Freightliner Coronado 132, 122SD Maintenance Manual
122SD and
CORONADO 132
Part Number STI 494 3
Publication Number STI-494-7
Maintenance Manual
122SD AND CORONADO 132 MAINTENANCE MANUAL
Models: 122SD
Coronado 132
STI-494-7 (2/16)
Published by
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 122SD and 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 specifically 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.
© 2010–2016 Daimler Trucks North America LLC
All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced,
stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North
America LLC. Daimler Trucks North America LLC is a Daimler company.
Daimler Trucks North America LLC
Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208–3849
Introduction
Descriptions of Service Publications
Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
(via ServicePro®) formats.
Workshop/Service
Manual
Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for
Driver’s/Operator’s
Manual
Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-
Workshop/service manuals contain service and repair information for all vehicle
systems and components, except for major components such as engines, transmissions, and rear axles. For service and repair information of major components, 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 specifications.
vehicle components and systems. They have information such as lubrication
procedures and tables, fluid replacement procedures, fluid capacities, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.
Driver’s/operator’s 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/operator’s manuals do not contain detailed repair or service information.
ments, and related information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.
Web-based repair, service, and parts documentation can be accessed using the following applications on the
AccessFreightliner.com website.
ServicePro ServicePro® provides Web-based access to the most up-to-date versions of the
publications listed above. In addition, the Service Solutions feature provides diagnostic assistance with Symptoms Search, by connecting to a large knowledge
base gathered from technicians and service personnel. Search results for both
documents and service solutions can be narrowed by initially entering vehicle
identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
™
EZWiring EZWiring
Freightliner Custom Chassis Corporation products’ wiring drawings and floating
pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro.
makes Freightliner, Sterling, Western Star, Thomas Built Buses, and
122SD and Coronado 132 Maintenance Manual, September 2013 I–1
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 distributed to dealers; customers receive notices that apply to their vehicles.
I–2 122SD and Coronado 132 Maintenance Manual, September 2013
Page Description
For an example of a 122SD and Coronado 132 Maintenance Manual page, see Fig. 1.
Introduction
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A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Vehicle Names
E. Release Date
F. Group Number/Page Number
Fig. 1, Example of a 122SD and Coronado 132 Maintenance Manual Page
122SD and Coronado 132 Maintenance Manual, September 2013 I–3
Introduction
Group No. Group Title
00...................... General Information
01................................ Engine
09.............................. AirIntake
13 ......................... AirCompressor
15................... Alternators and Starters
20................... Engine Cooling/Radiator
25................................ Clutch
26........................... Transmission
31 ............. Frame and Frame Components
32............................ Suspension
33 ............................. Front Axle
35 ............................. Rear Axle
40........................ Wheels and Tires
41 .............................. Driveline
42................................ Brakes
46............................... Steering
47 ................................. Fuel
49............................... Exhaust
60.................................. Cab
72 ................................ Doors
83................. Heater and Air Conditioner
88.............. Hood, Grille, and Cab Fenders
Maintenance Manual Contents
I–4 122SD and Coronado 132 Maintenance Manual, September 2013
General Information 00
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Determining Scheduled Maintenance Intervals.............................................00–01
Initial Maintenance (IM) Operations.....................................................00–03
M1 Maintenance Interval Operations ....................................................00–04
M2 Maintenance Interval Operations ....................................................00–05
M3 Maintenance Interval Operations ....................................................00–06
Noise Emission Controls Maintenance...................................................00–07
Vehicle Maintenance Schedule Tables...................................................00–02
Verification of Inspections Log.........................................................00–08
122SD and Coronado 132 Maintenance Manual, February 2016
General Information 00
Determining Scheduled Maintenance Intervals: 00–01
Determining Scheduled
Maintenance Intervals
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 maintenance program can result in inefficient operation and
unscheduled down time.
Determine the correct maintenance intervals and operations for your vehicle as follows.
1. Using
2. Using
3. When the vehicle reaches the distance (or hours
Table 1, determine the type of service or
conditions the vehicle will be operating in. Generally, most vehicles operate under conditions that
fall within one of the four types of service listed.
Table 2, determine how often maintenance
should be performed, based on the vehicle’s service schedule.
of operation) given for a maintenance interval, as
shown in the appropriate table in
Vehicle Main-
propriate Maintenance Interval Operation Table
(listed below) for a list of the maintenance operations to be performed.
•
Initial Maintenance (IM) Operations:
00-03
• M1 Maintenance Interval Operations:
00-04
• M2 Maintenance Interval Operations:
00-05
• M3 Maintenance Interval Operations:
00-06
Use the maintenance operation reference numbers 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 normal
operating conditions. Unusual vehicle operating
conditions may require service at more frequent
intervals.
tenance Schedule Tables: 00-02, see the ap-
Types of Service
Service Schedule Service Conditions
Vehicles that annually travel less than 6000 miles (10 000 kilometers) or that operate under
severe conditions. Examples of severe service, Schedule I usage include:
• Operation on extremely poor roads or where there is heavy dust accumulation;
Schedule I
(Severe Service)
Schedule II
(Short-Haul Transport)
Schedule III
(Long-Haul Transport)
*
†
†
• Constant exposure to extreme hot, cold, salt-air, or other extreme climates;
• Frequent short-distance travel;
• Construction-site operation;
• City operation (fire truck);
• Farm operation.
Vehicles that annually travel less than 60,000 miles (100 000 kilometers) and operate under normal conditions. Examples of Schedule II usage are:
• Operation primarily in cities and densely populated areas;
• Local transport with infrequent freeway travel;
• High percentage of stop-and-go travel.
Vehicles that annually travel more than 60,000 miles (100 000 kilometers) with minimal city or
stop-and-go operation. Examples of Schedule III usage are:
• Regional delivery that is mostly freeway miles;
• Interstate transport;
• Any road operation with high annual mileage.
122SD and Coronado 132 Maintenance Manual, February 2016 00/1
General Information00
Determining Scheduled Maintenance Intervals: 00–01
Types 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.
• Synthetic transmission fluid used in transmission.
• Meritor FF–961 or FF–981 front axle (12,000 lb. capacity) with synthetic lubricant.
Schedule IV
†
(Long-Haul Transport
for Optimized Vehicle
Configuration)
*
For Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance traveled.
†
Use Schedule I (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.
• Front suspension with maintenance-free rubber bushings for 12,000 lb. capacity suspension.
• Meritor RPL series, or Dana Spicer SPL series driveline U-joints.
• Synthetic lubricant used in rear axle.
• Equipped with any Freightliner AirLiner suspension.
• Equipped with Meritor Q-Plus extended-lube cam brakes and automatic slack adjusters,
front and rear.
• Standard brake system package including Bendix AD-9 air dryer with heater, and a Bendix
air compressor.
• TRW TAS65 power steering.
Table 1, Types of Service
Service Schedule
Schedule I
(Severe Service)
Schedule II
(Short-Haul Transport)
Schedule III
(Long-Haul Transport)
and
Schedule IV
(Long-Haul Transport for
Optimized Vehicle Configuration)
Service Schedule
Maintenance Interval
Operation
Frequency Miles km Hours
Maintenance Interval
Initial Maintenance (IM) first 1000 1600 50
Maintenance 1 (M1) every 1000 1600 50
Maintenance 2 (M2) every 5000 8000 500
Maintenance 3 (M3) every 15,000 24 000 1500
Initial Maintenance (IM) first 10,000 16 000
Maintenance 1 (M1) every 10,000 16 000
Maintenance 2 (M2) every 50,000 80 000
—
Maintenance 3 (M3) every 150,000 240 000
Initial Maintenance (IM) first 25,000 40 000
Maintenance 1 (M1) every 25,000 40 000
Maintenance 2 (M2) every 100,000 161 000
—
Maintenance 3 (M3) every 300,000 483 000
Table 2, Service Schedule
122SD and Coronado 132 Maintenance Manual, February 201600/2
General Information 00
Vehicle Maintenance Schedule Tables: 00–02
Maintenance for Service Schedules I and II
Maint. No.
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 70,000 112 000
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
Maintenance
Interval
Service
Date
Miles km Hours Miles km
Service Schedule I Service Schedule II
122SD and Coronado 132 Maintenance Manual, February 2016 00/3
General Information00
Vehicle Maintenance Schedule Tables: 00–02
Maintenance for Service Schedules I and II
Maint. No.
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 67,000 107 800 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
Maintenance
Interval
Service
Date
Miles km Hours Miles km
Service Schedule I Service Schedule II
122SD and Coronado 132 Maintenance Manual, February 201600/4
General Information 00
Vehicle Maintenance Schedule Tables: 00–02
Maintenance for Service Schedules I and II
Maint. No.
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, M2, 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
Maintenance
Interval
Service
Date
Table 3, Maintenance for Service Schedules I and II
Miles km Hours Miles km
Service Schedule I Service Schedule II
122SD and Coronado 132 Maintenance Manual, February 2016 00/5
Vehicle Maintenance Schedule Tables: 00–02
Maintenance for Service Schedules III and IV
Maint. No. Maintenance Interval
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 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
Service
Date
General Information00
Service Schedules III and IV
Miles km
122SD and Coronado 132 Maintenance Manual, February 201600/6
General Information 00
Vehicle Maintenance Schedule Tables: 00–02
Maintenance for Service Schedules III and IV
Maint. No. Maintenance Interval
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 III and IV
Service
Date
Service Schedules III and IV
Miles km
122SD and Coronado 132 Maintenance Manual, February 2016 00/7
Initial Maintenance (IM) Operations: 00–03
General Information00
The Initial Maintenance table lists all maintenance
operations that are to be performed at the initial
maintenance (IM) interval. Maintenance operation
numbers are reference numbers used to help you
find detailed instructions in this manual on the main-
Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV
Maintenance
Operation Number
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 I, II, III, and IV
• Schedule I: at 1000 miles (1600 km) or 50 hours
• Schedule II: at 10,000 miles (16 000 km)
• Schedule III: at 25,000 miles (40 000 km)
tenance operations to be performed. All operations
listed in the table, along with the operations listed in
the applicable M1 maintenance interval table, must
be performed to complete the initial maintenance
(IM).
Check
122SD and Coronado 132 Maintenance Manual, February 201600/8
General Information 00
M1 Maintenance Interval Operations: 00–04
The M1 Maintenance Interval Operations tables list
all maintenance operations that are to be performed
at the M1 maintenance interval. Maintenance operation numbers are reference numbers used to help
you find detailed instructions in this manual on the
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
the 122SD and Coronado 132 Driver’s Manual.
maintenance operations to be performed.
M1 Maintenance Interval Operations for Service Schedules I, II, and III
Maintenance
Operation Number
13–01 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, Detroit™and Dana Spicer Axles
33–04 Tie Rod Lubrication, Detroit and Dana Spicer Axles
40–02 Tire Check
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
42–06 Meritor Camshaft Bracket Lubrication
42–08 Dana Spicer Camshaft Bracket Lubrication
42–09 Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
42–11 WABCO System Saver Air Dryer Desiccant Cartridge Replacement
42–12 Versajust Slack Adjuster Inspection and Lubrication
49–01 Exhaust System Inspection (noise emission control)
60–02 Aerodynamic Component Inspection
72–01 Door Seal and Door Latch Lubrication
88–01 Hood Rear Support Lubrication
*
For Detroit axles, complete this procedure once a year or at the following applicable interval, whichever comes first: every 5000 miles (8000 km) for Schedule
I vehicles; every 25,000 miles (40 000 km) for Schedule II vehicles; or every 100,000 miles (161 000 km) for Schedule III vehicles.
†
If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M3 maintenance interval.
‡
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
Table 6, M1 Maintenance Interval Operations for Service Schedules I, II, and III
• Schedule I: every 1000 miles (1600 km) or 50 hours
• Schedule II: every 10,000 miles (16 000 km)
• Schedule III: every 25,000 miles (40 000 km)
*
*
‡
Check
†
†
122SD and Coronado 132 Maintenance Manual, February 2016 00/9
M1 Maintenance Interval Operations: 00–04
General Information00
Maintenance
Operation Number
M1 Maintenance Interval Operations for Service Schedule IV
• Schedule IV: every 25,000 miles (40 000 km)
Check
13–01 Air Compressor Inspection
31–01 Fifth Wheel Inspection
31–02 Fifth Wheel Lubrication
31–04 Trailer Electrical Connector Lubrication
31–05 Premier 690 Coupling Inspection
40–02 Tire Check
42–02 Bendix Air Dryer Desiccant Replacement (with an oil-coalescing desiccant cartridge)
*
42–05 Brake Inspection
42–06 Meritor Camshaft Bracket Lubrication
42–11 WABCO System Saver Air Dryer Desiccant Cartridge Replacement
42–12 Versajust Slack Adjuster Inspection and Lubrication
†
*
49–01 Exhaust System Inspection (noise emission control)
60–02 Aerodynamic Component Inspection
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.
†
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
Table 7, M1 Maintenance Interval Operations for Service Schedule IV
122SD and Coronado 132 Maintenance Manual, February 201600/10
General Information 00
M2 Maintenance Interval Operations: 00–05
The M2 Maintenance Interval Operations tables list
all maintenance operations that are to be performed
at the M2 maintenance interval. Maintenance operation numbers are reference numbers used to help
M2 Maintenance Interval Operations for Service Schedules I, II, and III
Maintenance
Operation Number
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 Allison Transmission Fluid and Filter Change (Castrol TranSynd or other TES 295
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
42–07 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 Folding Check
83–01 Air Conditioner Inspection
• Schedule I: every 5000 miles (8000 km) or 500 hours
• Schedule II: every 50,000 miles (80 000 km)
• Schedule III: every 100,000 miles (161 000 km)
fluid)
you find detailed instructions in this manual on the
maintenance operations to be performed. Perform all
M1 maintenance interval operations at the M2 maintenance interval.
Check
122SD and Coronado 132 Maintenance Manual, February 2016 00/11
General Information00
M2 Maintenance Interval Operations: 00–05
M2 Maintenance Interval Operations for Service Schedules I, II, and III
Maintenance
Operation Number
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 I, II, and III
• Schedule I: every 5000 miles (8000 km) or 500 hours
• Schedule II: every 50,000 miles (80 000 km)
• Schedule III: every 100,000 miles (161 000 km)
*
Check
Maintenance
Operation Number
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 Breather 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
M2 Maintenance Interval Operations for Service Schedule IV
• Schedule IV: every 100,000 miles (161 000 km)
Check
122SD and Coronado 132 Maintenance Manual, February 201600/12
General Information 00
M2 Maintenance Interval Operations: 00–05
Maintenance
Operation Number
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
M2 Maintenance Interval Operations for Service Schedule IV
• Schedule IV: every 100,000 miles (161 000 km)
*
Check
122SD and Coronado 132 Maintenance Manual, February 2016 00/13
M3 Maintenance Interval Operations: 00–06
General Information00
The M3 Maintenance Interval Operations table lists
all maintenance operations that are to be performed
at the M3 maintenance interval. Maintenance operation numbers are reference numbers used to help
M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV
Maintenance
Operation Number
00–04 Perform All M1 Operations
00–05 Perform All M2 Operations
09–01 Air Cleaner Inspection
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
42–11 WABCO System Saver Air Dryer Desiccant Cartridge Replacement
46–02 Power Steering Fluid and Filter Change
Table 10, M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV
• Schedule I: every 15,000 miles (24 000 km) or 1500 hours
• Schedule II: every 150,000 miles (240 000 km)
• Schedule III: every 300,000 miles (483 000 km)
• Schedule IV: every 300,000 miles (483 000 km)
you find detailed instructions in this manual on the
maintenance operations to be performed. Perform all
M1 and M2 maintenance interval operations at the
M3 maintenance interval.
Check
122SD and Coronado 132 Maintenance Manual, February 201600/14
General Information 00
Noise Emission Controls Maintenance: 00–07
Noise Emission Control
Maintenance
Federal Law, Part 205:
Transportation Equipment Noise
Emission Controls
Part 205, Transportation Equipment Noise Emission
Controls, requires the vehicle manufacturer to furnish, with each new vehicle, such written instructions
for the proper maintenance, use, and repair of the
vehicle by the ultimate purchaser to provide reasonable assurance of the elimination or minimization of
noise-emission-control degradation throughout the
life of the vehicle. In compliance with the law, the
noise emission controls maintenance information in
each applicable group of this manual, in conjunction
with the vehicle workshop manual, provides these
instructions to owners.
Recommendations for
Replacement Parts
Replacement parts used for maintenance or repair of
noise emission controls should be genuine Freightliner parts. If other than genuine Freightliner parts
are used for replacement or repair of components
affecting noise emission control, the owner should be
sure that such parts are warranted by their manufacturer to be equivalent to genuine Freightliner parts in
performance and durability.
Freightliner Noise Emission
Controls Warranty
Refer to the vehicle owner’s warranty information
book for warranty information concerning noise emission controls.
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser, or while it is in
use.
2. The use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
A. Removal of engine noise-deadening panels.
B. Removal of cab-tunnel or hood noise-
deadening panels.
C. Removal of, or rendering inoperative, the en-
gine speed governor so as to allow engine
speed to exceed manufacturer’s specifications.
D. Removal of, or rendering inoperative, the fan
clutch, including bypassing the control on
any thermostatic fan drive to cause it to operate continuously.
E. Removal of the fan shroud.
F. Removal of, or rendering inoperative, ex-
haust components, including exhaust pipe
clamping.
G. Removal of air intake components.
Maintenance Instructions
Scheduled intervals are in the maintenance tables in
this group. A "Verification of Inspections Log (Groups
01, 20, and 49)" follows, and should be filled in each
time noise emission controls on the vehicle are maintained or repaired.
Tampering with Noise Controls is
Prohibited
Federal law prohibits the following acts or the causing thereof:
1. The removal or rendering inoperative by any person (other than for purposes of maintenance,
repair, or replacement) of any device or element
of design incorporated into any new vehicle for
122SD and Coronado 132 Maintenance Manual, February 2016 00/15
General Information00
Verification of Inspections Log: 00–08
Verification of Inspections Log
Verification of Inspections Log, Group 01
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 20 — Fan Clutch
Date Mileage Item Cost Maintenance Facility
122SD and Coronado 132 Maintenance Manual, February 201600/16
General Information 00
Verification of Inspections Log: 00–08
Verification of Inspections Log, Group 49
Verification of Inspections Log — Group 49 — Exhaust System Components
Date Mileage Item Cost Maintenance Facility
122SD and Coronado 132 Maintenance Manual, February 2016 00/17
Engine 01
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Engine Drive Belt Inspection..........................................................01–01
Safety Precautions .................................................................01–00
122SD and Coronado 132 Maintenance Manual, February 2016
Engine 01
01–00 Safety Precautions
Safety Precautions in this section apply to all
procedures within this group.
DANGER
When working on the vehicle, shut down the engine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle can not drop. Failure to follow these steps
could result in serious personal injury or death.
01–01 Engine Drive Belt
Inspection
Worn or loose drive belts may cause engine overheating or loss of alternator power. Excessive tension, or too little tension on the belt may result in excessive 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 represented by shiny sidewalls, and is caused by friction created when a loose belt slips in the pulleys. 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 before 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 foreign objects in the pulley, or by prying or forcing
the belt during removal or installation.
5. Check for uneven ribs on serpentine belts. Foreign objects in the pulley will erode the undercord 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.
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 stethoscope on the component being checked, not the
pulley, to isolate the area from outside interference.
9. Inspect all pulleys for foreign objects, oil, or
grease in the grooves.
Belt Tensioner Inspection
On belts equipped with a spring tensioner, belt tension is automatically adjusted. Check that the tensioner 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
122SD and Coronado Workshop Manual for replacement instructions.
122SD and Coronado 132 Maintenance Manual, February 2016 01/1
Engine01
A
B
C
09/21/2009 f012181
A. New Belt
B. Worn Belt
C. Material loss results in belt riding directly on pulley tips.
Fig. 1, EPDM Belt Wear
122SD and Coronado 132 Maintenance Manual, February 201601/2
Air Intake 09
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Air Cleaner Inspection .............................................................. 09–01
122SD and Coronado 132 Maintenance Manual, February 2015
Air Intake 09
09–01 Air Cleaner Inspection
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 dashmounted restriction gauge.
Vehicles may be equipped with either a manual-reset
restriction indicator with graduations (
go/no-go restriction indicator without graduations
Fig. 2).
(
08/07/2007 f090452
Fig. 1, Manual-Reset Air Restriction Indicator,
Graduated
Fig. 1), or a
2. Inspect the air cleaner housing for cracks, leaks,
or any other damage. If the air cleaner housing
or element is damaged, replace it.
3. Check the inserts at all four assembly fastener
locations (see
Fig. 3). Each insert should pro-
trude from the housing as shown in Fig. 4.
If the head/flange of any of the threaded inserts
is flush with or countersunk into the housing, replace the air cleaner assembly. See Section
09.01 of the 122SD and Coronado Workshop
Manual for replacement instructions.
5
5
1
2
3
4
04/08/2005 f090431
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 allowable restriction. For instructions, see Group
09 of the 122SD and Coronado Workshop
Manual.
11/07/2014 f090471a
1. Air Cleaner Element Housing
2. Air Cleaner Element
3. Housing Cover
4. Screws
5. Inserts
Fig. 3, Air Cleaner Assembly
4
NOTICE
Do not use aftermarket air cleaner elements. Aftermarket air cleaner elements may not seal the
housing correctly, which can lead to engine damage and potentially the loss of warranty. When replacing an air cleaner element, use only the part
listed in PartsPro for the serial number of the vehicle.
4. If necessary, replace the air cleaner element. For
air cleaner element replacement instructions, see
Group 09 of the 122SD and Coronado Work-
shop Manual.
122SD and Coronado 132 Maintenance Manual, February 2015 09/1
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