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freightliner 122SD Maintenance Manual

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122SD and
CORONADO 132
Part Number STI 494 3
Publication Number STI-494-7
Maintenance Manual

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Summary of Contents for freightliner 122SD

  • Page 1 122SD and CORONADO 132 Maintenance Manual Part Number STI 494 3 Publication Number STI-494-7...
  • Page 2 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.
  • Page 3 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...
  • Page 4 EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro.
  • Page 5 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; cus- tomers receive notices that apply to their vehicles. I–2 122SD and Coronado 132 Maintenance Manual, September 2013...
  • Page 6 Introduction Page Description For an example of a 122SD and Coronado 132 Maintenance Manual page, see Fig. Driveline 41−01 Driveline Inspection 1. Park the vehicle on a flat, level surface, apply the parking brakes, and chock the tires. WARNING Self− locking bearing− cup or bearing− strap cap−...
  • Page 7 83 ....Heater and Air Conditioner 88 ....Hood, Grille, and Cab Fenders I–4 122SD and Coronado 132 Maintenance Manual, September 2013...

  • Page 8: Table Of Contents

    Verification of Inspections Log............00–08 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 9: Determining Scheduled Maintenance Intervals

    Examples of Schedule III usage are: † Schedule III • Regional delivery that is mostly freeway miles; (Long-Haul Transport) • Interstate transport; • Any road operation with high annual mileage. 00/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 10 25,000 40 000 — Schedule IV Maintenance 2 (M2) every 100,000 161 000 (Long-Haul Transport for Maintenance 3 (M3) every 300,000 483 000 Optimized Vehicle Configuration) Table 2, Service Schedule 00/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 11 32,000 51 200 3200 320,000 512 000 33,000 52 800 3300 330,000 528 000 34,000 54 400 3400 340,000 544 000 M1 and M2 35,000 56 000 3500 350,000 560 000 00/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 12 670,000 1 078 000 68,000 109 400 6800 680,000 1 094 000 69,000 111 000 6900 690,000 1 110 000 M1 and M2 70,000 112 700 7000 700,000 1 127 000 00/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 13 1 577 000 99,000 159 300 9900 990,000 1 593 000 M1 and M2 100,000 160 900 10,000 1,000,000 1 609 000 Table 3, Maintenance for Service Schedules I and II 00/5 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 14 725,000 1 167 000 750,000 1 207 000 775,000 1 248 000 M1 and M2 800,000 1 287 000 825,000 1 328 000 850,000 1 368 000 875,000 1 408 000 00/6 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 15 1 448 000 925,000 1 490 000 950,000 1 529 000 975,000 1 569 000 M1 and M2 1,000,000 1 609 000 Table 4, Maintenance for Service Schedules III and IV 00/7 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 16: Initial Maintenance (Im) Operations

    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 00/8 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 17: M1 Maintenance Interval Operations

    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 00/9 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 18 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 00/10 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 19: M2 Maintenance Interval Operations

    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 00/11 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 20 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 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 21 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 00/13 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 22: M3 Maintenance Interval Operations

    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 00/14 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 23: Noise Emission Controls Maintenance

    Maintenance Instructions sure that such parts are warranted by their manufac- turer to be equivalent to genuine Freightliner parts in performance and durability. Scheduled intervals are in the maintenance tables in this group. A "Verification of Inspections Log (Groups Freightliner Noise Emission 01, 20, and 49)"...

  • Page 24: Verification Of Inspections Log

    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 00/16 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 25: Verification Of Inspections Log, Group

    General Information 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 00/17 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 26 Safety Precautions ..............01–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 27 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. 01/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 28 Engine 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 01/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 29 Air Cleaner Inspection ............. . 09–01 122SD and Coronado 132 Maintenance Manual, February 2015...
  • Page 30 4. If necessary, replace the air cleaner element. For 09 of the 122SD and Coronado Workshop air cleaner element replacement instructions, see Manual. Group 09 of the 122SD and Coronado Work- shop Manual. 09/1 122SD and Coronado 132 Maintenance Manual, February 2015...
  • Page 31 9. Rear Isolator C. Damaged Insert, Countersunk 10. Rear Isolator Mounting Capscrews (2) 1. Insert 11. Rear Isolator Nut 2. Screw Fig. 5, Air Cleaner Assembly Fig. 4, Air Cleaner-Housing Fasteners 09/2 122SD and Coronado 132 Maintenance Manual, February 2015...
  • Page 32 Air Intake 01/17/2012 f090496 1. Steel Plate 2. Rubber Fig. 6, Mounting Isolator 09/3 122SD and Coronado 132 Maintenance Manual, February 2015...
  • Page 33 Safety Precautions ..............13–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 34 Tighten the connections and replace the lines and fasteners if needed. 3. For the air governor, inspect the piping and con- nections for leaks. Replace gaskets and faulty components as needed. 13/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 35 Safety Precautions ..............15–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 36 NOTE: Engines equipped with a serpentine belt have automatic belt tensioners, and do not re- quire belt tension adjustment. 4. Check the alternator wiring for missing insulation, kinks, and heat damage. Replace or repair as needed. 15/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 37 Safety Precautions ..............20–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 38 3. Remove the surge tank cap. the cap if the gasket shows deterioration or dam- 4. Remove the drain plug at the radiator end tank; age. Fig. 2. Allow the coolant to drain. 20/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 39 2. Drain Plug the fan belt pulley. 3. Lower Radiator Hose 5. Compare the two measurements; if the difference Fig. 2, Typical Coolant Drain Plug Location between the two measurements exceeds 0.150 20/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 40 Manually engage and disengage the fan clutch. friction facing. Check the fan and fan clutch from a distance. Look for vibration, fan blade contact, fan clutch slippage, and overall fan clutch operation. 20/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 41 11.3 If either the hub or sheave bearings are worn, replace them, using a Horton Drive- Master Super Kit; see Group 20 of the vehicle Workshop Manual. 20/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 42 Safety Precautions ..............25–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 43 EP lithium grease with a 325°F (163°C) operat- Fig. 4 Fig. 5. Wipe any dirt from the grease ing temperature, or Roadranger Grease MP-2. fittings, and lubricate with NLGI Grade 2 or 3 EP 25/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 44 Over-lubrication could contaminate the clutch in- gun with Meritor Specification 0-661 Lithium Complex ternally, causing clutch slippage and premature Grease, NLGI Grade 3, and lubricate until grease failure. Do not use chassis grease or multipurpose lubricants. 25/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 45 Clutch 4. Wipe off excess grease, and apply it to both the yoke finger and sleeve bushing contact points. Fig. 5. Install the clutch inspection plate, if removed. 25/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 46 Transmission Fluid Level Inspection ........... . 26–02 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 47 5. Clean the fill and drain plugs. For magnetic mission lubricants. See Table 2 for Eaton Fuller plugs, use a piece of key stock or any other con- transmission lubricant capacities. 26/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 48 13-Speed Series Eaton Fuller RTLO and RTLOM Series 14 (13) 15-Speed Series NOTE: Check the transmission fluid level with the transmission at operating temperature. RT and RTO Series 14 (13) 18-Speed Series 26/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 49 7. Check the fluid level reading, then repeat the check procedure to verify the reading. Safe oper- check procedure to verify the reading. ating level is within the HOT RUN band on the 26/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 50 (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. 26/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 51 fluid filter elements on the cover assemblies. 7. Lubricate the new O-rings with transmission fluid, then install them on the cover assemblies. 9. Install the filter and cover assemblies into the filter compartment. 26/5 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 52 252-5283, or see www.AllisonTransmission.com for a complete list of Alli- son approved lubricants. † Dexron-VI may only be used in units beginning with S/N 6610220990. Table 4, Allison Approved Automatic Transmission Lubricants 26/6 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 53 Trailer Electrical Connector Lubricating ..........31–04 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 54: Fifth Wheel Inspection

    1. Disconnect the tractor from the trailer. For in- 03/28/2013 f311140 structions, see the vehicle Driver’s/Operator’s 1. Release Handle 2. Lever Bar Manual. Fig. 2, Lever Bar and Release Handle Alignment 2. Thoroughly steam clean the fifth wheel. 31/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 55 1. Disconnect the tractor from the trailer. For in- fication. Do not loosen the bolt to check the structions, see the vehicle Driver’s/Operator’s torque. For torque specifications, see Group 00 Manual. of the vehicle Workshop Manual. 31/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 56 25. Hair Pin Cotter 8. Cotter Pin, 3/16" x 1" 17. Bolt, Bumper 26. Wedge 9. Bumper Spring 18. Bushing 27. Step Jaw 10. Handle Spring Fig. 4, Fontaine Fifth Wheel 31/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 57 9. If the fifth wheel is equipped with a sliding mechanism, inspect and adjust it as follows. 5. Check the fifth wheel for bent, worn, or broken parts. Replace as needed. 31/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 58 Inspect the locking plungers for full en- 10. Replace cracked, worn, or damaged parts with gagement. new parts. Replace all loose mounting bolts with 5/8–11 SAE grade 8 bolts, grade C locknuts, and 31/5 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 59: Fifth Wheel Lubrication

    fittings. A “low temp” grade grease rated for -30°F (-34°C) or lower such as Cato Oil and 31/6 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 60 The low-lube plates re- 1. Cam Plate quire no further lubrication. Fig. 9, Holland FW35 Fifth Wheel, Oil Lubrication 31/7 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 61: Frame Fastener Torque Check

    For a new or replaced 294 bolt: Any component that shows signs of cracking or other • Record the date of installation. damage must be repaired or replaced. Refer to the 6 months after installation date: 31/8 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 62 • Regardless of service duty, replace the 294 bolt with a new one. 07/13/2010 f310313a 1. Linch Pin 3. Pintle Hook 2. Handle 4. 294 Bolt Fig. 11, Premier 690 Trailer Coupling 31/9 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 63 Suspension U-Bolt Torque Check ............32–03 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 64: Safety Precautions

    B. Top to bottom crack extending beyond 3/4 of the tions exist, replace the spring assembly. See Group length of the spring 32 of the 122SD and Coronado Workshop Manual C. Intersecting cracks of any length for instructions. Fig. 1, Out-of-Service Conditions, Composite Spring...
  • Page 65 See Group 32 of the 122SD and a new one. See Group 32 of the 122SD and Coro- Coronado Workshop Manual for instructions. nado Workshop Manual for replacement instructions.
  • Page 66 If any of these conditions exist, replace the leaf causes hidden damage to other leaves. Re- damaged parts. See Group 32 of the 122SD and placement of only the visibly damaged part(s) is Coronado Workshop Manual for instructions.
  • Page 67 If free- figurations; refer to Group 32 of the 122SD and play is felt, replace the torque rod end bushing. Coronado Workshop Manual for details.

  • Page 68: Front Suspension

    Hendrickson NOTE: Service Schedule IV vehicles equipped with a 12,000 lb (5452 kg) front axle are fitted The Hendrickson RS Series suspension does not require lubrication. 32/5 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 69 1. Park the vehicle on a flat surface, apply the park- Tighten in a diagonal pattern as shown in Fig. ing brakes, and chock the tires. Table 1, Spring Assembly U-Bolt High Nut Torque Values 32/6 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 70 Suspension 03/10/2011 f320783 Fig. 10, Tightening Pattern for U-Bolt High Nuts 32/7 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 71: Front Axle

    Tie Rod Lubrication, Meritor Axles............33–05 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 72: Knuckle Pin Lubrication, Detroit And Dana Spicer® Axles

    Wipe the fittings clean, then apply multipurpose permanently lubricated. chassis grease, NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12- hydroxy lithium stearate grease), until new grease is 33/1 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 73: Knuckle Pin Lubrication, Meritor® Axles

    fittings clean, and apply multipurpose chassis the components if this cannot be done; see grease, NLGI Grade 2 (8% 12-hydroxy lithium stear- Group 33 of the 122SD and Coronado Work- ate grease), until new grease is seen at the bushing shop Manual.

  • Page 74: Tie Rod Lubrication, Meritor Axles

    The scribe must be held firmly in place so that a pump multipurpose chassis grease, NLGI Grade 2 single straight line is scribed all the way around (8% 12-hydroxy lithium stearate grease), into the tie- each front tire. 33/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 75 Group 33 of the ve- hicle Workshop Manual. If corrections are needed, refer to Group 33 of the vehicle Work- shop Manual for instructions on adjusting the toe-in. 33/4 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 76: Rear Axle

    Safety Precautions ..............35–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 77 4. Oil Fill Plug changed at least every four years, and more often if the axle is exposed to high temperatures Fig. 1, Detroit Tandem Axle (forward axle shown) and steep grades. 35/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 78 There is no upper limit on the ambient temperature, but axle sump tem- perature must never exceed 250°F (121°C). 1. Park the vehicle on level ground, apply the park- Table 1, Detroit Drive Axle Lubricants ing brakes, and chock the front tires. 35/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 79 Fig. 1.5 pounds (0.7 kg) of low-carbon steel. Install and tighten the fill plug 35 lbf·ft (47 N·m). After cleaning, install the drain plug(s) and tighten to 35 lbf·ft (47 N·m). 35/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 80 flushed. Rear 36.1 (17.1) NOTE: Some tandem-drive axles are equipped with a cylindrical magnetic strainer, located below the lube pump on the front of the power 35/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 81 D40-170P, D46- them if necessary. † 39 (18.5) 170P For magnetic plugs, use a piece of key 2-Speed (dual- stock or any other convenient steel slug † DT463P 40 (18.9) range) 35/5 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 82 "All Axle Models." For a two- one part kerosene to three parts SAE 10 heavy- speed axle with a shift unit, also check the shift unit duty engine oil, API service classification SD 35/6 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 83 5. Install and tighten the fill plug 30 lbf·ft (41 N·m). the breather more frequently under adverse op- IMPORTANT: Always check the axle breather erating conditions. whenever checking the lubricant level. Check 35/7 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 84 Chock the or replace it as needed. tires. 2. If the vehicle has just been driven, allow a few minutes for the lubricant to settle. 35/8 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 85 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. 35/9 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 86 Wheel Nut Check..............40–01 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 87 • tread worn to a minimum depth; Tires should be inspected closely during the first • inability to maintain proper tire pressure. 3000 to 10,000 miles (5000 to 16 000 km) for abnor- mal wear. 40/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 88 Safety Precautions ..............41–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 89 20 lbf·ft (25 N·m) to the torque specifications needed, then tighten the yoke nut. Refer to Sec- listed in Table tion 41.00, Specifications 400of the 122SD and Coronado Workshop Manual for torque specifica- 41/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 90 U-joint cross in the bear- Workshop Manual for torque specifications. Re- ings can be felt or seen, replace the U-joint as- place the midship bearing assembly if the rubber sembly. cushion is deteriorated or oil-soaked. 41/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 91 122SD and Coronado Workshop Manual for re- Grade 2, with EP additives), lubricate until new pair and replacement instructions. grease can be seen at all four U-joint seals. Fresh grease must be seen escaping from all 41/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 92 If grease still does not appear, loosen the cap- 41/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 93 WABCO System Saver Air Dryer Desiccant Cartridge Replacement ......42–11 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 94: Air Brake System Valve Inspection

    2. Completely drain all air reservoirs. Air pressure are cracked, crimped, or otherwise damaged, gauges should read 0 psi (0 kPa). replace them to ensure an airtight seal. Clean the O-ring grooves of any dirt or obstruction. 42/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 95 16. Install the 6 bolts, 12 washers, and 6 new Nylok degrees to fully tighten the desiccant cartridge to nuts. Torque the Nylok nuts in a star pattern 17 the end cover. to 24 lbf·ft (23 to 33 N·m). See Fig. 42/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 96 3. Pull the cartridge bolt out of the cover and re- 12.2 Build system pressure to governor cut- move the cartridge. out, and note that the AD-IP air dryer purges with an audible escape of air. 42/3 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 97: Air Dryer Inspection

    3. Inspect the air dryer for external damage, and sealing rings with silicone grease. check that the unit is tightly mounted on the frame. If the air dryer mounting is loose, See 42/4 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 98: Alcohol Evaporator Cleaning And Inspection

    6. Install the disc, spring, and check-valve retainer, 1. End Cover Assembly and connect the line to the evaporator outlet. 2. Heater/Thermostat Terminals 7. Install the cover tetraseal. Fig. 4, End Cover Terminals Location 42/5 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 99: Brake Inspection

    Brake Component Inspection hicle Workshop Manual. 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. 42/6 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 100 Standard Stroke 2 (51) Long Stroke 2-1/2 (64) Meritor Standard Stroke Less than 1-1/2 (38) Less than 1-3/4 (44) Less than 1-7/8 (48) Long Stroke Less than 2 (51) Standard Stroke 42/7 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 101 fitting on the camshaft bracket or the spider in personal injury or property damage. until new grease flows from the inboard seal. See Fig. 42/8 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 102: Dana Spicer Camshaft Bracket Lubrication

    NLGI Grade 1 clay-base grease, or an NLGI Grade 1 the camshaft bracket grease seal is worn or dam- or 2 lithium-base grease. aged; replace it. See Group 42 of the 122SD and Coronado Workshop Manual for grease seal replace- For slack adjusters with grease fittings and for oper- ment instructions.
  • Page 103 2. Remove the roll pin from the brake pedal pivot No. 77. pin. See Fig. For operating temperatures between –20°F (–29°C) 3. Remove the brake pedal pivot pin. and –40°F (–40°C), use Lubriplate Aero grease. 4. Remove the brake pedal. 42/10 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 104 Check the plunger for signs of wear or cracks. NOTICE Replace it if necessary. The WABCO System Saver air dryers can use ei- ther a standard or oil coalescing desiccant car- 42/11 122SD and Coronado 132 Maintenance Manual, February 2016...

  • Page 105: Versajust Slack Adjuster Inspection And Lubrication

    Make and hold a full brake application the surfaces of the new O-ring and the dryer while the strokes are checked. base. Install the O-ring. 42/12 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 106 Table 2, Actuator Stroke–Standard Stroke Actuator Stroke–Long Stroke Recommended Maximum Brake Actuator Size Operating Stroke (Inches) 30 Long Stroke 2-1/2 24 Long 24 Long Stroke 2-1/2 20 Long 16 Long Table 3, Actuator Stroke–Long Stroke 42/13 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 107 Safety Precautions ..............46–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 108 Drain the fluid from the filter into the ball stud end. If it is loose, replace the drag link. 46/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 109 14. Attach the retaining ring to the reservoir to se- 1. Park the vehicle on a level surface, shut down cure the filter and filter cover. the engine, and set the parking brake. Chock the tires. 46/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 110 fittings until old grease is forced out of the socket. 11/27/95 f461072 1. Grease Fitting at Pitman Arm 2. Grease Fitting at Axle Steering Arm Fig. 3, Drag Link 46/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 111 Safety Precautions ..............47–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 112 filter element. 1. Drain off some fuel by loosening the vent plug There is no significant restriction to fuel flow until the and opening the drain valve. element is completely clogged. 47/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 113 DAVCO Collar Wrench is used for removal. During installation, the vent cap and collar are 47/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 114 Fig. 4, DAVCO Fuel Pro 382 the engine, or engine coolant. Drain the fuel/water separator only when the engine and fluids have 47/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 115 11. Install the cover O-ring, clear cover, and the col- 6. Cover O-Ring 13. Drain Valve lar. Hand-tighten the collar. 7. Clear Cover 12. Install and hand-tighten the vent cap O-ring and Fig. 5, DAVCO Fuel Pro 482 vent cap. 47/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 116 30 to 35 lbf·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 lbf·ft (41 N·m). IMPORTANT: Do not overtighten. 47/5 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 117 Safety Precautions ..............49–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 118 Do not reuse • Diesel Particulate Filter (DPF)—a component in seal clamps. Once a seal clamp is loosened or the ATD that traps soot from the exhaust gas. removed, it must be replaced. 49/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 119 Do not reuse 10. Check the DEF tank, pump, metering unit, and seal clamps. Once a seal clamp is loosened or lines for leaks. See Section 49.01 of the 122SD removed, it must be replaced. and Coronado Workshop Manual for repair pro- 3.
  • Page 120 ATD. Heat discoloration may indicate internal damage; especially around the DPF. 9. Check any wires, lines, or hoses within 4 inches (10 cm) of the exhaust system for heat damage. Repair or reroute as needed. 49/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 121 7. DPF Inlet Temperature Sensor 10. DPF Outlet NOx Sensor Sensor 8. DPF Outlet Pressure Sensor 11. SCR Outlet NOx Sensor 4. SCR Inlet Temperature Sensor Fig. 2, 2V2 Two-Box ATS Sensor Locations (EPA10) 49/4 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 122 Fig. 3, 2HV Two-Box ATS Sensor Locations (EPA10) 04/11/2012 f490470 A. Inspect the canister for dents. 1. Clamp 4. ATD 2. Bellows 5. ATD Outlet Pipe 3. ATD Intake Pipe Fig. 4, Typical Aftertreatment Device (ADR2011) 49/5 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 123 Mirror Folding Check ............. . . 60–01 122SD and Coronado 132 Maintenance Manual, November 2014...
  • Page 124 • Chassis fairings • Battery access kickplate • Side skirts • Cab side extenders • Roof fairing/deflector • Bumper • Hood Replace or repair damaged or missing components as needed. 60/1 122SD and Coronado 132 Maintenance Manual, November 2014...
  • Page 125 Door Seal, Door Latch, and Door Check Lubrication ........72–01 122SD and Coronado 132 Maintenance Manual, January 2010...
  • Page 126 1. Use an appropriate applicator that will not leave material behind. Approved Grease NLGI Application Lubricant Grade Door Latches ConocoPhillips Triton® 460 Door Checks ConocoPhillips Megaplex® XD3 Table 1, Approved Grease 72/1 122SD and Coronado 132 Maintenance Manual, January 2010...

  • Page 127: Heater And Air Conditioner

    Safety Precautions ..............83–00 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 128 3. Note the direction of the arrow on the air filter 122SD and Coronado Workshop Manual. Also cover, then remove the cover and the attached check for signs of loose fittings on all of the air filter. conditioning components. 83/1 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 129 The edge of the filter should be flush with the HVAC assembly. 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 83/2 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 130 Fig. 3, Cab Recirculation Air Filter Location 02/26/2002 f831492 1. Air Filter Fig. 5, Sleeper HVAC Assembly 02/26/2002 f831491 1. Retainer 2. Recirculation Air Filter Fig. 4, Cab Recirculation Air Filter 83/3 122SD and Coronado 132 Maintenance Manual, February 2016...
  • Page 131 Hood Rear Support Lubrication............88–01 122SD and Coronado 132 Maintenance Manual, November 2014...
  • Page 132 Approved Suppliers of Multi-Purpose Lithium Grease Supplier Grease Chevron Delo 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 88/1 122SD and Coronado 132 Maintenance Manual, November 2014...

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