in this maintenance manual at scheduled intervals Perform the pretrip and post trip inspections and daily weekly monthly maintenance as outlined in the vehicle driver s manual Major components such as engines transmissions and rear axles are covered in their own maintenance and operation manuals that are provided with the vehicle Perform any maintenance operations listed at the intervals scheduled in those manuals Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you They can also set up a scheduled maintenance program tailored specifi
48. Coronado Workshop Manual for instructions Suspension 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 radius rod end up down in and out If there is any movement replace the torque arm If a torque arm needs to be re placed see Group 32 of the Coronado Work shop Manual for instructions 4 nspect the weld seams between the torque arm tube and the shorter bushing tubes If there are cracks replace the torque arm Do not weld the torque arm for any reason 5 Inspect the rubber bushing ends See Fig 3 Re place the torque arm for any of the following rea sons e if there are gaps between the rubber bush ing and the pin or outer steel sleeve e if either bushing end contacts a torque arm pin mounting bolt e if there are cracks in the bushing e if part of the rubber bushing extends be yond the outer circumference of the outer bushing sleeve 05 27 93 f320021a Fig 3 Torque Arm Bushings 6 Block up the frame enough to take chassis weight off the springs Attempt to move the equalizer up and down using a pry bar between the top of the equalizer and top of the equalizer 32 2 Coronado Maintenance Manual August 2010 Suspension bracket apply hand pressure only See Fig 4 If movement at the center of
49. For fifth wheels equipped with bracket liners rock the fifth wheel If it does not rock freely re move the top plate and inspect the bracket lin ers Replace liners that are broken or less than Frame and Frame Components 0 125 inch 3 mm thick at the top of the liners For the liner replacement procedure see the Fontaine website www fifthwheel 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 the bolt to check the torque See Group 00 for bolt torque specifica tions 9 Check all springs to see if they are securely fas tened and are not deformed 4h WARNING Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause serious injury 10 Check wedge adjustment 10 1 Open the kingpin lock and vertically in sert a 2 inch 50 mm diameter shaft 10 2 Release the lock by tripping the release latch at the bottom of the throat 10 3 Adjust the wedge stop at the end of the wedge to approximately 1 4 inch 6 mm clearance by turning the wedge stop rod located on the right side of the top plate 11 Replace cr
50. Move the vehicle backward then for ward about six feet two meters 6 Place a trammel bar at the rear of the front tires locate the trammel pointers at spindle height and adjust the pointers to line up with the scribe 33 lines on the center ribs of the front tires See Fig 5 Lock in place Check that the scale is set on zero 4 B gt 08 29 94 NOTE B minus A equals toe in f330082a Fig 5 Wheel Toe In overhead view 7 Place the trammel bar at the front of the tires see Fig 6 and adjust the scale end so that the pointers line up with the scribe lines See Fig 7 08 30 94 f330014a Fig 6 Trammel Bar Positioning 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Coro nado Workshop Manual If corrections are needed refer to Group 33 of the Coronado Workshop Manual for instructions on adjusting the toe in Coronado Maintenance Manual January 2010 33 3 33 Front Axle 08 30 94 f400100a Fig 7 Setting Trammel Bar Pointers 33 4 Coronado Maintenance Manual January 2010 Rear Axle Title of Maintenance Operation MOP Axle Breather and Axle Lubricant Level Inspection Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Eubricarib acuto obe REED Eb e ean OY PAGA eink one onde da 35 Index Alphabetical MOP Number Coronado Maintena
51. Oil Fill Plugs 3 Interaxle Differential f350062a Fig 7 Meritor Axle Housing Breathers 6 On non drive axles using oil lubricated 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 35 possibility of dirt and road grime entering the assembly Freightliner NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock the tires IMPORTANT After 300 000 miles 500 000 km oil level must be checked at each M1 interval on Freightliner axles 2 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature NOTE Some Freightliner 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 used as a fill or level hole 3 Check that the lubricant is level with the bottom of the fill hole see Fig 2 If low check for oil leaks and correct as needed 4 Install and tighten the fill plug 41 Ibf ft 55 N m IMPORTANT Always check the axle
52. Regular Hex Flanged Hcc Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 GradeB Grade 8 or Grade G Pitch Bolt B Nut 8 2 Bolt C Nut Bolt Nut 8 2 Bolt Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m 230002 230003 230004 230005 1230006 1230007 1230008 1230009 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 16 18 15 20 16 22 13 18 21 28 5 16 24 16 22 17 23 14 19 23 31 3 8 16 26 35 28 38 23 31 37 50 3 8 24 30 41 32 43 25 34 42 57 716 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2 20 72 98 77 104 65 88 102 138 9 16 12 92 125 98 133 80 108 130 176 9 16 18 103 140 110 149 90 122 146 198 5 8 11 128 173 136 184 110 149 180 244 5 8 18 145 197 154 209 130 176 204 277 3 4 10 226 306 241 327 200 271 320 434 3 4 16 253 343 269 365 220 298 357 484 7 8 9 365 495 388 526 320 434 515 698 7 8 14 402 545 427 579 350 475 568 770 1 8 582 789 1 12 637 863 1 14 652 884 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 13 Torque Values for U S Customary Thread Fas
53. Table 1 For half round yokes with bearing straps tighten the bearing strap capscrews following the tight ening sequence shown in Fig 1 in increments of 20 Ibf ft 25 N m to the torque specifications listed in Table 1 Bearing Cap or Bearing Strap Capscrew Torque Specifications Torque Ibf ft N m U Joint Type Half Round Yokes with Bearing Straps and 3 8 inch Capscrews see Fig 2 Ref 8 Half Round Yokes with Bearing Straps and 1 2 inch Capscrews 45 60 60 80 130 135 175 185 Fig 2 Ref 8 Full Round Yokes with Bearing Cups Fig 3 43 58 RPL Series U Joints with 125 169 Bearing Cups Fig 4 Table 1 Bearing Cap or Bearing Strap Capscrew Torque Specifications 41 12 16 2008 1410529 Tighten the capscrews in a counterclockwise sequence starting with either number 1 position Fig 1 Tightening Sequence Half Round Yoke Bearing Strap Capscrews 3 Check the driveline yokes for cracks and check end yokes for looseness see Fig 2 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 Replace the seal if needed then tighten the yoke nut Refer to Sec tion 41 00 Specifications 400 of the Coronado Workshop Manual for
54. a M1 and M2 maintenance interval operations at the tion numbers are reference numbers used to help M3 maintenance interval M3 Maintenance Interval Operations for Service Schedules Il Ill and IV e Schedule every 15 000 miles 24 000 km or 1500 hours Nana hinipan e Schedule Il every 150 000 miles 240 000 km Check e Schedule Ill every 300 000 miles 483 000 km e Schedule IV every 300 000 miles 483 000 km 00 04 Perform All M1 Operations 00 05 Perform All M2 Operations 09 01 Air Cleaner Element Inspection and Replacement 20 02 Radiator Pressure Flushing and Coolant Change 26 01 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning synthetic lubricant 42 02 Bendix Air Dryer Desiccant Replacement 42 10 Bendix E 6 Foot Control Valve Inspection and Lubrication 46 02 Power Steering Fluid and Filter Change Table 10 M3 Maintenance Interval Operations for Service Schedules Il Ill and IV 00 14 Coronado Maintenance Manual August 2010 General Information 00 Noise Emission Controls Maintenance 00 07 Noise Emission Control the purpose of noise control prior to its sale or Maintenance delivery to the ultimate purchaser or while it is in use 2 The use of the vehicle after such device or ele Federal Law Part 205 ment of design has been removed or rendered Transportation Equipment Noise ihoperaNve By any person Among those acts p
55. a Spicer Tandem Drive Axle Magnetic Strainer 5 Clean the fill and drain plugs as follows Change them if necessary 5 1 For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 2 Clean away the collected material depos ited on each pole Magnets will rapidly lose their effectiveness as collected mate rial bridges the gap between the two poles 5 9 After the first oil is changed inspect the drain plug each time for large quantities of metal particles 5 4 After cleaning install the drain plug s and tighten to 40 to 60 Ibf ft 54 to 81 N m 6 Fill the axle with the recommended lubricant as follows See Table 4 for recommended drive axle lubricants and Table 5 for drive axle lubricant capacities Lubricant SAE Lubricant Type Condition Viscosity Grade Dana Spicer Over the Road Roadranger Service 75W 90 Synthetic Drive Axle Lubricants or na Equivalent with quipment or W 14 Military Specification Under Extra 80 A MIL L 2105D Heavy Loads Table 4 Dana Spicer Drive Axle Recommended Lubricant Dana Spicer Drive Axle Lubricant Capacities Capacity Axle Type Axle Model Pints liters Tandem Drive Axle Installation DD404 DD404P 31 14 7 t DD405 31 14 7 t DS404 DS404P 31 14 7 t Single DS405 DS405P 31 14 7 t nooner DDH40 DDH40P DSH40 U 81 14 7 t D40 170P D46 170P 39 18 5 t 2 Speed dual r
56. a shop towel or a clean rag to clean the area around the power steering reservoir fill cap Twist the cap counter clockwise to remove 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 See Table 1 for recom mended power steering fluids Remove the dipstick and check that power steering fluid is between ADD HOT and FULL HOT If the fluid level is low add enough fluid to bring the level up to the FULL HOT mark on the dipstick 46 04 Power Steering Gear Lubrication TRW TAS and THP PCF Series Sector Shaft NOTICE Apply grease to the sector shaft with a hand type grease gun only Use of a high pressure power grease gun will supply grease too quickly and could affect the high pressure seal contaminating the hydraulic fluid Using a hand type grease gun apply NLGI Grade 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal Fig 2 11 28 95 1461071 1 Sector Shaft Grease Fitting Fig 2 TRW TAS Series Sector Shaft Lubrication 46 05 Drag Link Lubrication 1 Using a clean rag wipe all dirt from both drag link grease fittings see Fig 3 46 2 Coronado Maintenance Manual January 2010 Steering 2 Using a pressure gun apply clean grease at the grease fittings until old grease is forced out of the socket Use
57. acked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 12 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fill the grooves or depressions on the top plate See MOP 31 02 for lubrication instruc tions Jost 1 Disconnect the tractor from the trailer For in structions see the Coronado Driver s Manual 31 2 Coronado Maintenance Manual June 2011 Frame and Frame Components 31 12 02 2010 NOTE 6000 Series shown 7000 Series fifth wheels use similar parts 1 2 3 4 D 6 7 8 9 1 0 Wedge Stop Rod Nut Flat Washer 5 8 Wedge Stop Rod Spring Wedge Stop Rod Grease Fitting Bracket Pin Bracket Retainer Pin Cotter Pin 3 16 x 1 Bumper Spring Handle Spring 11 12 13 14 15 16 17 18 Bolt Secondary Safety Lock Flat Washer Secondary Safety Lock Bushing Secondary Safety Lock Hex Locknut Pull Handle Bolt Bumper Bushing 19 20 21 22 23 24 25 26 2f 1311134 Bumper Timer Spring Timer Operating Handle Bolt Operating Handle Bushing Operating Handle Hair Pin Cotter Wedge Step Jaw Fig 4 Fontaine Fifth Wheel Coronado Maintenance Manual June 2011 31 3 3
58. al operating conditions Unusual vehicle operating conditions may require service at more frequent intervals Service Schedule Types of Service Service Conditions Vehicles that annually travel ess than 6000 miles 10 000 kilometers or that operate under severe conditions Examples of severe service Schedule usage include Operation on extremely poor roads or where there is heavy dust accumulation e Constant exposure to extreme hot cold salt air or other extreme climates Short Haul Transport Schedule Severe Service e Frequent short distance travel Construction site operation City operation fire truck e Farm operation Vehicles that annually travel less than 60 000 miles 100 000 kilometers and operate under nor mal conditions Examples of Schedule Il usage are Schedule Il t Operation primarily in cities and densely populated areas Local transport with infrequent freeway travel High percentage of stop and go travel Schedule IIIT Long Haul Transport e Interstate transport Vehicles that annually travel more than 60 000 miles 100 000 kilometers with minimal city or stop and go operation Examples of Schedule Ill usage are e Regional delivery that is mostly freeway miles e Any road operation with high annual mileage Coronado Maintenance Manual August 2010 00 1 00 General Information Determining Scheduled Maintenance Intervals 00 01 T
59. all the reservoir on the cover and tighten the capscrews 9 Fill the reservoir with 40 ounces 1183 mL of methyl alcohol then install the filler cap 42 05 Brake Inspection IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check Ah 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 Coronado Maintenance Manual January 2010 42 5 42 1 With the engine running and air pressure at cut out pressure set the parking brake 2 Putthe vehicle in the lowest gear and gently at tempt to move it forward The vehicle should not move If the vehicle moves the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service See Group 42 of the Coronado Workshop Manual for repair procedures Brake Component Inspection 1 Park the vehicle on a level surface set the park ing brake and chock the tires Once the tires are chocked release the parking brake 4h WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle bra
60. ange DT463P 40 18 9 Double t Reduction DP463P 40 18 9 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground t Add 2 pints 1 L of additional lubricant to the power divider Table 5 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 used as a fill or level hole 6 1 With the vehicle on a level surface fill the axle through the oil fill hole or standpipe opening Lubricant should be level with the bottom of the oil fill hole or the top of Coronado Maintenance Manual January 2010 35 5 35 the standpipe opening To check fluid level see Fig 2 6 2 Install and tighten the fill plug 40 to 60 Ibf ft 54 to 81 N m Two Speed Axles With Shift Unit IMPORTANT Also do the appropriate procedure under the heading All Axle Models Dana Spicer and Meritor 1 Remove the shift unit housing cover see Fig 6 Drain and discard the old lubricant Discard the housing cover gasket 08 06 93 1 Housing Cover Gasket 2 Oil Fill Plug 3 Shift Unit Housing Cover f350021a Fig 6 Two Speed Axle Shift Unit 2 Thoroughly wash the axle shift parts and housing cover and allow them to air dry 3 Install the housing cover and a new
61. aplex9 XD3 2 Table 1 Approved Grease 72 Coronado Maintenance Manual January 2010 72 1 Heater and Air Conditioner Title of Maintenance Operation MOP Air Conditioner Inspection 00000 eee eee Air Filter Replacement aces o d pei ACRES das 83 Index Alphabetical MOP Number Coronado Maintenance Manual January 2010 Heater and Air Conditioner 83 01 Air Conditioner Inspection NOTE The following procedure applies to an air conditioner system with a Denso compressor WARNING Wear eye protection gloves and protective cloth ing when working on the air conditioning system Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Inspect the A C compressor hub A torn or melted rubber dampener center section indi cates internal damage has occurred within the compressor Inspect friction surfaces for wear oil soaked condtions or discoloration due to ex cessive heat 3 With the belt removed check to make sure that the rotor pulley spins freely It should not wobble or make contact with the hub when it is spinning The average air gap between the hub and rotor should be 0 014 to 0 024 inch 0 35 to 0 6 mm Check the gap at several locations and average the results See Fig 1 4 Check the overall condition of the air conditioning hose
62. are off of the saddles Inspect the walking beam for cracks or other damage If damage is found replace the walking beam Keep the vehicle supported by the jack stands for the next operation 5 Manipulate the walking beam so that a microme ter vernier or dial caliper can be used to deter mine the wear area thickness on the bottom face See Fig 7 Measurements should be taken a minimum of 1 2 inch from the beam flange edges to eliminate any edge wear that may have occurred Subtract the wear area thickness see Fig 7 Ref B from the thickness at the non wear area see Fig 7 Ref A to determine the amount of wear If the beams show any wear greater than 0 062 inch 1 5 mm a Chalmers wear plate must be installed or the walking beam must be replaced 09 27 95 320432 A Non Wear Area B Wear Area 1 Walking Beam Fig 7 Walking Beam End Wear Thickness 32 6 Rotate the restrictor cans 360 degrees and in spect the cans for cracks severe corrosion and distortion If any of these conditions are present or the restrictor can is missing replace the re strictor can A 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 grease fittings if equipped on the spring eye bushings
63. ated through the fuel water separator to heat the fuel may be diesel fuel returned from the engine or engine coolant Drain the fuel water Coronado Maintenance Manual January 2010 47A 47 separator only when the engine and fluids have cooled Draining it when the engine is hot could cause severe personal injury due to scalding If returning fuel is released into the atmosphere its vapors can ignite in the presence of any igni tion source Do not expose the fuel to or work with the fuel system near open flame or intense heat To do so could cause fire possibly resulting in serious personal injury or property damage The filter element should be changed only when the fuel level has reached the top of the filter element There is no significant restriction to fuel flow until the element is completely clogged 1 Shut down the engine apply the parking brake and chock the tires 2 Check the fuel level in the fuel filter Replace the fuel water separator element only when the filter element is completely covered If the fuel level has reached the top of the filter element follow the procedure below to replace the element NOTE In the event of an emergency when the filter needs replacement but a Davco filter is not available for the Fuel Pro 382 a temporary filter can be used see the procedure under the heading Emergency Temporary Filter Replace ment Fuel Pro 382 3 Puta clean receptacle under the fuel water s
64. cally adjusted Check that the ten sioner is holding tension on the belt by inserting the end of a breaker bar in the 1 2 inch square hole on the forward face of the tensioner and rotating the tensioner away from the belt When the breaker bar is slowly released the tensioner should return to its original position The tensioner should rotate smoothly with no binding If not see Group 01 of the Coronado Workshop Manual for replacement in structions Coronado Maintenance Manual January 2010 01 1 Engine A aa KOY KA 00 00 90 ow KG Roa KOY NA BI 4 SD 8D Sb SP SD SP SD SP SP SP SP ED SP 8D SP DOON B Le a Yew a Ile E y IP Pee EN py SP 992 oO 293 299292 09 21 2009 Mac geret EDI IC EE RET 1012181 A New Belt B Worn Belt C Material loss results in belt riding directly on pulley tips Fig 1 EPDM Belt Wear 01 2 Coronado Maintenance Manual January 2010 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement else 09 01 Coronado Maintenance Manual January 2010 Air Intake 09 01 Air Cleaner Element Inspection and Replacement Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash mounted restricti
65. cally to your needs Optionally they can assist you in learning how to perform these maintenance procedures IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerTrucks com for more information or contact Daimler Trucks North America LLC at the address below Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appropriate environmental rules and regulations when disposing of materials NOTICE Parts Replacement Considerations Do not replace suspension axle or steering parts such as springs wheels hubs and steering gears with used parts Used parts may have been subjected to collisions or improper use and have undetected structural damage 2010 2011 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 mecha
66. cartridge clockwise about one full turn Tighten the cartridge firmly AD IP 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Using a wrench or a socket loosen the desiccant cartridge bolt Then separate the desiccant car tridge from the end cover 3 Pull the cartridge bolt out of the cover and re move the cartridge 04 16 98 1 Desiccant Cartridge 2 Cartridge Sealing Ring 3 Threaded Base Post 1421910 Fig 3 AD IS Desiccant Cartridge Replacement A WARNING Do not attempt to disassemble the desiccant car tridge assembly Parts for the assembly are not available and the cartridge contains a 150 Ib spring that cannot be mechanically caged Disas sembly could release the spring resulting in per sonal injury 4 Remove and discard both O rings from the car tridge bolt 5 Using a clean rag wipe clean 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 supplied with Bendix replacement kits 8 Lubricate the O rings bolt O ring grooves seal ing rings and cartridge grooves Lubricate the end cover bore
67. cedures fluid capacities specifica tions and procedures for adjustments and for checking the tightness of fasten ers Maintenance manuals do not contain detailed repair or service information Driver s operator s manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components Each manual contains a chapter that covers pretrip and post trip inspections and daily weekly and monthly maintenance of vehicle components Driver s operators manuals do not contain detailed repair or service information Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa 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 particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid Parts technical bulletins provide information on parts These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures parts documentation can be accessed using the following appl
68. cover gas ket Tighten the housing cover capscrews 90 to 110 Ibf in 1020 to 1240 N cm then remove the oil fill plug from the cover IMPORTANT When the ambient temperature is above O F 18 C use SAE 10 heavy duty en gine oil API service classification SD sulfated ash content must not exceed 1 8596 When the ambient temperature is below 0 F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classification SD Rear Axle sulfated ash content must not exceed 1 85 This cold weather mixture can be safely used up to 32 F OC Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures do not mix it with kerosene To prevent component damage do not mix engine oil and automatic transmission fluid 4 Using the recommended lubricant fill the shift unit housing through the oil fill hole until the lubri cant is level with the bottom of the opening 5 Coat the threads of the fill plug with a small amount of Loctite 242 or equivalent sealant Install the fill plug finger tight in the rear axle shift unit housing Using a wrench tighten it an addi tional 1 1 2 turns 35 02 Axle Breather and Axle Lubricant Level Inspection For all axles including tandem drive axles and two speed axles do the procedures under the heading All Axle Models For a two speed axle with a shift
69. dges the gap between the two poles 5 3 Each time the oil is changed replace any magnetic drain plug that does not meet the minimum pickup capacity NOTE Meritor recommends plugs with ele ments having a minimum pickup capacity of 1 5 pounds 0 7 kg of low carbon steel 5 4 After cleaning install the drain plug s and tighten to 35 Ibf ft 47 N m Fill the axle with recommended lubricant as fol lows See Table 2 for drive axle lubricant capaci ties NOTE Some Meritor axles have a small tapped and plugged hole near and below the housing lubricant fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 6 1 With the vehicle on a level surface fill the axle through the oil fill hole Allow a few minutes for the oil to flow into the axle Lubricant should be level with the bottom of the oil fill hole To check fluid level see Fig 2 6 2 Install and tighten the fill plug 35 Ibf ft 47 N m Whenever the interaxle differential housing has been drained add an additional 2 pints 0 9 L of the recommended lubricant directly into the inter axle differential housing Remove the chocks then drive the vehicle un loaded for 1 or 2 miles 2 or 3 km at speeds not to exceed 25 mph 40 km h to thoroughly circulate lubricant throughout the carrier and housing assemblies Rear Axle
70. ding Check 83 01 Air Conditioner Inspection Coronado Maintenance Manual August 2010 00 11 00 General Information M2 Maintenance Interval Operations 00 05 M2 Maintenance Interval Operations for Service Schedules Il and Ill Maintenance e Schedule I every 5000 miles 8000 km or 500 hours Check Operation Number Schedule Il every 50 000 miles 80 000 km e Schedule Ill every 100 000 miles 161 000 km 83 02 Air Filter Replacement Replace the HVAC filters every 6 months regardless of mileage more often if the vehicle is operated under extreme conditions Table 8 M2 Maintenance Interval Operations for Service Schedules Il and Ill Maintenance M2 Maintenance Interval Operations for Service Schedule IV Check Operation Number e Schedule IV every 100 000 miles 161 000 km 00 04 Perform All M1 Operations 01 01 Engine Drive Belt Inspection 15 01 Alternator Battery and Starter Connections Check 20 01 Pressure Relief Cap Check 20 03 Fan Clutch Check noise emission control 25 02 Clutch Release Cross Shaft Lubrication 26 02 Transmission Fluid Level Inspection 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 32 01 Suspension Inspection 32 03 Suspension U Bolt Torque Check 33 02 Knuckle Pin Lubrication Meritor Axles 33 03 Tie Rod Inspection 33 05 Tie Rod Lubrication Meritor Axles 35 02 Axle Breat
71. e apply the parking brakes and chock the tires Clean the area around the drain plug and the transmission fluid pan Place a drain pan under the transmission and remove the drain plug Ex amine the fluid as it drains Remove the 12 mounting bolts six each from the two filter covers NOTE A considerable amount of fluid will drain when the filter covers are removed 5 Remove the filter covers O rings and two square cut seals from the transmission See Fig 5 Remove the filters from the bottom of the control module Lubricate the new O rings with transmission fluid then install them on the cover assemblies Install a new square cut seal on each cover as sembly then install the fluid filter elements on the cover assemblies Install the filter and cover assemblies into the filter compartment Align each cover assembly with the holes in the channel plate sump and push the cover assem blies in by hand to seat the seals NOTICE Do not use the bolts to draw the filter covers to the sump This can damage the covers seals or sump 11 Install six bolts in each cover and torque the bolts 38 to 44 Ibf ft 51 to 61 N m 26 1 2 3 4 09 15 2009 1260317b Filter Cover 5 Gasket Filter Element 6 Capscrew Filter Element O Ring 7 Drain Plug Square Cut
72. e coated with oil before installation Table 14 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads 00 20 Coronado Maintenance Manual August 2010 General Information 00 Torque Specifications Tables 00 10 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threadst Thread Class 8 8 Bolt Class 8 Nut Class 10 9 Bolt Class 10 Nut Diameter Pitch Torque Ibf ft N m Torque Ibf ft N m N 7 N Ss N TOP F P N uds a E WA 230010 230011 1230012 230013 M6 5 7 7 9 M8 12 16 17 23 M8 x 1 13 18 18 24 M10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12 x 1 5 43 58 62 84 M14 66 89 95 129 M14 x 1 5 72 98 103 140 M16 103 140 148 201 M16 x 1 5 110 149 157 213 M18 147 199 203 275 M18 x 1 5 165 224 229 310 M20 208 282 288 390 M20 x 1 5 213 313 320 434 M22 283 384 392 531 M22 x 1 5 315 427 431 584 M24 360 488 498 675 M24 x 2 392 531 542 735 M27 527 715 729 988 M27 x 2 569 771 788 1068 M30 715 969 990 1342 M30 x 2 792 1074 1096 1486 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 15 Torque Values for Metric T
73. e maximum torque of the fastener you are checking Apply pressure until the torque wrench clicks Do not loosen the bolt to check the torque See the applicable torque table in Group 00 for torque specifications NOTICE Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage Check the fasteners at the following locations Axle Stops e Deck Plates Equalizer Brackets Exhaust Brackets Fifth Wheel Legs Fifth Wheel Mountings e Frame Crossmembers and Gussets Front Frame Brackets Front Suspension Spring Brackets Fuel Tank Brackets e Radius Rods e Rear Suspension Spring Brackets e Shock Absorbers e All Other Frame Fasteners Any component that shows signs of cracking or other damage must be repaired or replaced Refer to the Coronado Workshop Manual for repair or replace ment information in the respective section for the component in question 31 04 Trailer Electrical Connector Protection In some cases failure of trailer cables occurs due to intrusion of chloride based road deicing chemicals into the trailer connector Once inside the connector the chloride based chemicals corrode the brass ter Coronado Maintenance Manual June 2011 31 7 31 minals and create bridging between positive and ground terminals NOTE The use of soap is not recommended for cleaning the electrical connector as some soaps may increase
74. e the bushings as needed Inspect the shock absorber for oil leakage If the shock absorber is damaged or leaking replace it with a new one See Group 32 of the Coronado Work shop Manual for replacement instructions Coronado Maintenance Manual August 2010 32 1 32 11 27 95 1320465 Fig 2 Direct Acting Shock Absorber front suspension shown Rear Suspension Check Freightliner Spring Suspension Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only visibly damaged parts is no as surance that the spring is safe Failure to replace a damaged spring assembly could cause an acci dent resulting in serious personal injury or prop erty damage Replace worn cracked or damaged spring brackets Failure to do so could result in bracket breakage possibly leading to loss of vehicle con trol and resulting in personal injury or property damage 1 Inspect the forward and rear spring brackets and equalizer brackets for wear cracks and other damage If any of these conditions exist replace the damaged bracket s See Group 32 of the Coronado Workshop Manual for instructions 2 Inspect the tandem axle frame crossmember and gussets for wear cracks and other damage If any of these conditions exist replace the dam aged parts See Group 32 of the
75. e to apply grease until it is coming out of the back of the bearing It may be Coronado Maintenance Manual June 2011 31 5 31 necessary to raise the rear of the fifth wheel with a pry bar to open up the pocket slightly and allow the grease to flow through A substantial amount of grease may be required initially to fill the reservoir Tilt the fifth wheel ramps down the rear of the fifth wheel 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 not use a lube plate high density polyethylene on top of the fifth wheel or on the kingpin instead of grease without prior approval by Fontaine Fifth Wheel The additional thick ness of this material can prevent the proper op eration of the fifth wheel and may cause a dan gerous condition NOTE Fontaine suggests the use of a Moly based lubricant such as Mobilgrease XHP 320 or equivalent when applying lubricant to the locking jaw and wedge 3 Lubricate the fifth wheel prior to opening and closing it Separate the jaw and wedge with a screwdriver and grease the full length of their mating surfaces Lubricate the top and bott
76. ear tension and align ment Correct if necessary Check for wear on the friction facing Replace the friction facing if it is worn to a 3 16 inch 4 8 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evi Coronado Maintenance Manual January 2010 20 3 20 Engine Cooling R adiator dence of oil or burn marks are found replace the friction facing 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and fan clutch from a distance Look for vibration fan blade contact fan clutch slippage and overall fan clutch operation If the fan clutch does not operate correctly see Group 20 of the Coronado Workshop Manual for troubleshooting and repair procedures 8 With the air system charged to 120 psi 827 kPa check the fan clutch for audible air leaks using a suitable listening device Check at the solenoid valve the air filter assem bly and the air hoses and fittings See Fig 6 Using a wet finger or a soapy water solution check for a leak in the same areas 05 30 2002 l O 1200581 Fig 6 Checking for Air Leaks Horton DriveMaster 9 If a leak is detected remove the fan blade In stall a new seal kit See Group 20 of the Coro nado Workshop Manual for repair procedures 10 Check the fan drive for discoloration or any other signs
77. engagement For ad justment refer to the fifth wheel installa tion instructions 10 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 11 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fill the grooves or depressions on the top plate See MOP 31 02 for lubrication instruc tions 31 02 Fifth Wheel Lubrication To maintain proper fifth wheel operation always lubri cate the fifth wheel after an inspection has been performed IMPORTANT Lubricate the fifth wheel e After power washing or steam cleaning e f the vehicle operates in harsh conditions such as salt spray from road surfaces or in ex tremely dusty environments e After any service that requires removal of lubri cation from the fifth wheel head or components A WARNING Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Fontaine 1 Tilt the top plate forward the front of the fifth wheel is down and apply grease to each bearing area through the zerk fittings located on each side of the top plate just to the front of the bracket pins Continu
78. epa rator and attach a piece of hose to the drain valve to direct fuel into the receptacle The drain valve has a 1 2 inch 12 7 mm pipe use a hose with a 1 2 inch pipe thread to fit cor rectly 4 Remove the vent cap Fig 2 Item 4 and open the drain valve Fig 2 Item 1 to drain the fuel completely then close the drain valve 5 Using a DAVCO Collar Wrench Fig 3 remove the clear cover and collar NOTE Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVCO Oollar Wrench is used for removal During installation the vent cap and collar are to be hand tightened only not tightened with a wrench Use part number 482017 on Fuel Pro 482 units part number 380134 on Fuel Pro 382 units Fuel 05 05 2009 A 1470506b 1 Drain Valve 4 Vent Cap 2 Lower Housing 5 Oollar 3 Clear Cover 6 Inlet Port Check Valve Fig 2 DAVCO Fuel Water Separator Fuel Pro 382 Shown VENT CAP 02 16 2009 1470277 Fig 3 DAVCO Collar Wrench 6 Remove the filter cover O ring and vent cap O ring Dispose of them in an environmentally acceptable manner See Fig 4 or Fig 5 7 Clean all threads and sealing surfaces very thor oughly Even a small amount of dirt will prevent the fuel water separator from sealing and an air leak may result 8 On Fuel Pro 382 units install the grommet on the bottom of the new filter 9 Install the
79. er on the lower mounting bracket Install the two previously marked bolts four washers and two new Nylok nuts Torque 19 the two remaining Nylok nuts 17 to 24 Ibf ft 370 to 520 N m Install the bolt two washers and a new Nylok nut in the upper mounting bracket Fig 1 AD 9 Air Dryer exploded view information strap Torque the upper mounting bracket strap Nylok nut 80 to 120 Ibf in 900 to 1360 N cm 18 Connect and tighten the three air lines Connect the harness connector to the heater and thermo stat assembly until the lock tab snaps in place Start the engine build the air pressure and check the air brake system for leaks If any air leaks are present see Group 42 of the Coro nado Workshop Manual for diagnosis and repair 42 2 Coronado Maintenance Manual January 2010 Brakes 42 09 20 94 f420544a Fig 2 AD 9 End Cover to Housing Torque Pattern AD IS 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Drain the air reservoirs 3 Using a strap wrench or equivalent loosen the desiccant cartridge Spin the cartridge off by hand and discard it See Fig 3 4 On the new desiccant cartridge lubricate the sealing rings with silicone grease IMPORTANT Only use the silicone grease sup plied with Bendix replacement kits 5 Screw the desiccant cartridge onto the body by hand until the seal makes contact with the body Rotate the
80. etering unit DEF Tank holds DEF and regulates its tem perature DEF Metering Unit mixes DEF with com pressed air and meters this mixture into the exhaust flow via an injection nozzle SCR Catalyst the housing containing a treated ceramic flow through block where the DEF and 49 exhaust gases undergo selective catalytic re duction SCR e Selective Catalytic Reduction SCR a process used to reduce NOx emissions EPA10 Exhaust System Inspection To meet EPA10 emissions regulations for vehicles domiciled in the USA or Canada engines manufac tured after December 31 2009 are equipped with an emission aftertreatment system Vehicles domiciled outside of the USA and Canada may not have after treatment equipment depending upon local statutory emissions guidelines IMPORTANT The aftertreatment device ATD which is part of the aftertreatment system ATS requires special attention during regularly scheduled maintenance inspections No leaks are allowed anywhere in the system If any dis crepancies are discovered refer to the engine manufacturer s service literature for repair in structions 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
81. fall freely into position See Fig 10 29 2007 1 Lubricant Grooves 2 Safety Latch f311052 3 Release Handle 4 Mount Fig 1 Holland FWS1 Fifth Wheel 5 The lever bar and release handle must be in proper alignment See Fig 2 Compare the lever bar and release handle alignment to a new or a 31 properly operating lever bar and release handle Replace any bent or misaligned lever bar or re lease handle V af 2 Lever Bar pi N pe 01 13 2011 1 Release Handle 1310470 Fig 2 Lever Bar and Release Handle Alignment 6 Check all cotter pins for cracking or damage Re place any cotter pin that shows any signs of damage 7 Check all mounting bolts for signs of fatigue and tighten them to the proper torque For torque specifications see Group 00 Inspect all angles plates and brackets for cracks or other damage 8 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 9 After inspecting the fifth wheel lubricate all mov 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 Coronado Driver s Manual 2 Thoroughly steam clean all fifth wheel compo nents before ins
82. for the bolt Coronado Maintenance Manual January 2010 42 3 42 10 Install both O rings on the cartridge bolt then using a twisting motion insert the assembled desiccant cartridge bolt in the end cover Install the desiccant cartridge on the end cover making sure the cartridge is properly seated and flush on the end cover NOTE It may be necessary to rotate the car tridge slightly until the anti rotation lugs are properly aligned and allow the cartridge to rest flush against the end cover 11 12 Using a wrench or socket tighten the desiccant cartridge bolt 70 Ibf ft 95 N m Do notover torque Before placing the vehicle in service perform the test below 12 1 Close all reservoir drain cocks 12 2 Build system pressure to governor cut out and note that the AD IP air dryer purges with an audible escape of air 12 3 Fan the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pres sure and is followed by a purge at the AD IP air dryer exhaust 12 4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover With the com pressor in loaded mode compressing air apply a soapy solution to these areas and observe that any leakage does not exceed a 1 inch bubble in 1 second If leakage exceeds this measure remove and re install the desiccant car tridge 42 03 Air Dryer Inspection
83. fth wheels spray diesel fuel on the slide path of the base plate 31 6 Coronado Maintenance Manual June 2011 Frame and Frame Components 12 03 2010 f311135 1 Release Handle and 3 Yoke Tip Spring 4 Locks 2 Grease Fitting Fig 9 Holland FW35 Fifth Wheel Grease Lubrication 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 is equipped with low lube plates the top plate only requires lubrication at the new product break in stage The low lube plates re quire no further lubrication 31 03 Frame Fastener Torque Check Frame brackets and components secured with Huck bolt fasteners do not require a torque check how ever they should be inspected for damage Frame brackets and components secured with conventional bolts and nuts are to be checked at Initial Mainte nance IM Check the torque of frame fasteners to offset the effects of bedding in or seating When checking torque torque the nut not the bolt head 31 whenever possible This will give a true torque read ing by eliminating bolt body friction When checking the torque of frame fasteners inspect the frame for cracks and other damage Set a click type torque wrench to th
84. heel Lubrication 31 04 Trailer Electrical Connector Lubrication 31 05 Premier 690 Coupling Inspection Coronado Maintenance Manual August 2010 00 9 00 General Information M1 Maintenance Interval Operations 00 04 Maintenance M1 Maintenance Interval Operations for Service Schedule IV Check Operation Number e Schedule IV every 25 000 miles 40 000 km 42 02 Bendix Air Dryer Desiccant Replacement with an oil coalescing desiccant cartridge 42 05 Brake Inspection 49 01 Exhaust System Inspection noise emission control 72 01 Door Seal and Door Latch Lubrication 88 01 Hood Rear Support Lubrication If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwise use the M3 maintenance interval Table 7 M1 Maintenance Interval Operations for Service Schedule IV 00 10 Coronado Maintenance Manual August 2010 General Information The M2 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M2 maintenance interval Maintenance opera 00 M2 Maintenance Interval Operations 00 05 you find detailed instructions in this manual on the maintenance operations to be performed Perform all M1 maintenance interval operations at the M2 main tion numbers are reference numbers used to help tenance i
85. her and Axle Lubricant Level Inspection 40 01 Wheel Nut Check 41 01 Driveline Inspection 41 02 Driveline Lubrication 42 01 Air Brake System Valve Inspection 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 46 01 Drag Link Inspection 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 47 01 Fuel Filter Replacement 47 02 Fuel Water Separator Element Checking and Replacement 60 01 Mirror Folding Check 83 01 Air Conditioner Inspection 00 12 Coronado Maintenance Manual August 2010 General Information 00 M2 Maintenance Interval Operations 00 05 Maintenance M2 Maintenance Interval Operations for Service Schedule IV Check Operation Number Schedule IV every 100 000 miles 161 000 km 83 02 Air Filter Replacement Replace the HVAC filters every 6 months regardless of mileage more often if the vehicle is operated under extreme conditions Table 9 M2 Maintenance Interval Operations for Service Schedule IV Coronado Maintenance Manual August 2010 00 13 00 General Information M3 Maintenance Interval Operations 00 06 The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed Perform all at the M3 maintenance interval Maintenance oper
86. hread Fasteners With Lubricated or Plated Threads Coronado Maintenance Manual August 2010 00 21 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Belt InSpOCcllOne x Sendo aue sie She ERN a EM e Sonar pP Bre A 01 01 Coronado Maintenance Manual January 2010 Engine 01 01 Engine Drive Belt Inspection Worn or loose drive belts may cause engine over heating or loss of alternator power Excessive ten sion or too little tension on the belt may result in ex cessive and premature belt wear or accessory bearing failure Serpentine belts are retained by a belt tensioner that requires no tension adjustment Replace the drive belt if any conditions described below are found To inspect a belt gently twist it to view the belt sidewalls and bottom IMPORTANT For EPDM rubber drive belts do not rely on cracking as an indicator of belt wear EPDM rubber drive belts resist cracking better than Neoprene belts A better indicator of wear on EPDM belts is material loss Belt and Pulley Inspection 1 Inspect the belt for glazing Glazing is repre sented by shiny sidewalls and is caused by fric tion created when a loose belt slips in the pul leys It can also be caused by oil or grease on the pulleys 2 Check the belt for ply separation Oil grease or belt dressing can cause the belt to fall apart in layers Repair any oil or coolant leaks that are affecting the belts bef
87. ications on the 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 is an electronic parts catalog system showing the specified vehicle s build record 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 ac cessed from within PartsPro Coronado Maintenance Manual June 2011 Introduction Descriptions of Service Publications Warranty related service information available on the AccessFreightliner com website includes the following documentation Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles Field Service Campaigns Field service campaigns are concerned with non safety related service work or replacement of parts All field service campaigns are di
88. ice Schedules Il Ill and IV e Schedule I at 1000 miles 1600 km or 50 hours e Schedule Il at 10 000 miles 16 000 km e Schedule Ill at 25 000 miles 40 000 km Check 00 04 Perform all M1 Operations 31 03 Frame Fastener Torque Check 31 05 Premier 690 Coupling Inspection 32 03 Suspension U Bolt Torque Check 33 06 All Axle Alignment Check 40 01 Wheel Nut Check 47 03 Fuel Tank Band Nut Tightening Table 5 Initial Maintenance IM Operations for Service Schedules Il Ill and IV 00 8 Coronado Maintenance Manual August 2010 General Information The M1 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M1 maintenance interval Maintenance opera tion numbers are reference numbers used to help 00 M1 Maintenance Interval Operations 00 04 you find detailed instructions in this manual on the the Coronado Driver s Manual maintenance operations to be performed IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and Post Trip Inspections and Maintenance chapter of Maintenance M1 Maintenance Interval Operations for Service Schedules I Il and Ill e Schedule I every 1000 miles 1600 km or 50 hours Operation Number e Schedule Il every 10 000 miles 16 000 km e Schedule Ill every 25 000 miles 40 000 km Check
89. ig 5 42 8 Coronado Maintenance Manual January 2010 Brakes Use an NLGI Grade 1 or Grade 2 multipurpose chas sis grease If grease leaks out under the camhead the camshaft bracket grease seal is worn or dam aged replace it See Group 42 of the Coronado Workshop Manual for grease seal replacement in structions 42 09 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication IMPORTANT Perform MOP 42 05 before lubri cating the camshaft bracket Automatic slack adjusters that have a grease fitting must be lubricated periodically to ensure proper brake operation Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death Dana Spicer and Haldex Do not use moly disulfide loaded grease or oil Both the life and reliability of the slack adjuster will be reduced if this type of grease is used which could lead to brake failure resulting in property damage personal injury or death Lubricate the automatic slack adjuster at the grease fitting See Fig 7 Use standard chassis lubricant for Haldex slack adjusters Dana Spicer Low Lube slack adjusters should be lubricated with SHC 460 syn thetic lubricant Gunite For operating temperatures of 20 F 29C and higher use Texaco Multifak EP 2 or Mobil Grease No 77 For operating temperatures between 20 F 29 C and 40 F 40 C use Lubriplate Aero grease Lub
90. ing when working around batteries 1 Check the tightness of the alternator fasteners tighten as needed For torque values see Group 15 of the Coronado Workshop Manual 2 Inspect the alternator drive belt for cracking glazing and wear see Group 01 Replace the belt if it shows any of these symptoms NOTE Engines equipped with a serpentine belt have automatic belt tensioners and do not re quire belt tension adjustment 3 Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed 4 Check that all electrical connections at the alter nator and starter are free of corrosion Clean and tighten all charging system electrical connec tions including the connections at the starter B terminal and ground terminal the magnetic switch and where the alternator charging cable terminates Apply red dielectric enamel to all ex posed connections 5 Inspect the battery retainer assembly or hold downs and the battery box Replace worn or damaged parts Remove any corrosion with a wire brush and wash with a weak solution of baking soda and water Flush with clean water and dry Paint the retainer assembly if needed to prevent rusting 15 Check that foreign material such as road debris is removed from the battery box Inspect and clean the battery cables terminals and clamps as follows See Group 54 of the Coronado Workshop Manual for troubleshooting instructions and f
91. ithium stear ate grease until new grease is seen at the bushing grease seal opposite the fittings The grease seal will accept grease pressure without damage and is de signed 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 3 NOTE For operation in very cold climates use NLGI Grade 1 696 12 hydroxy lithium stearate grease Coronado Maintenance Manual January 2010 33 1 33 Front Axle 09 06 96 1320032a A Grease Exit 1 Grease Fitting Fig 3 Meritor Knuckle Pin Lubrication 33 03 Tie Rod Inspection 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Check for a missing cotter pin or loose tie rod end nut Tighten as needed Install a cotter pin if it is missing 3 Shake the cross tube A loose fit or movement between the tapered shaft of the ball and the cross tube socket members indicates that the tie rod end assembly must be replaced 4 The threaded portion of the tie rod end assembly must be inserted all the way into the cross tube split for adequate clamping see Fig 4 Replace the components if this cannot be done see Group 33 of the Coronado Workshop Manual 33 04 Tie Rod Lubrication Freightliner and Dana Spicer Axles
92. k ing system may lead to brake failure resulting in property damage personal injury or death Brakes 2 With the engine off and 100 psi 689 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 550 to 620 kPa brake applica tion 3 Check to see if the colored over stroke band on each brake chamber pushrod is exposed If a band shows the stroke is too long Check the foundation brake components for wear or damage and repair as needed See Group 42 of the Coronado Workshop Manual for 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 or adjustment of the automatic slack adjuster See Group 42 of the Coronado Workshop Manual for inspection and trouble shooting procedures 5 Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine 6 Check all of the foundation brake components for damage wear and loose or missing parts Re pair as needed See Group 42 of the Coronado Workshop Manual for repair procedures Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Size t Gunite Standard Stroke 9 1 3 8 35 12 16 20 1 3 4 44 24 30 2 51 36 t 2 1 4
93. ke system the slack adjuster will not have a grease fitting These slack adjusters use a special NLGI Grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance slack adjusters are lubricated dur ing the brake reline service interval For service Brakes and lubrication instructions see Group 42 of the Coronado Workshop Manual For slack adjusters with grease fittings and for oper ating temperatures above 40 F 40 C use an NLGI Grade 1 clay base grease or an NLGI Grade 1 or 2 lithium base grease For slack adjusters with grease fittings and for oper ating temperatures below 40 F 40 C and above 65 F 54 C use an NLGI Grade 2 synthetic oil clay base grease Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure relief capscrew or past the gear splines around the inboard snap ring See Fig 6 10 20 93 1420012a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or plug eub cec NO Fig 6 Meritor Automatic Slack Adjuster 42 08 Dana Spicer Camshaft Bracket Lubrication IMPORTANT Perform MOP 42 05 before lubri cating the camshaft bracket Pump grease into the camshaft bracket until it ap pears at the slack adjuster end of the bracket See F
94. l stud neck 33 06 All Axle Alignment Check Drive Axle Alignment Checking Check the axle alignment parallelism and thrust angle measurements for the rear drive axles Use the applicable procedure and specifications in Group 35 of the Coronado Workshop Manual Toe In Inspection For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for the front wheels must rotate freely without friction and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufacturer Freightliner dealers must have proof of this calibration history 1 Apply the parking brakes and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Place safety stands under the axle 3 Using spray paint or a piece of chalk mark the entire center 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 tires are exactly straight ahead NOTE If turn plates or turntables are not avail able lower the vehicle Remove the chocks from the rear tires and release the parking brakes
95. liliters mL 0 03381 fluid ounces fl oz pints pt 0 47318 liters L 2 1134 pints pt quarts qt 0 94635 liters L 1 0567 quarts qt gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic feet ft cubic feet ft3 0 02832 cubic meters m3 35 315 cubic feet ft3 Weight Force ounces av oz 28 35 grams g 0 03527 ounces av oz pounds av Ib 0 454 kilograms kg 2 205 pounds av Ib U S tons t 907 18 kilograms kg 0 001102 U S tons t U S tons t 0 90718 metric tons t 1 1023 U S tons t Torque Work Force inch pounds Ibf in 11 298 Newton centimeters N cm 0 08851 inch pounds Ibf in foot pounds Ibf ft 1 3558 Newton meters N m 0 7376 foot pounds Ibf ft Pressure Vacuum inches of mercury inHg 3 37685 kilo Pascals kPa 0 29613 inches of mercury inHg pounds per square inch psi 6 895 kilo Pascals kPa 0 14503 pounds per square inch psi Table 11 Metric U S Customary Conversion Then When You Multiply Then When You Know Subtract Divide By To Get Know By Add To Get degrees Fahrenheit F 32 1 8 degrees Celcius C 1 8 32 degrees Fahrenheit F Table 12 Temperature Conversion 00 18 Coronado Maintenance Manual August 2010 General Information 00 Torque Specifications Tables 00 10 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst
96. llli 49 01 Coronado Maintenance Manual January 2010 Exhaust 49 01 Exhaust System Inspection Noise Emission Control In addition to inspecting the exhaust system at the scheduled maintenance interval inspect the exhaust system if the noise level of the vehicle has in creased Freightliner Trucks recommends replacing parts that show leakage wear or damage with genuine Freightliner parts It is a violation of US federal law to alter exhaust plumbing or aftertreatment in any way that would bring the engine out of compliance with certification requirements Ref 42 U S C S7522 a 3 It is the owner s responsibility to maintain the vehicle so that it conforms to EPA regulations Definitions of ATS Terms Refer to the following list of definitions of ATS terms and components e Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a housing that contains the DOC and DPF also the SCR and the mixing tube in one box systems BlueTece Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that oxidizes soot in the ATD Diesel Particulate Filter DPF a component in the ATD that traps soot from the exhaust gas Diesel Exhaust Fluid DEF the chemical agent that reacts with the exhaust gases in the SCR to reduce NOx DEF Pump filters and supplies DEF to the DEF m
97. lug as follows e 25 to 35 Ibf ft 34 to 48 N m for transmis sions with 3 4 inch pipe threads 26 2 Coronado Maintenance Manual January 2010 Transmission e 60 to 75 Ibf ft 81 to 102 N m for transmis sions with 1 1 4 inch pipe threads Allison Cold Check Clean all dirt from around the end of the fluid fill tube before removing the dipstick Do not allow foreign matter to enter the transmission Dirt or foreign mat ter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog pas sages It is important to check the fluid level cold to deter mine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed 1 Park the vehicle on a level surface apply the parking brakes and chock the tires Run the engine for at least one minute Shift from DRIVE to NEUTRAL and then shift to REVERSE to fill the hydraulic system 4 Shift to NEUTRAL and allow the engine to idle at 500 to 800 rpm 5 With the engine running at idle remove the dip stick from the tube and wipe it clean 6 Insert the dipstick into the tube then remove it Check the fluid level reading then repeat the check procedure to verify the reading If the fluid level is within the COLD RUN band the transmission may be operated until the fluid is hot enough to perform a hot check If the fluid level is not within the COLD RUN band add or drain fluid a
98. luid level again Transmission 9 Clean the fill plug then install it in the transmis sion Tighten the plug as follows e 25 to 35 Ibf ft 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads 10 Operate the vehicle to check for correct opera tion 26 02 Transmission Fluid Level Inspection NOTICE Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi tives friction modifiers extreme pressure gear fluids or multiviscosity lubricants Eaton Fuller NOTE Check the transmission fluid level with the transmission at operating temperature 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Clean the area around the fill plug then remove the plug from the side of the gear case 3 Using your finger or a bent pipe cleaner check if the fluid is level with the fill opening See Fig 1 4 lf the fluid level is low check the transmission for leaks and correct as needed 5 f needed add recommended fluid until it is level with the lower edge of the fill opening See Table 1 for approved transmission fluids 6 Clean the fill plug then install it Tighten the p
99. mirror fully forward and backward two times to break loose any debris that may affect the fold away feature of the mirror 60 Coronado Maintenance Manual August 2010 60 1 Doors 72 Index Alphabetical Title of Maintenance Operation MOP MOP Number Door Seal Door Latch and Door Check Lubrication cc ee eee 72 01 Coronado Maintenance Manual January 2010 Doors 72 01 Door Seal Door Latch and Door Check Lubrication NOTICE Do not lubricate the door hinges Lubrication could adversely affect the performance of the hinge bushings NOTE Light penetrating oils such as WD 40 should not be used because they wash out ben eficial factory installed grease and they evapo rate Door Seals Lightly coat the door seals with a lubricant that is safe for rubber Door Latches Wipe old grease and dirt from all door latch assem blies then apply liberal amounts of an approved grease to each moving joint see Table 1 Use an appropriate applicator that will not leave material behind Door Checks Wipe old grease and dirt from door checks Lubricate each moving joint of the door checks at installation and every six months thereafter with an approved grease see Table 1 Use an appropriate applicator that will not leave material behind Approved Grease A NLGI Application Lubricant Grade Door Latches ConocoPhillips Triton 460 1 5 Door Checks ConocoPhillips Meg
100. mscr bir wks 2 NGH hoe eee NG KAWA pd Ras es ERR 42 07 Coronado Maintenance Manual January 2010 Brakes 42 01 Air Brake System Valve Inspection NOTE There is no scheduled air valve mainte nance on vehicles equipped with Bendix air valves and a Bendix air dryer if the air dryer desiccant is replaced at 350 000 miles 563 000 km If the desiccant is not changed at 350 000 miles 563 000 km or if the vehicle is equipped with another air dryer maintenance will have to be performed to the air brake valves See Group 42 of the Coronado Workshop Manual for procedures IMPORTANT For vehicles equipped with an oil coalescing air dryer desiccant cartridge replace the cartridge once a year regardless of mileage 42 02 Bendix Air Dryer Desiccant Replacement IMPORTANT For vehicles equipped with an oil coalescing air dryer desiccant cartridge replace the cartridge once a year regardless of mileage AD 9 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read O psi 0 kPa NOTE The compressor discharge line may still contain residual air pressure open the line slowly 3 ldentify tag and disconnect the three air lines from the end cover 4 Disconnect the harness connector from the heater and thermostat assembly 5 Loosen the bolt that secures the upper mounting bracket strap 6 Remove
101. multipurpose chassis grease NLGI Grade 2 896 12 hydroxy lithium stearate grease or NLGI Grade 1 696 12 hydroxy lithium stearate grease Grade 2 is preferred CD 1 2 11 27 95 1461072 1 Grease Fitting at Pitman Arm 2 Grease Fitting at Axle Steering Arm Fig 3 Drag Link 46 Coronado Maintenance Manual January 2010 46 3 Fuel Title of Maintenance Operation MOP Fuel Filter Replacement s D eps NGA HI Piece xiu nis Fuel Tank Band Nut Tightening s soos NA NAKAKA NG KAKA etal LAWAS Fuel Water Separator Element Checking and Replacement 47 Index Alphabetical MOP Number Coronado Maintenance Manual January 2010 Fuel 47 01 Fuel Filter Replacement For engine mounted fuel filter replacement refer to the engine manufacturer s service manual for re moval and installation procedures 47 02 Fuel Water Separator Element Checking and Replacement Alliance Racor The only maintenance necessary on an Alliance or Racor fuel water separator is to replace the filter element Fluid circulated through the fuel water separator to heat the fuel may be diesel fuel returned from the engine or engine coolant Drain the fuel water separator only when the engine and fluids have cooled Draining it when the engine is hot could cause severe personal injury due to scalding If returning fuel is released into the atmosphere its vapors can ignite in the presence of any igni tion source
102. n 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 engine apply the parking brakes and chock the rear tires 2 Place a drain pan under the power steering res ervoir 46 3 Remove the retaining ring from the reservoir See Fig 1 2 3 4 MAX HOT 1 MIN COLD N vd 10 19 2001 1461917 1 Power Steering Reservoir 2 Retaining Ring 3 Filter Cover 4 Return Hose Fig 1 Power Steering Reservoir 4 Remove the filter filler cover and gasket from the reservoir Drain the fluid from the filter into the drain pan Leave the filter hanging over the drain pan 5 Remove the nuts bolts and washers that attach the power steering reservoir to the mounting bracket but do not remove the supply line to the reservoir Drain the power steering fluid from the reservoir 6 Using bolts nuts and washers attach the reser voir to the mounting bracket 7 Fill the reservoir with an approved power steer ing fluid to the line between the MIN COLD and MAX HOT lines See Fig 1 See Table 1 for ap proved power steering fluids Approved Power Steering Fluids Fluid Type Approved Fluid Dexron III Automatic Transmission Fluid Super ATF TES 389 Table 1 Approved Po
103. nce Manual January 2010 Rear Axle 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Lubricant NOTICE When operating under adverse conditions it may be necessary to change the axle lubricant at more frequent intervals than listed in the scheduled maintenance tables Failure to do so could result in axle damage IMPORTANT For all axles including tandem drive axles and two speed axles do the proce dures under the heading All Axle Models For a two speed axle with a shift unit also change the shift unit lubricant See under the heading Two Speed Axles With Shift Unit All Axle Models Meritor IMPORTANT If using synthetic lubricant in an axle equipped with a pump and filter system the lubricant change interval is extended to 500 000 miles 800 000 km IMPORTANT Meritor rear axles do not require the use of friction modifiers 1 Park the vehicle on level ground apply the park ing brakes and chock the front tires 2 Remove the axle carrier fill plug Then remove the drain plug from the bottom of the housing Completely drain the lubricant while the unit is warm to allow the lubricant to drain faster 35 On tandem drive axles it is also necessary to remove the plug at the bottom of the interaxle differential housing to drain that lubricant 3 If equipped with an oil pump remove the axle oil filter Use a suitable filter strap wrench see Fig 1 Discard the
104. nditions for composite spring assemblies as a separation in any axis which passes completely through the composite spring material For additional information on composite spring as semblies refer to the CVSA Out of Service OOS Criteria Inspect the Liteflex spring for cracks that result in an out of service condition as follows see Fig 1 a side to side crack extending beyond 3 4 of the length of the spring e a top to bottom crack extending beyond 3 4 of the length of the spring e intersecting cracks of any length The Liteflex composite spring should also be re moved from service if splintering has occured to the point where noticeable vehicle ride height loss has occurred 32 b sd y C 08 14 2008 1321135 A Side to side crack extending beyond 3 4 of the length of the spring B Top to bottom crack extending beyond 3 4 of the length of the spring C Intersecting cracks of any length Fig 1 Out of Service Conditions Composite Spring Shock Absorber Check Front and Rear Suspensions Make sure the shock absorber brackets are tight and the shock absorber is not striking or rubbing the frame or some other part of the chassis Striking or rubbing the frame is characterized by chafe marks on the shock absorber body and the frame rail See Fig 2 Check the rubber mounting bushings for cracks cuts swelling and dry rot Also check the bushings for missing pieces Replac
105. nical 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 Introduction Descriptions of Service Publications Daimler Trucks North America L via ServicePro9 formats Workshop Service Manual Maintenance Manual Driver s Operator s Manual Service Bulletins Parts Technical Bulletins Web based repair service and AccessFreightliner com website ServicePro PartsPro EZWiring LC distributes the following major service publications in paper and electronic 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 compo nents refer to the OEM website A listing of many OEM websites can be found in Section 00 02 of the workshop service manual Each workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation and specifi cations Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables fluid replacement pro
106. nnect the vehicle air hose to the inlet 7 Connect the battery cables Start the engine Horton DriveMaster Fan Clutch NOTE If any part of the fan clutch needs to be repaired or replaced after performing the checks below see Group 20 of the Coronado Work shop Manual 1 Disconnect the batteries at the negative termi nals 2 Inspect the electrical connections and wires to the fan clutch solenoid see Fig 4 Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filter if equipped as follows 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment see Fig 5 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 solenoid air filter then install it on the vehicle 4 Check the fan for bent cracked or damaged blades Replace if damaged Check for adequate clearance between the fan and other compo nents 20 MEM HORTON 07 24 2009 1200724 1 Air Filter Housing 2 Solenoid Valve Fig 4 Horton DriveMaster Air Solenoid Valve 0 gt lt gt E S Ll 2 3 f200725 3 Bleed Valve 07 24 2009 1 Filter Element 2 Filter Bowl Fig 5 Horton DriveMaster Solenoid Valve Air Filter 5 Check the fan belt for w
107. nterval M2 Maintenance Interval Operations for Service Schedules Il and Ill Maintenance e Schedule every 5000 miles 8000 km or 500 hours Check Operation Number e Schedule Il every 50 000 miles 80 000 km e Schedule Ill every 100 000 miles 161 000 km 00 04 Perform All M1 Operations 01 02 Engine Drive Belt Inspection 15 01 Alternator Battery and Starter Connections Check 20 01 Pressure Relief Cap Check 20 03 Fan Clutch Check noise emission control 25 02 Clutch Release Cross Shaft Lubrication 25 03 Meritor Clutch Release Bearing Lubrication 26 02 Transmission Fluid Level Inspection 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 26 04 ang Transmission Fluid and Filter Change Castrol TranSynd or other TES 295 ui 32 01 Suspension Inspection 32 03 Suspension U Bolt Torque Check 33 02 Knuckle Pin Lubrication Meritor Axles 33 03 Tie Rod Inspection 33 05 Tie Rod Lubrication Meritor Axles 35 02 Axle Breather and Axle Lubricant Level Inspection 40 01 Wheel Nut Check 42 01 Air Brake System Valve Inspection 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 42 06 Meritor Camshaft Bracket Lubrication 42 07 Meritor Slack Adjuster Lubrication 46 01 Drag Link Inspection 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 47 01 Fuel Filter Replacement 47 02 Fuel Water Separator Element Checking and Replacement 60 01 Mirror Fol
108. ntil excess grease purges from the rear of the re lease bearing toward the transmission NOTICE Do not over lubricate the clutch release bearing Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature failure Do not use chassis grease or multipurpose lubricants 4 Wipe off excess grease and apply it to both the yoke finger and sleeve bushing contact points See Fig 3 5 Install the clutch inspection plate if removed 25 2 Coronado Maintenance Manual January 2010 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison Transmission Fluid and Filter Change ooooococococooo e 26 04 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning llli 26 01 Manual Transmission Air Filter Regulator Check Cleaning or Replacement a 26 03 Transmission Fluid Level Inspection x32 une Ka una god x eR FE E EUR qae ENEE AS 26 02 Coronado Maintenance Manual January 2010 Transmission 26 01 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning NOTICE Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Overfilling will force fluid out of the case through the main shaft openings Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi ti
109. nut rim nut torque can cause wheel shimmy resulting in wheel damage stud 40 breakage and extreme tire tread wear Excessive wheel nut torque can break studs damage threads and crack discs in the stud hole area Use the recommended torque values and follow the tightening sequence shown in Fig 1 When checking stud piloted rear dual disc wheels with inner and outer nuts remove one outer nut at a time tighten the inner nut then reinstall and tighten the outer nut Repeat this procedure for all wheel nuts using the tightening sequence shown in Fig 1 Disc Wheel Fastener Torques Description Nut Size Wheel Manufacturer Torque Ibf ft N m 10 Hole and 8 Hole Hub Piloted Disc Wheel With Two Piece Flange Nuts Front and Rear Wheel Nut M22 x 1 5 All 450 500 610 678 10 Hole Stud Piloted Disc Wheel With Inner and Outer Nuts t 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 accidentally t Torque values for stud piloted wheels are given for clean dry threads Table 1 Disc Wheel 1 a 10 8 7 N 4 3 E i 6 5 N 6 5 f 4 3 8 7 E 9 A B 09 18 2001 140016
110. od may be on the forward or aft side of the lever to get it to be vertical 4 Measure the distance from the axle stop to the top of the axle U bolt pad The correct distance is determined by the axle and suspension con figurations refer to Group 32 of the Coronado Workshop Manual for details 5 If the axle stop measurement is not correct see Group 32 of the Coronado Workshop Manual for adjustment procedures Suspension 01 12 2000 Valve Mounting Bracket Height Control Valve Stud Bolt Linkage Rod Axle f320562a gd orc Fig 6 Typical Barksdale Height Control Valve Installation side view 6 Apply the parking brakes and remove the chocks Chalmers Suspension 1 Chock the front tires place the transmission in neutral and release the parking brakes 2 Power wash the suspension or clean it with a hard bristle brush before performing a visual in spection 3 Inspect the rubber bushings for cracks or other damage Try to move the torque rod ends using your hands only and check for any free play If free play is felt replace the torque rod end bushing Do not use a pry bar to check for free play Use of a pry bar may lead to premature bushing re placement 32 4 Coronado Maintenance Manual August 2010 Suspension 4 Lift the rear of the vehicle and support the frame on jack stands to unload the suspension compo nents The vehicle is lifted high enough when the beam ends
111. 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 filter over the adapter and tighten the filter one full turn after the gasket contacts the base do not overtighten See Table 1 for recommended lubricants 5 Clean the fill and drain plugs as follows Change them if necessary 05 27 93 f350119a Fig 1 Meritor Axle Oil Filter Removal Meritor Drive Axle Recommended Lubricant Recommended Lubricant Type Ambient Temperature Lubricant SAE Viscosity Grade Meritor Specification 40 F 40 C and Up 75W 90 0 76 N Synthetic Gear Oil 40 F 40 C and Up 75W 140 0 76 M There is no upper limit on these outside temperatures but axle sump temperature must never exceed 250 F 121 C Table 1 Meritor Drive Axle Recommended Lubricant Coronado Maintenance Manual January 2010 35 1 35 5 1 For magnetic plugs use a piece of key Stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 2 Check the drain plug for metal particles every 100 000 miles 160 000 km Clean away the collected material deposited on each pole Magnets will rapidly lose their effectiveness as collected material bri
112. om contact surfaces of the jaw and wedge See Fig 4 Open and close the fifth wheel several times to further distribute the grease Lightly oil other moving parts in the fifth wheel 4 Apply grease to the top plate Spread grease all over the mating surface of the top plate Be sure the grease pockets built into the top plates are full of grease Holland FWS1 Apply a heavy coat of grease to the top plate either through the grease fittings located on the underside of the top plate or by direct application Frame and Frame Components Holland FW35 1 Using a water resistant lithium base grease grease the top plate 2 Using a light oil such as SAE 10W or 20W motor oil lubricate the cam track and pivot See Fig 8 3 Grease the yoke tips locks and the release handle and spring see Fig 9 Grease the mounting bracket supports through the grease fittings A low temp grade grease rated for 30 F 34 C or lower such as Cato Oil and Grease 5213 Craftsman Chemical Co LTF 2 Mystic LP 200 or equivalent is recommended 12 03 2010 f311136 Use a light oil such as SAE 10W or 20W motor oil to lubricate the cam track and pivot 1 Cam Plate Fig 8 Holland FW35 Fifth Wheel Oil Lubrication Jost Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel see Fig 7 Apply a light oil to all moving parts For sliding fi
113. on air filter in place see Fig 4 4 Remove and discard the recirculation air filter 5 Install a new recirculation air filter in the retainer 6 Install the retainer in the HVAC assembly see Fig 4 7 Install the dash lower console Tighten the Torx screws 24 to 30 Ibf in 270 to 340 N cm See Fig 3 Sleeper Air Filter Replacement Replace the air filter in the sleeper HVAC unit every six months regardless of mileage The filter should not be cleaned NOTICE 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 chock the tires 2 Access the sleeper HVAC assembly by raising the mattress and bunk panel to the locked posi tion If there is a baggage compartment the sleeper HVAC assembly may be accessed through the baggage door on the right side of the vehicle 3 Slide the air filter out of the sleeper HVAC as sembly see Fig 5 4 Place a new air filter in the sleeper HVAC as sembly The edge of the filter should be flush with the HVAC assembly 83 2 Coronado Maintenance Manual January 2010 Heater and Air Conditioner 83
114. on gauge Vehicles may be equipped with either a manual reset restriction indicator with graduations Fig 1 or a go no go restriction indicator without graduations Fig 2 08 07 2007 1090452 Fig 1 Manual Reset Air Restriction Indicator Graduated 04 08 2005 1090431 Fig 2 Manual Reset Air Restriction Indicator Go No Go 1 Inspect the air restriction indicator to see if air restriction equals or exceeds the maximum al lowable restriction For instructions see Group 09 of the Coronado Workshop Manual 09 If necessary replace the air cleaner element For air cleaner element replacement instructions see Group 09 of the Coronado Workshop Manual Inspect the air cleaner housing for cracks leaks or any other damage If the air cleaner housing or element is damaged replace it Remove the pre cleaners if so equipped from the hood plenum then clean them with com pressed air Reset the air restriction indicator Each time the air cleaner housing is replaced perform the procedures in MOP 13 01 Coronado Maintenance Manual January 2010 09 1 Air Compressor 13 Index Alphabetical Title of Maintenance Operation MOP MOP Number Bendix Air Compressor IR1spectlol s uude odode anes Doe DAKS LILINIS SRL aL Deen ANNE 13 01 Coronado Maintenance Manual January 2010 Air Compressor 13 01 Bendix Air Compressor Inspection
115. on the frame If the air dryer mounting is loose See Group 42 of the Coronado Workshop Manual for mounting instructions Turn on the ignition switch but do not start the engine Disconnect the harness connector from the air dryer Connect a voltmeter to circuit 94 on the air dry er s harness connector and to a body ground point Check for battery voltage If voltage is not found check and repair the open or short to ground in wire 94 Connect a voltmeter between the two terminals on the air dryer s harness connector If voltage is not found repair the open in the ground circuit wiring Use an ohmmeter to check resistance between the terminals on the end cover See Fig 4 The end cover contains the heater thermostat If the heater thermostat is between 40 and 90 F 5 and 42 4 Coronado Maintenance Manual January 2010 Brakes 32 C the heater thermostat measured resis tance will be infinite ohms If the measured resis tance is less than infinity replace the heater thermostat 06 04 96 1421384 1 End Cover Assembly 2 Heater Thermostat Terminals Fig 4 End Cover Terminals Location 9 Remove the heater thermostat assembly and place itin a freezer for about five minutes to cool it below 40 F 5 C Remove the cold heater thermostat assembly and check resis tance between the heater thermostat terminals Resistance should be 1 5 to 3 0 ohms As the temperature of the heater thermostat as
116. or adjustment repair or re placement instructions 7 1 Inspect the battery cables and replace any that are damaged 7 2 Clean and tighten the battery ground cables terminals and clamps Clean the cable connector terminals with a wire brush 7 3 Connect the cables to the batteries and tighten them to the torque specifications listed on the battery generally 10 to 15 Ibf ft 14 to 20 N m 7 4 Coat the battery terminals with dielectric grease Check the connections at the power net distribu tion box Clean and protect the power cables with dielectric enamel as necessary Coronado Maintenance Manual January 2010 15 1 Engine Cooling R adiator Title of Maintenance Operation MOP Fan Clutch Check Noise Emission Control Pressure Relief Cap Check 0 00 00 cece ee Radiator Pressure Flushing and Coolant Change 20 Index Alphabetical MOP Number Coronado Maintenance Manual January 2010 Engine Cooling R adiator 20 01 Pressure Relief Cap Check Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury 1 Remove the fill cap first to relieve the cooling system pressure then remove the SAE cap see Fig 1 06
117. ore replacing the drive belts Do not use belt dressing on any belt 3 Check the belt for a jagged or streaked sidewall Jagged or streaked sidewalls are the result of foreign objects such as sand or gravel in the pulley or a rough pulley surface 4 Check for tensile breaks breaks in the cord body Cuts in a belt are usually caused by for eign objects in the pulley or by prying or forcing the belt during removal or installation 5 Check for uneven ribs on serpentine belts For eign objects in the pulley will erode the under cord ribs causing the belt to lose its gripping power 6 For EPDM belts check the belt for material loss which causes the belt to seat further down in the pulley and to ride directly on the pulley tips See Fig 1 01 7 For Neoprene belts check the drive belts for cracks Small irregular cracks are usually signs of an old belt 8 Inspect the pulleys for excessive play or wobble Excessive play or wobble indicates a failure of the pulley bearing Check for belt squealing or squeaking Replace the bearings as necessary NOTE If it is difficult 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 9 Inspect all pulleys for foreign objects oil or grease in the grooves Belt Tensioner Inspection On belts equipped with a spring tensioner belt ten sion is automati
118. ottom of the fill hole or the top of the standpipe opening 4 Check that the lubricant is level with the bottom of the fill hole or with the top of the standpipe opening see Fig 2 If low check for oil leaks and correct as needed 5 Install and tighten the fill plug 40 to 60 Ibf ft 54 to 81 N m Rear Axle IMPORTANT Always check the axle breather whenever checking lubricant level Check the breather more frequently under adverse operat ing conditions 6 Check the axle housing breather Make sure that it is unclogged and free from corrosion see Fig 8 If the breather is plugged or damaged clean or replace it as needed Two Speed Axles With Shift Unit Dana Spicer and Meritor IMPORTANT Also do the appropriate procedure under the heading All Axle Models NOTICE Failure to keep lubricant at the specified level could cause damage to the axle shift unit 1 Clean the shift unit oil fill plug and the area sur rounding the plug see Fig 6 Turn the fill plug counterclockwise to remove it 2 Insert a finger or pipe cleaner into the fill plug hole and check the fluid 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
119. oval of air intake components affecting noise emission control the owner should be sure that such parts are warranted by their manufac Maintenance Instructions turer to be equivalent to genuine Freightliner parts in performance and durability Scheduled intervals are in the maintenance tables in MAGA this group A Verification of Inspections Log Groups Freightliner Noise Emission 01 20 and 49 follows and should be filled in each time noise emission controls on the vehicle are main Controls Warranty tained or repaired Refer to the vehicle owner s warranty information book for warranty information concerning noise emis sion controls Tampering 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 Coronado Maintenance Manual August 2010 00 15 00 Verification of Inspections Log 00 08 Verification of Inspections Log Verification of Inspections Log Group 01 General Information Verification of Inspections Log Group 01 Engine Mounts Date Mileage Item Cost Maintenance Facility Verification of Inspections Log Group 20 Verification of Inspections Log Group
120. ower Steering Gear Lubrication ia macaa ma miia Ea a a GE Ra ee 46 04 Coronado Maintenance Manual January 2010 Steering 46 01 Drag Link Inspection All steering system components are critical for safe operation of the vehicle Failure to maintain the steering system as specified may result in loss of steering control which could lead to per sonal injury and property damage Have someone turn the steering wheel from left to right Check for movement between the ball stud end at both the pitman arm and the steering arm Also check if the ball stud nut is loose If the ball stud end is loose replace the drag link If the ball stud nut is loose replace the nut and cotter key See Group 00 for proper torque specifications Inspect the boot of the drag link at both the pitman arm and the steering arm end for cracks splits or other damage Replace the boot as needed See Group 46 of the Coronado Workshop Manual for drag link removal and installation instructions Grasp the drag link near the pitman arm end then push and pull laterally to check for axial movement in the ball stud end If it is loose replace the drag link see Group 46 of the Coronado Workshop Manual If there is 1 8 inch 3 mm movement or more do not drive the vehicle until the drag link is replaced 46 02 Power Steering Fluid and Filter Changing Fill only with approved clean fluid Failure to use the proper fluid could cause seal deterioratio
121. pection 3 Check for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Check the fastener torques on the fifth wheel assembly and fifth wheel mounting Tighten bolts and nuts as needed Replace missing or dam aged bolts Coronado Maintenance Manual June 2011 31 1 31 5 Inspect the fifth wheel for bent worn damaged and missing parts replace them as needed with genuine Holland parts 6 Using a Holland Kingpin Lock Tester Holland tool number TF TLN 5001 available through the PDCs as HLD TFTLN5001 check the operation of the locking mechanism by opening and closing the locks See Fig 3 7 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions AE 04 11 2011 B 1310887 A The nut and washer should be snug against the fifth wheel B The locks should be completely closed around the kingpin Fig 3 Holland Fifth Wheel Properly Closed Fontaine 1 Disconnect the tractor from the trailer For in structions see the Coronado Driver s Manual 2 Thoroughly steam clean the fifth wheel 3 Check for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Ensure that both bracket pins are in place and secured by retainer pins and cotter pins See Fig 4 5
122. pply a light coat of transmission fluid to the O ring gasket on the new filter Fill the filter with specified transmission fluid and spin the filter onto the mount NOTE The filter fills slowly so be patient to ensure the proper fluid level has been reached 6 4 Once the filter makes contact with the mount use a strap wrench to rotate the canister an additional 180 to 270 degrees to firmly tighten the filter Wipe the filter clean of any fluid after it is tightened 7 Add fluid until it is level with the lower edge of the fill opening See Fig 1 If the transmission has two fill openings add fluid to the level of both openings See Table 1 for approved trans mission lubricants See Table 2 for Eaton Fuller transmission lubricant capacities Install and tighten each drain plug 50 Ibf ft 68 y D gt p D gt m Y f NOTE The optional transmission fluid filter is a y y A remote mount spin on type and is located be ze y tween the transmission and the fluid cooler The YS as f filter bracket is attached to the frame rail or SE Si Pe AA some other nearby location The filter is mounted in a vertical position and should be 05 27 93 1260006a filled with fluid before installation to assure the A Full B Low proper fluid level For optimum transmission per Fig 1 Checking Transmission Fluid Level Coronado Maintenance Manual January 2010 26 1 26 Approved Transmission Lubricants Transmis
123. r 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 intake plenum Coronado Maintenance Manual January 2010 83 1 83 d He 38 09 11 2009 1 Air Filter Cover 831822 2 Wire Retainer Fig 2 HVAC Air Intake Plenum 7 Pull the wire retainer up and over the upper edge of the air filter cover Cab Recirculation Air Filter Replacement The cab recirculation air filter must be replaced every six months regardless of mileage to permit proper operation of the HVAC system The filter can be ac cessed by removing the dash lower console See Fig 3 NOTICE If the recirculation air filter is not replaced every six months damage to the heater and air condi tioner components could occur The HVAC system should not be operated without the recirculation air filter installed IMPORTANT When replacing the air filter use only a Freightliner approved air filter 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires Heater and Air Conditioner 2 Remove the dash lower console The lower con sole is secured by nine Torx screws see Fig 3 3 Remove the retainer that holds the recirculati
124. resumed to constitute tam pering are the acts listed below Emission Controls Part 205 Transportation Equipment Noise Emission A Removal of engine noise deadening panels Controls requires the vehicle manufacturer to fur nish with each new vehicle such written instructions B Removal of cab tunnel or hood noise for the proper maintenance use and repair of the deadening panels vehicle by the ultimate purchaser to provide reason able assurance of the elimination or minimization of noise emission control degradation throughout the life of the vehicle In compliance with the law the C Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica noise emission controls maintenance information in tions each applicable group of this manual in conjunction D Removal of or rendering inoperative the fan with the vehicle workshop manual provides these clutch including bypassing the control on instructions to owners any thermostatic fan drive to cause it to op erate continuously Recommendations for Replacement Parts Removal of the fan shroud Removal of or rendering inoperative ex Replacement parts used for maintenance or repair of haust components including exhaust pipe noise emission controls should be genuine Freight clamping liner parts If other than genuine Freightliner parts are used for replacement or repair of components G Rem
125. ricate a Gunite automatic slack adjuster at the grease fitting until grease appears on the camshaft or flows from the grease relief See Fig 8 42 02 01 2001 1 Grease Fitting 1421649a 2 Slack Adjuster Fig 7 Dana Spicer Automatic Slack Adjuster 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 10 Bendix E 6 Foot Control Valve Inspection and Lubrication 1 Remove the brake valve from the vehicle see Group 42 of the Coronado Workshop Manual 2 Remove the roll pin from the brake pedal pivot pin See Fig 9 3 Remove the brake pedal pivot pin 4 Remove the brake pedal 5 Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses the area from which the pivot pin was removed Re place it if necessary Coronado Maintenance Manual January 2010 42 9 42 Brakes 4 5 6 7 8 2 9 1 10 10 27 93 1420653a 1 7 16 Inch Adjusting 6 Clevis Nut 7 1 2 Inch Clevis Pin 2 Grease Fitting 8 1 4 Inch Clevis Pin 3 Boot 9 Grease Relief 4 Link Opening 5 Brake Chamber Piston 10 Slack Adjuster Spline Rod Fig 8 Gunite Automatic Slack Adjuster 6 Check the brake pedal roller
126. ronze ball indented bushings in the spring eyes at the grease fitting see Fig 9 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 Lower the vehicle and remove the safety stands 32 03 Suspension U Bolt Torque Check NOTICE Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 1 Park the vehicle on a flat surface apply the park ing brakes and chock the tires 09 15 95 1 Bronze Bushing 2 Lubrication Hole f320424 3 Grease Fitting 4 Lubrication Groove Fig 9 Hendrickson RT2 and RTE2 Series Bushing Lubrication 2 Check the U bolt torque in a diagonal pattern Set a click type torque wrench to the highest torque value for the fastener being checked See Table 1 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks Spring Assembly U Bolt High Nut Torque Values Size Torque Ibf ft N m Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 180 to 230 245 to 313 5 818 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 3 4 16 7 8 14 Stage 1 Hand tighten Stage 2
127. s Look for cracks cuts and abrasions on the hoses Replace damaged hoses For re placement instructions see Group 83 of the Coronado Workshop Manual Also check for signs of loose fittings on all of the air condition ing components 83 02 Air Filter Replacement The HVAC system has three filters that must be re placed periodically to maintain proper system opera tion The cabin fresh air intake filter is accessed from under the hood and the recirculation filter is ac cessed from inside the cab The sleeper air filter is located under the bunk T e 01 13 2010 1831825 A Gap Dimension 0 014 to 0 024 inch 0 35 to 0 60 mm 1 Hub 2 Rotor Magnetic Clutch Fig 1 Hub Rotor Gap Cab Fresh Air Filter Replacement NOTICE If equipped with a fresh air filter it should be re placed every six months more often if the vehicle is operated under extreme conditions If the fresh air filter is not replaced at proper intervals dam age to the heater and air conditioner components could occur IMPORTANT When replacing the air filter use only a Freightliner approved air filter 1 Apply the parking brakes and chock the tires 2 Lift the wire retainer on the air filter cover up and over the upper edge of the cover and pull the wire retainer down see Fig 2 3 Note the direction of the arrow on the air filter cover then remove the cover and the attached filte
128. s for signs of wear or cracks Replace the rollers as needed 7 If the rollers are replaced replace the roller pin install a new cotter pin bend it to 90 degrees and apply Torque Seal OPG F900 White to the cotter pin 8 Remove the plunger from the valve Using alco hol clean the existing grease from the plunger Check the plunger for signs of wear or cracks Replace it if necessary 9 Lubricate the plunger with barium grease BW 246671 10 Insert the plunger in the valve 11 Install the brake pedal with the pivot pin BIN e 7 2 e ER gt SIS 5 A SA SI NYC I KA WAN Y7 1 a 4 NG Ac 6 8 KY 4 09 10 2004 i 1430405 1 E 6 Foot Control Valve 5 Roll Pin 2 Mounting Plate 6 Roller 3 Nut and Washer 7 Roller Pin 4 Pivot Pin 8 Pedal Fig 9 Brake Pedal and Valve Assembly 12 Install a new roll pin and apply Torque Seal OPG F900 White to the roll pin 13 Install the brake valve assembly see Group 42 of the Coronado9 Workshop Manual 14 Test the brakes before returning the vehicle to service 4210 Coronado Maintenance Manual January 2010 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag LINK InSpec HORE ess Gaan cw tenet wont a d a NEGA Ent d a E qubd qe E pde 46 01 Drag Link USMC OM ei aa CI PETIT 46 05 Power Steering Fluid Level Inspection rns 46 03 Power Steering Fluid and Filter Changing eh 46 02 P
129. s needed to adjust the fluid level to the middle of the COLD RUN band See Fig 2 NOTICE As the fluid temperature increases so does the fluid level Do not fill above the COLD RUN band if the transmission fluid is below normal operating temperature NOTE Perform a hot check at the first opportu nity after the normal operating temperature 160 to 200 F 71 to 93 C has been reached 26 a 12 01 97 A Cold Run Band f270002a B Hot Run Band Fig 2 Dipstick Markings Hot Check 1 Park the vehicle on a level surface apply the parking brakes and chock the tires Shift the transmission to NEUTRAL Operate the engine at idle 500 to 800 rpm until normal operating temperature is reached Check that the sump temperature is 160 to 200 F 71 to 93 C Check that the converter out temperature is 180 to 220 F 82 to 104 C 4 With the engine idling remove the dipstick from the tube and wipe it clean 5 Insert the dipstick into the tube then remove it Check the fluid level reading then repeat the check procedure to verify the reading Safe oper ating level is within the HOT RUN band on the dipstick The HOT RUN band is between the HOT FULL and HOT ADD marks If the fluid level is not within the HOT RUN band add or drain fluid as needed to bring the fluid level within the HOT RUN band See Fig 2 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement Eaton F
130. seal replacement or any other reason 4 Check U joint assemblies for wear by moving the driveshaft up and down and from side to side If any movement of the U joint cross in the bear ings can be felt or seen replace the U joint as sembly 5 Checkif the midship bearing and mounting are loose or have deteriorated by attempting to move the driveshaft up and down and from side to side If the bearing is loose on its shaft or rattles replace it If the bearing mount is loose on the frame tighten the mounting fasteners to the proper torque value See Section 41 00 Specifications 400 of the Coronado Workshop Coronado Maintenance Manual January 2010 t 411 10 12 2009 Group Title Group Number Vehicle Name Release Date moom D E Group Number Page Number Maintenance Operation Number consists of the Group Number followed by the Sequence Number f020173 Fig 1 Example of a Coronado Maintenance Manual Page Coronado Maintenance Manual June 2011 Introduction Maintenance Manual Contents Group No Group Title ar ME TREO o eA General Information lenin IEEE Engine OD crit sz dara a Air Intake 18 cc PIC AA Air Compressor CA Alternators and Starters 201x Mak kaa Ent ater D Engine Cooling Radiator CERT Clutch 2D ks endo cet dE E E Transmission Ch ARA PP Frame and Frame Components eT EEEE EARE TELET Once Sue Suspension BO an E EE E EE E E EE E EET S Front Axle cB a adan ds
131. sembly increases the ohm reading will increase When the temperature goes above 45 F 7 C mea sured resistance should be infinite ohms If the heater thermostat does not operate as outlined replace it If it does operate as outlined install it 42 04 Alcohol Evaporator Cleaning and Inspection Maintenance is required during both the freeze sea son and the off season to keep the alcohol evapora tor in good working order 42 Off Season During the off season drain the unit of alcohol At regular engine service intervals open the drain cock to remove moisture from the alcohol evaporator Be fore reactivating the evaporator for the next freeze season drain disassemble inspect and steam clean the unit of any sludge that may have accumu lated It is advisable to replace any rubber parts when assembling the alcohol evaporator Perform this service just before the freeze season Freeze Season Reactivation 1 Park the vehicle on a level surface and apply the parking brakes Shut down the engine Chock the tires 2 Remove the filler cap and check the cap tet raseal 3 Remove the capscrews and reservoir from the cover 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 Install the cover tetraseal Inst
132. sion Lubricant Type Mobil Delvac Synthetic Transmission Fluid 50 Eaton Fuller mE i Synthetic transmission lubricant approved by Eaton t Do not mix types or brands of fluid Multi weight and extreme pressure gear fluids are not recommended T Call 1 800 826 4357 or see www RoadRanger com for a complete list of Eaton approved lubricants Table 1 Approved Transmission Lubricants Eaton Fuller Transmission Lubricant Capacities Transmission Model Refill Capacity qt L 9 Speed Series All Models 14 13 10 Speed Manual except deep reduction FR and FRO Series 11 75 11 10 Speed Deep Reduction RTO 14908LL RTO 16908LL 14 0 13 10 Speed Automatic RTO 16910C AS Autoshift RTO 14910C AS Autoshift 14 13 RTO 16910B DM2 Ultrashift RTO 18910B AS Autoshift RTO 16910B AS Autoshift 13 012 13 Speed Series RTLO and RTLOM Series 14 13 15 Speed Series RT and RTO Series 14 13 18 Speed Series RTLO Series 14 13 18 Speed Autoshift AS Quantities listed are approximate Fill transmission until lubricant is level with bottom of fill hole with vehicle in normal operating position Table 2 Eaton Fuller Transmission Lubricant Capacities NOTE In all cases the correct fluid level is es tablished by checking at the fill opening 8 Operate the engine for five minutes after filling the transmission then check the f
133. stributed to dealers cus tomers receive notices that apply to their vehicles I 2 Coronado Maintenance Manual June 2011 Page Description For an example of a Coronado Maintenance Manual page see Fig 1 Introduction Driveline Driveline Inspection 1 Parkthe vehicle on a flat level surface apply the parking brakes and chock the tires NWARNING Self locking bearing cup or bearing strap caps crews must not be reused replace the cap screws with new ones Also do not undertighten or overtighten any bearing cup or bearing strap capscrews A loose or broken fastener at any point in the driveline weakens the driveline con nection which could cause serious vehicle dam age or could result in a driveshaft separating from the vehicle possibly causing loss of vehicle control that could result in serious personal injury or death 2 Check the torque of the bearing cup or bearing strap capscrews see Table 1 for installed torque values Remove and discard any loose capscrews Do not reuse any loosened self locking capscrews they are designed for one time installation only Replace all loosened and removed capscrews with new ones Tighten the new capscrews as specified in Table 1 For half round yokes with bearing straps tighten the bearing strap capscrews following the tight ening sequence shown in Fig 1 in increments of 20 Ibf ft 25 N m to the torque specifications lis
134. ted in Table 1 12 16 2008 1410529 Tighten the capscrews in a counterclockwise sequence starting with either number 1 position Bearing Cap or Bearing Strap Capscrew Torque Specifications U Joint Type Torque Ibf ft N m Half Round Yokes with Bearing Straps and 3 8 inch Capscrews see Fig 2 Ref 8 45 60 60 80 Half Round Yokes with Bearing Straps and 1 2 inch Capscrews 130 135 175 185 Fig 2 Ref 8 Full Round Yokes with Bearing Cups Fig 3 22 89 RPL Series U Joints with Bearing Cups Fig 4 125 169 Table 1 Bearing Cap or Bearing Strap Capscrew Torque Specifications Fig 1 Tightening Sequence Half Round Yoke Bearing Strap Capscrews 3 Check the driveline yokes for cracks and check end yokes for looseness see Fig 2 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 Replace the seal if needed then tighten the yoke nut Refer to Sec tion 41 00 Specifications 400 of the Coronado Workshop Manual for torque specifications If the yoke is still loose after tightening the yoke nut replace the end yoke and yoke nut Replace the prevailing torque locknut end yoke nut if it was removed for yoke replacement
135. teners With Lubricated or Plated Threads Coronado Maintenance Manual August 2010 00 19 00 Torque Specifications Tables 00 10 General Information Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged Thread Grade 5 or B Grade 8 or 8 2 Grade 8 or C Grade 8 or 82 a Grade 5 Bolt Nut Bolt Nut Bolt Grade G Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Br po pa eue al Wa 1 4 20 8 11 10 14 1 4 28 9 12 12 16 5 16 18 15 20 22 30 22 30 5 16 24 17 23 25 34 3 8 16 28 38 40 54 40 54 3 8 24 31 42 45 61 7 16 14 45 61 65 88 65 88 7 16 20 50 68 70 95 1 2 13 70 95 95 129 95 129 1 2 20 75 102 110 149 9 16 12 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 818 155 210 215 292 3 410 240 325 340 461 340 461 3 4 16 270 366 380 515 7 8 9 385 522 540 732 7 8 14 425 576 600 813 1 8 580 786 820 1112 1 12 635 861 900 1220 1 14 650 881 915 1241 Threads may have residual oil but will be dry to the touch t Male and female threads bolt and nut must both be unlubricated and unplated if either is plated or lubricated use Table 13 Freightliner recommends that all plated and unplated fasteners b
136. tervals Performing regular maintenance on your Freightliner vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come Failure to follow a regular mainte nance program can result in inefficient operation and unscheduled down time Determine the correct maintenance intervals and op erations for your vehicle as follows 1 Using Table 1 determine the type of service or conditions the vehicle will be operating in Gener ally most vehicles operate under conditions that fall within one of the four types of service listed 2 Using Table 2 determine how often maintenance should be performed based on the vehicle s ser vice schedule 3 When the vehicle reaches the distance or hours of operation given for a maintenance interval as shown in the appropriate table in Vehicle Main tenance Schedule Tables 00 02 see the ap propriate Maintenance Interval Operation Table listed below for a list of the maintenance opera tions to be performed e Initial Maintenance IM Operations 00 03 e M1 Maintenance Interval Operations 00 04 e M2 Maintenance Interval Operations 00 05 e M3 Maintenance Interval Operations 00 06 Use the maintenance operation reference num bers in the Maintenance Interval Operation Tables to find detailed instructions in the manual on each operation NOTE Maintenance instructions in this manual are based on average vehicle use and norm
137. the corrosion process 1 Wash out any existing grease dirt and corrosion on the trailer connectors with electrical contact cleaner spray 2 Grease the trailer connector with a lithium based dielectric grease 31 05 Premier 690 Coupling Inspection IMPORTANT Before servicing the Premier cou pling refer to the Premier web site at www premier mfg com for complete safety operation and maintenance instructions If at any time the 690 coupling is bound up jack knifed the 294 bolt MUST be replaced immedi ately Do not use the coupling until the bolt has 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 10 For a new or replaced 294 bolt e Record the date of installation 6 months after installation date e Remove the 294 bolt Using dye penetrate or magnetic particle testing along the length of the bolt inspect for fractures e If the 294 bolt has no damage install it and continue to use for another 6 months e f the 294 bolt is fractured DO NOT USE Con tact Premier Mfg Co 1 year after installation date Frame and Frame Components Regardless of ser
138. the desiccant cartridge on the end cover Turn the cartridge clockwise until the desiccant cartridge makes contact with the end cover 14 Place the desiccant cartridge in a vise and turn the end cover clockwise an additional 180 to 225 degrees to fully tighten the desiccant cartridge to the end cover NOTE Desiccant cartridge torque should not exceed 50 Ibf ft 68 N m 15 Place the housing over the desiccant cartridge and align the mounting holes with the end cover IMPORTANT Replace do not reuse the Nylok nuts on the air dryer cover Coronado Maintenance Manual January 2010 42 1 42 Brakes 08 09 95 1 5 16 x 4 1 2 Upper Mounting Bracket Bolt Upper Mounting Bracket Strap Lockwasher 5 16 Inch Nylok Nut Upper Mounting Bracket Housing Nylok Nut 3 8 Inch Special Washer PUDOR 9 Desiccant Cartridge 10 O Ring 11 Safety Valve 12 Lower Mounting Bracket 13 3 8 Inch Bolt long 14 Check Valve Assembly 15 Purge Valve Assembly 16 Purge Valve Capscrew 17 Exhaust Diaphragm 18 19 20 21 22 23 24 25 Py ICS Purge Valve 1 4 Inch Tapping Screw Purge Valve Housing Heater and Thermostat Housing Return Spring Purge Piston 3 8 Inch Bolt End Cover 1421383 16 Install the 6 bolts 12 washers and 6 new Nylok nuts Torque the Nylok nuts in a star pattern 17 to 24 Ibf ft 370 to 520 N m See Fig 2 17 Install the air dry
139. the two bolts and Nylok nuts that se cure the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the bolts to ease installation 7 Remove the upper mounting bracket strap fas teners then remove the strap and the air dryer 42 8 Place the air dryer on a bench and remove the remaining 6 bolts 12 washers 6 Nylok nuts and the air dryer housing See Fig 1 Discard the Nylok nuts Remove the end cover to housing O ring 9 Clamp the desiccant cartridge in a vise Clamping the end cover or housing in a vise could seriously compromise the air dryer s ability to hold air pressure which could cause a failure in the brake system resulting in property damage personal injury or death 10 Twist the end cover counterclockwise to release the cartridge from the end cover Rotate the end cover until it completely separates from the des iccant cartridge NOTE A substantial torque up to 50 Ibf ft 68 N m may be necessary to remove the desic cant cartridge NOTICE Dirt or obstructions in the O ring grooves can cause an O ring failure that will result in an air leak 11 Inspect the condition of the O ring seals If they are cracked crimped or otherwise damaged replace them to ensure an airtight seal Clean the O ring grooves of any dirt or obstruction 12 Lubricate the O rings with silicone or lithium grease and install them in the end cover 13 Install
140. to 40 000 Ib 15 000 to 18 000 kg using synthetic lubricant Oil must be changed at least every four years and more often if the axle is exposed to high temperatures and steep grades 1 Park the vehicle on level ground apply the park ing brakes and chock the tires IMPORTANT Freightliner rear axles do not re quire the use of friction modifiers 2 Clean the fill plug and the area around it In the axle housing rear cover remove the plug from the oil fill hole See Fig 3 3 Place a drain pan under the rear axle drain plug Drain the oil when it is warm At this tempera ture the oil will run more freely and ensure that the axle is flushed 4 Clean the fill and drain plugs as follows Change them if necessary 4 1 For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 4 2 Clean away the collected material depos ited on each pole Magnets will rapidly lose their effectiveness as collected mate rial bridges the gap between the two poles 4 3 After the first oil is changed inspect the drain plug each time for large quantities of metal particles 35 4 4 After cleaning install the drain plug s and tighten to 41 Ibf ft 55 N m 5 Fill the axle with the recommended lubricant as follows See Table 3 for recommended drive axle lubricants and drive axle lubricant capacities Freightliner Rear Axle Approved Lubricant T
141. to the valve housing will void the warranty e Do not attempt to disassemble the Barksdale valve body or the control lever There are no serviceable parts in the valve and any disas sembly will void the warranty NOTICE When removing or loosening a Barksdale height control valve from a mounting bracket always hold the valve side mounting studs in place with an Allen wrench while loosening or tightening the nuts that attach the valve to the bracket Because the mounting studs are threaded into the valve body loosening the nuts without holding the studs can tighten the studs which can crush the valve body and damage the valve Conversely tightening the nuts without holding the studs can back the studs out causing a separation of the two halves of the valve body and possibly a leak 1 Park the vehicle on a level surface using a light application of the brakes Do not apply the park ing brakes Shift the transmission into neutral and build the secondary air pressure to at least 100 psi 690 kPa Shut down the engine 2 Mark the location of the front and rear tires on the floor and chock the tires on one axle only 3 Check that the height control valve vertical link age is connected and oriented correctly NOTE The stud bolt that fastens the height control valve horizontal lever to the vertical link age is oriented correctly when the linkage rod is vertical as viewed from the side of the vehicle see Fig 6 The r
142. uid A WARNING Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury 3 Remove the surge tank cap 4 Remove the drain plug at the radiator endtank see Fig 2 Allow the coolant to drain If possible drain the engine block of coolant 6 Fill the cooling system with water Operate the engine until the water reaches oper ating temperature 8 Drain the water and coolant mix from the cooling system 9 Fill the cooling system with water again 10 Drain the water from the cooling system 11 Fill the cooling system with the appropriate cool ant see Table 1 for some approved coolants Coronado Maintenance Manual January 2010 20 1 20 Engine Cooling R adiator Approved Coolant Manufacturer Coolant Type Cummins Fleetguard Compleat Premix Premixed solution with supplement additives Detroit Diesel Detroit Diesel Power Cool Premixed solution with supplement additives Old World Industries Fleet Charge With supplement additives Table 1 Approved Coolant 09 14 2009 1200728 1 Transmission Coolant Hose 2 Drain Plug 3 Lower Radiator Hose Fig 2 Typical Coolant Drain Plug Location 20
143. uller 1 Apply the parking brakes and chock the tires Drain the air reservoirs Coronado Maintenance Manual January 2010 26 3 26 Drain the air supply if the air supply is not drained before the air filter regulator is serviced serious injury and component damage could re sult 2 Clean the outside of the air filter regulator with cleaning solvent See Fig 3 OS p E 05 27 93 1260037a Fig 3 Air Filter Regulator Location Eaton Fuller transmission shown 3 Remove the end cap large O ring and filter ele ment from the filter housing See Fig 4 Remove the small O ring from the end cap NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep ing air pressure between 58 and 63 psi 400 to 435 kPa replace the air filter regulator It can not be repaired Wear safety goggles when using compressed air to clean parts as permanent harm to eyes could result from flying debris Transmission 10 17 2001 f260052a 1 Air Regulator 5 Small O Ring 2 Housing 6 End Cap 3 Large O Ring 7 Plug 4 Filter Element Fig 4 Eaton Fuller Transmission Air Filter Regulator Components 4 Clean the filter element by dipping it in alcohol or other cleaning solvent Blow compressed air through the element inside to outside to loosen surface dirt and to dry the element If it is not damaged the sintered metallic filter element will last
144. ved Automatic Transmission Lubricants 26 6 Coronado Maintenance Manual January 2010 Frame and Frame Components 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number Erin VINCE Mpe esere rinra di Datus diga nds do o BIGKAS 31 01 Ent heel ubican aran de AR BRUT AKA ARA aed RUF Ron AN LA BA d KNA TA AA NANG 31 02 Frame Fastener Torque Clieek ions iie drip RR eda Ee Wee v VER EUG eee RE EOS NG 31 03 Premier 690 Coupling INSPECTION xiu io erg RR BLAKE A eee 31 05 Trailer Electrical Connector Protection a a 0 006 eee eee 31 04 Coronado Maintenance Manual June 2011 Frame and Frame Components 31 01 Fifth Wheel Inspection All fifth wheel maintenance adjustment and re building must be done only by a qualified me chanic Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Parts are under spring compression Wear safety goggles while servicing the fifth wheel Failure to do so can result in personal injury due to parts ejecting with force Holland FWS1 1 Disconnect the tractor from the trailer For in structions see the Coronado Driver s Manual Thoroughly steam clean the fifth wheel 3 Check the fifth wheel plate for cracks Check for sharp edges on top the chamfer should be 1 8 to 1 4 inch 3 to 6 mm 4 When the wheel is locked the safety latch must swing free and
145. ves friction modifiers extreme pressure gear fluids or multiviscosity lubricants NOTE Fluid change intervals are extended to 500 000 miles 800 000 km on any vehicles filled with synthetic transmission fluid 1 If the transmission fluid is not at normal operat ing temperature run the engine until the fluid reaches operating temperature 2 Park the vehicle on level ground apply the park ing brakes shift the transmission to neutral N shut down the engine and chock the tires 3 Place a large drain pan under the transmission 4 Clean the area around the fill plug and remove it from the side of the gear case Remove each drain plug from the bottom of the case 5 Clean the fill and drain plugs For magnetic plugs use a piece of key stock or any other con venient steel slug to short the two magnetic poles and divert the magnetic field 26 formance change the filter each time that the fluid is changed 6 Fora transmission equipped with a transmission fluid filter s replace the fluid filter s as follows 6 1 Place a drain pan under the transmission fluid filter 4h CAUTION To prevent skin burns from hot transmission fluid wear protective gloves when removing the filter 6 2 Place a strap or chain wrench around the filter canister and rotate it in a counter clockwise motion to separate the filter from the mounting Carefully spin the filter off the mount and remove it from the ve hicle 6 3 A
146. vice duty replace the 294 bolt with a new one 9 07 13 2010 310313a 1 Linch Pin 3 Pintle Hook 2 Handle 4 294 Bolt Fig 10 Premier 690 Trailer Coupling 31 8 Coronado Maintenance Manual June 2011 Suspension Title of Maintenance Operation MOP Suspension INSPECTION oc aaa dee BG caia da Suspension Lubrication saecu a ee ee ee Suspension U Bolt Torque Check o o o oooo o 32 Index Alphabetical MOP Number Coronado Maintenance Manual August 2010 Suspension 32 01 Suspension Inspection Front Suspension Check Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death Inspect the front spring assemblies for cracked bro ken or abnormally bent leaves If any of these condi tions exist replace the spring assembly See Group 32 of the Coronado Workshop Manual for instruc tions Composite Springs The Commercial Vehicle Safety Alliance CVSA de fines a crack that causes out of service co
147. wer Steering Fluids Coronado Maintenance Manual January 2010 46 1 46 Steering 8 Raise the front of the vehicle and support it with jack stands 9 Start the engine and operate it at idle Turn the steering wheel from full left to full right several times until clean fluid starts flowing from the power steering filter Add fluid to the reservoir to maintain the fluid level between the MIN COLD and MAX HOT lines 10 Shut down the engine NOTE Always install a new power steering res ervoir filter when changing the fluid 11 Disconnect the filter from the filter cover and dis card the filter 12 Apply a thin film of power steering fluid on the gasket of the new filter Then attach the filter to the filter cover Hand tighten the filter then turn it an additional 1 4 turn 13 Install the filter and filter cover in the reservoir Make sure that the gasket under the filter cover is not damaged If the gasket is damaged re place it Install the gasket on the reservoir 14 Attach the retaining ring to the reservoir to se cure the filter and filter cover 15 Start the engine and check that the power steer ing fluid level is between the MIN COLD and MAX HOT lines Add more power steering fluid if needed 16 Raise the vehicle remove the jack stands and lower the vehicle 46 03 Power Steering Fluid Level Inspection 1 Apply the parking brakes and chock the tires 2 With the engine cool use
148. with a low pressure adapter to lubricate the slip joint Add multipurpose chassis grease lithium 12 hydroxy stearate NLGI Grade 2 with EP additives until it appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger while continuing to apply gun pressure until new grease appears at the slip joint seal see Fig 6 This ensures complete lubrication of the splines Wipe the purged grease from the pressure relief hole and slip joint seal and any excess grease from the grease fitting 41 4 Coronado Maintenance Manual January 2010 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake System Valve Inspectlofic uiua n arit tbe qe uh EOS xe eec A dido use Reese 42 01 Ar Eor Dopa MN s Ada Ru dedi ota Rt d wage muah ul RUE d AAA I b buono GANA AAA ARE 42 03 Alcohol Evaporator Cleaning and Inspection eee 42 04 Bendix Air Dryer Desiccant Replacement voii sa ii a es cagGead SANANG 42 02 Bendix E 6 Foot Control Valve Inspection and Lubrication llle 42 10 Brake nspeelon aoc ma hme mes PERRA P IER rris Pede egudesedem edere i mes 42 05 Dana Spicer Camshaft Bracket LUDFICAON unseren oe ce pe Rx pha me x PE eR NANG DAG 42 08 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 0000 cece eee 42 09 Meritor Camshaft Bracket Lubrication 0 0 000 aae a ee 42 06 Mentor Slack Adjuster Eubticaltiofi 403 2 dada
149. y unless there is a system failure or a fault code 10 Check the DEF tank pump metering unit and lines for leaks See Section 49 01 of the Coro nado Workshop Manual for repair procedures 11 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed 08 20 2009 DOC inlet pressure sensor NOTE The sensor box item 8 contains the SCR inlet and outlet NOx sensors DPF outlet pressure sensor and the 1 DOC Outlet Temperature 6 Exhaust Outlet 11 SCR Outlet NOx Sensor Port Sensor 7 DEF Metering Unit 12 SCR Inlet NOx Sensor Port 2 DOC Inlet Pressure Sensor 8 Sensor Box see note above 13 14 Pin Connectors Port 9 Exhaust Inlet 14 DPF Outlet Pressure Sensor 3 DOC Inlet Temperature Sensor 10 SCR Outlet Temperature Port 4 Front Heat Shield Sensor 15 SCR Inlet Temperature Sensor 5 DEF Nozzle 1490355 Fig 1 One Box ATS Sensor Locations 49 2 Coronado Maintenance Manual January 2010 Exhaust 49 09 16 2009 DEF Metering Unit DEF Nozzle SCR Outlet Temperature Sensor SCR Inlet Temperature Sensor PP DNA 11 Y 10 al 9 PL 8 AA E NP 74 Ns j AN N SN NG E QS 6 AS Ni 0 to 5 DOC Inlet Temperature Sensor 9 DPF Outlet Temperature 6 DOC Inlet Pressure Sensor Sensor 7 DPF Inlet Temperature Sensor 10 DPF Outlet NOx Sensor 8 DPF Outlet Pressure Sensor
150. ype and Capacity Cil Capacity Quarts liters Lubricant Type Axle Hubs Hubs Full Dry 80W 90 Gear Oil 14 3 15 9 75W 90 Synthetic Forward Rear Gear Oil 13 5 15 0 80W 90 Gear Oil Single and por a 75W 90 Synthetic Rearmost 10 0 11 5 Gear Oil Tandem f Table 3 Freightliner Rear Axle Approved Lubricant Type and Capacity NOTE Some Freightliner 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 used as a fill or level hole 5 1 With the vehicle on a level surface fill the axle through the oil fill hole Lubricant 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 41 Ibf ft 55 N m Dana Spicer IMPORTANT The use of friction modifiers is not approved in Dana drive axles 1 Park the vehicle on level ground set the parking brakes and chock the tires 2 Clean the fill plug and the area around it In the axle housing rear cover remove the plug from the oil fill hole or standpipe if installed in the oil fill hole see Fig 4 3 Place a drain pan under the rear axle drain plug see Fig 4 Drain the oil at normal operating tem perature 150 F to 200 F 65 C to 93 C At this Coronado Maintenance Manual January 2010 35 3 35 Rear Axle
151. ypes of Service Service Schedule Service Conditions Vehicles that annually travel over 60 000 miles 100 000 km and meet the following qualifications Meritor 15 1 2 inch dampened ceramic Lite Pedal LTD clutch with sealed release bearing e Synthetic transmission fluid used in transmission e Meritor FF 961 or FF 981 front axle 12 000 Ib capacity with synthetic lubricant e Front suspension with maintenance free rubber bushings for 12 000 Ib capacity suspen Schedule IVt sion Long Haul Transport for Optimized Vehicle Configuration e Synthetic lubricant used in rear axle Meritor RPL series or Dana Spicer SPL series driveline U joints Equipped with any Freightliner AirLiner suspension Equipped with Meritor Q Plus extended lube cam brakes and automatic slack adjusters front and rear e Standard brake system package including Bendix AD 9 air dryer with heater and a Bendix air compressor e TRW TAS65 power steering For Schedule severe service vehicles equipped with an hourmeter use maintenance intervals based on hours of operation rather than distance traveled t Use Schedule severe service maintenance intervals for vehicles that operate under severe conditions such as extremely poor roads heavy dust accumu lation extreme climate frequent short distance travel construction site operation city operation garbage truck or farm operation Table 1 Types of Service

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