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Title of Maintenance Operation (MOP)

MOP Number

Allison Transmission Fluid and Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–04

Eaton Fuller Transmission Fluid Change, and Magnetic Plug Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01

Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement . . . . . . . . . . . . . . . . . . . . . . . 26–03

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–00

Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02

Transmission

Index, Alphabetical

122SD and Coronado 132 Maintenance Manual, February 2016

Summary of Contents for 122SD

Page 1: ...Maintenance Manual 122SD and CORONADO 132 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: ...ns 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 noti...

Page 4: ...rove 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...

Page 5: ...in 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 wit...

Page 6: ...e Specifications 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 sh...

Page 7: ...lutch 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...

Page 8: ...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...

Page 9: ...d 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 conditio...

Page 10: ...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 frequ...

Page 11: ...00 160 000 256 000 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 0...

Page 12: ...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 88...

Page 13: ...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...

Page 14: ...0 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 57...

Page 15: ...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 III and IV Gene...

Page 16: ...intenance Operation Number 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...

Page 17: ...oit 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 In...

Page 18: ...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...

Page 19: ...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 C...

Page 20: ...rol 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 0...

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 Serv...

Page 22: ...miles 483 000 km Schedule IV every 300 000 miles 483 000 km Check 00 04 Perform All M1 Operations 00 05 Perform All M2 Operations 09 01 Air Cleaner Inspection 20 02 Radiator Pressure Flushing and Coo...

Page 23: ...e 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 replace...

Page 24: ...gine 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 General...

Page 25: ...49 Verification of Inspections Log Group 49 Exhaust System Components Date Mileage Item Cost Maintenance Facility General Information 00 Verification of Inspections Log 00 08 122SD and Coronado 132 M...

Page 26: ...Title of Maintenance Operation MOP MOP Number Engine Drive Belt Inspection 01 01 Safety Precautions 01 00 Engine 01 Index Alphabetical 122SD and Coronado 132 Maintenance Manual February 2016...

Page 27: ...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 usu...

Page 28: ...9 21 2009 f012181 A B C A New Belt B Worn Belt C Material loss results in belt riding directly on pulley tips Fig 1 EPDM Belt Wear Engine 01 122SD and Coronado 132 Maintenance Manual February 2016 01...

Page 29: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Inspection 09 01 Air Intake 09 Index Alphabetical 122SD and Coronado 132 Maintenance Manual February 2015...

Page 30: ...s shown in Fig 4 If the head flange of any of the threaded inserts is flush with or countersunk into the housing re place the air cleaner assembly See Section 09 01 of the 122SD and Coronado Workshop...

Page 31: ...ures in MOP 13 01 11 19 2014 f090513 B C 2 1 A OK OK NOTE Each insert should protrude from the housing as shown in item A A Proper Fastener Installation B Damaged Insert Flush C Damaged Insert Counter...

Page 32: ...01 17 2012 f090496 1 2 1 Steel Plate 2 Rubber Fig 6 Mounting Isolator Air Intake 09 122SD and Coronado 132 Maintenance Manual February 2015 09 3...

Page 33: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical 122SD and Coronado 132 Maintenance Manual February 2016...

Page 34: ...rsonal injury or death 13 01 Air Compressor Inspection 1 Inspect the air compressor intake hoses and connections at the air intake and air compressor for physical damage If needed change the hoses and...

Page 35: ...enance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical 122SD and Coronado 132 Maintenance Manual...

Page 36: ...ssing insulation kinks and heat damage Replace or repair as needed 5 Check that all electrical connections at the alter nator and starter are free of corrosion Clean and tighten all charging system el...

Page 37: ...lutch Check Noise Emission Control 20 03 Pressure Relief Cap Check 20 01 Radiator Pressure Flushing and Coolant Change 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetical 122S...

Page 38: ...em cools Inspect the vacuum relief valve to be sure it is not stuck 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...

Page 39: ...f A 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 mo...

Page 40: ...loth 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 adeq...

Page 41: ...10 Check the fan drive for discoloration or any other signs 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...

Page 42: ...ross Shaft Lubrication 25 02 Eaton Fuller Heavy Duty Clutch Release Bearing Lubrication 25 01 Meritor LitePedal Clutch Release Bearing Lubrication 25 03 Safety Precautions 25 00 Clutch 25 Index Alphab...

Page 43: ...r 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...

Page 44: ...lutch 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 r...

Page 45: ...cess 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 Clutch 25 122SD and Coronado 132 Maintenance Manual Februa...

Page 46: ...Fuller Transmission Fluid Change and Magnetic Plug Cleaning 26 01 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 26 03 Safety Precautions 26 00 Transmission Fluid Level Inspec...

Page 47: ...agnetic field Install and tighten each drain plug 50 lbf ft 68 N m NOTE The optional transmission fluid filter is a remote mount spin on type and is located be tween the transmission and the fluid coo...

Page 48: ...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...

Page 49: ...he 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 7 Check the fluid level re...

Page 50: ...gulator It can not be repaired WARNING Wear safety goggles when using compressed air to clean parts as permanent harm to eyes could result from flying debris 4 Clean the filter element by dipping it i...

Page 51: ...to 93 C 2 Park the vehicle on a level surface apply the parking brakes and chock the tires 3 Clean the area around the drain plug and the transmission fluid pan Place a drain pan under the transmissi...

Page 52: ...qt L 4 Inch 39 37 2 Inch 31 30 Quantities listed are approximate Add listed amount of fluid then perform a hot check and add fluid as needed Do not overfill Add 3 qt 2 8 L for transmissions with PTO...

Page 53: ...fth Wheel Lubrication 31 02 Frame Fastener Torque Check 31 03 Premier 690 Coupling Inspection 31 05 Safety Precautions 31 00 Trailer Electrical Connector Lubricating 31 04 Frame and Frame Components 3...

Page 54: ...t 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...

Page 55: ...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 in this manual for lubrication instructions Fontaine 1 Disconnec...

Page 56: ...Pin 7 Bracket Retainer Pin 8 Cotter Pin 3 16 x 1 9 Bumper Spring 10 Handle Spring 11 Bolt Secondary Safety Lock 12 Flat Washer 13 Secondary Safety Lock 14 Bushing Secondary Safety Lock 15 Hex Locknut...

Page 57: ...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 5 Check the fifth wheel for bent worn or broken parts Replace as ne...

Page 58: ...ider is adjustable for frame width and plunger 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...

Page 59: ...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 ki...

Page 60: ...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 plate...

Page 61: ...he vehicle vehicle Workshop Manual for repair or re placement information 31 04 Trailer Electrical Connector Lubricating In some cases failure of trailer cables occurs due to intrusion of chloride bas...

Page 62: ...for another 6 months If the 294 bolt is fractured DO NOT USE Con tact Premier Mfg Co 1 year after installation date Regardless of service duty replace the 294 bolt with a new one 1 2 3 f310313a 07 13...

Page 63: ...ion MOP MOP Number Safety Precautions 32 00 Suspension Inspection 32 01 Suspension Lubrication 32 02 Suspension U Bolt Torque Check 32 03 Suspension 32 Index Alphabetical 122SD and Coronado 132 Mainte...

Page 64: ...ses out of service conditions for composite spring assemblies as a separation in any axis which passes completely through the composite spring material For additional information on composite spring a...

Page 65: ...r and gussets for wear cracks and other damage If any of these conditions exist replace the dam aged parts See Group 32 of the 122SD and Coronado Workshop Manual for instructions NOTICE Failure to rep...

Page 66: ...g 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 ditions exist replace the damaged bracket s See...

Page 67: ...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 h...

Page 68: ...s are present or the restrictor can is missing replace the re strictor can WARNING Replace all cracked or missing restrictor cans Failure to do so could lead to loss of vehicle con trol which could re...

Page 69: ...he park ing brakes and chock the tires 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...

Page 70: ...03 10 2011 f320783 1 2 3 4 Fig 10 Tightening Pattern for U Bolt High Nuts Suspension 32 122SD and Coronado 132 Maintenance Manual February 2016 32 7...

Page 71: ...and Dana Spicer Axles 33 01 Knuckle Pin Lubrication Meritor Axles 33 02 Safety Precautions 33 00 Tie Rod Inspection 33 03 Tie Rod Lubrication Detroit and Dana Spicer Axles 33 04 Tie Rod Lubrication M...

Page 72: ...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 seen at the junctions of the axle beam and knuckles For locati...

Page 73: ...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 c...

Page 74: ...nual 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 e...

Page 75: ...ines on the center ribs of the front tires See Fig 7 Lock in place Check that the scale is set on zero 7 Place the trammel bar at the front of the tires see Fig 8 and adjust the scale end so that the...

Page 76: ...reather and Axle Lubricant Level Inspection 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Lubricant 35 01 Safety Precautions 35 00 Rear Axle 35 Index Alphabetical 122...

Page 77: ...dels 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 Detroit IMPORTANT On Detroit axles the oil change...

Page 78: ...mercedes benz com Type Ambient Temperature SAE Viscosity Grade Mineral Oil 15 F 26 1 C and up 80W 90 Synthetic Oil 40 F 40 C and up 75W 90 Detroit rear axles do not require the use of friction modifie...

Page 79: ...Meritor Drive Axle Recommended Lubricant 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...

Page 80: ...6 1 17 1 RT 58 185 Forward 56 1 26 5 Rear 36 1 17 1 Meritor Drive Axle Lubricant Capacities Axle Model Capacity pt L RT 70 380 Forward 54 4 25 7 Rear 53 1 25 1 Quantities listed are approximate Fill a...

Page 81: ...wo poles 5 3 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 lbf ft 54 to 81...

Page 82: ...n remove the oil fill plug from the cover IMPORTANT When the ambient temperature is above 0 F 18 C use SAE 10 heavy duty en gine oil API service classification SD sulfated ash content must not exceed...

Page 83: ...the fill plug 30 lbf ft 41 N m IMPORTANT Always check the axle breather whenever checking the lubricant level Check the breather more frequently under adverse op erating conditions 6 Check the axle h...

Page 84: ...d in the oil fill hole IMPORTANT A lubricant level close enough to be seen or touched is not sufficient It must be level with the bottom of the fill hole or the top of the standpipe opening 4 Check th...

Page 85: ...transmission fluid IMPORTANT When the ambient temperature is above 0 F 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...

Page 86: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Check 40 01 Wheels and Tires 40 Index Alphabetical 122SD and Coronado 132 Maintenance Manual February 2016...

Page 87: ...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...

Page 88: ...f Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical 122SD and Coronado 132 Maintenance Manual Februar...

Page 89: ...th 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 incremen...

Page 90: ...en the mounting fasteners to the proper torque value See Section 41 00 Specifications 400 of the 122SD and Coronado Workshop Manual for torque specifications Re place the midship bearing assembly if t...

Page 91: ...ut contact your Regional Service Office for assis tance in determining the correct driveshaft length 41 02 Driveline Lubrication Universal Joint Lubrication NOTE Vehicles equipped with Meritor RPL Se...

Page 92: ...ritty or burned replace the U joint 7 Wipe the purged grease from the seals and any excess grease from the grease fitting Slip Joint Spline Lubrication NOTE Vehicles equipped with Meritor RPL Se ries...

Page 93: ...on 42 10 Brake Inspection 42 05 Dana Spicer Camshaft Bracket Lubrication 42 08 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 42 09 Meritor Camshaft Bracket Lubrication 42 06 Meritor Slack A...

Page 94: ...pressure open the line slowly 3 Identify 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 se...

Page 95: ...ts 12 washers and 6 new Nylok nuts Torque the Nylok nuts in a star pattern 17 to 24 lbf ft 23 to 33 N m See Fig 2 08 09 95 f421383 1 2 3 4 5 9 10 11 12 13 14 15 17 18 19 21 22 23 24 25 10 10 10 10 10...

Page 96: ...ge 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...

Page 97: ...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 replaced...

Page 98: ...a 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 M...

Page 99: ...djusting 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 tro...

Page 100: ...4 3 inch rated stroke 2 1 2 64 30 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...

Page 101: ...use a special NLGI Grade synthetic polyurea grease and do not require lubrication for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance camshaft bushings are lubricat...

Page 102: ...r 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 42 08 Dana Spicer Camshaft Bracket Lubrication IMPORTAN...

Page 103: ...Lubricate a Gunite automatic slack adjuster at the grease fitting until grease appears on the camshaft or flows from the grease relief See Fig 9 The newest Gunite automatic slack adjusters are produce...

Page 104: ...OPG F900 White to the roll pin 13 Install the brake valve assembly see Group 42 of the vehicle Workshop Manual 14 Test the brakes before returning the vehicle to service 42 11 WABCO System Saver Air...

Page 105: ...mage such as bro ken air lines and broken or missing parts 2 Using a quality multipurpose chassis lubricant NLGI Grade 2 lubricate the slack adjuster through the grease fitting until clean lubricant f...

Page 106: ...3 4 12 1 3 8 Table 2 Actuator Stroke Standard Stroke Actuator Stroke Long Stroke Brake Actuator Size Recommended Maximum Operating Stroke Inches 30 Long Stroke 2 1 2 24 Long 2 24 Long Stroke 2 1 2 20...

Page 107: ...1 Drag Link Lubrication 46 05 Power Steering Fluid Level Inspection 46 03 Power Steering Fluid and Filter Changing 46 02 Power Steering Gear Lubrication 46 04 Safety Precautions 46 00 Steering 46 Inde...

Page 108: ...e Workshop Manual for drag link removal and installation instructions See Group 00 in this manual for torque specifica tions Inspect the boot of the drag link at both the pitman arm and the steering a...

Page 109: ...ged 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...

Page 110: ...lithium stearate grease chassis grease apply clean grease at the grease fittings until old grease is forced out of the socket f461071 1 11 28 95 1 Sector Shaft Grease Fitting Fig 2 Steering Gear Lubri...

Page 111: ...umber Fuel Filter Replacement 47 01 Fuel Tank Band Nut Tightening 47 03 Fuel Water Separator Element Checking and Replacement 47 02 Safety Precautions 47 00 Fuel 47 Index Alphabetical 122SD and Corona...

Page 112: ...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...

Page 113: ...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 co...

Page 114: ...d 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 en...

Page 115: ...tool other than a DAVCO Collar 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 5 Remove the filter...

Page 116: ...ne 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 lbf ft 41 to 46 N m After the re ten...

Page 117: ...of Maintenance Operation MOP MOP Number Exhaust System Inspection Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical 122SD and Coronado 132 Maintenance Manual February...

Page 118: ...s with the exhaust gases in the SCR to reduce NOx DEF Pump filters and supplies DEF to the DEF metering unit DEF Tank holds DEF and regulates its tem perature DEF Metering Unit mixes DEF with com pres...

Page 119: ...the DEF metering unit injection nozzle See the engine manufacturer s maintenance manual for filter replacement instructions and maintenance intervals ADR2011 Exhaust System Inspection IMPORTANT The A...

Page 120: ...contains the SCR inlet and outlet NOx sensors DPF outlet pressure sensor and the DOC inlet pressure sensor 1 DOC Outlet Temperature Sensor 2 DOC Inlet Pressure Sensor Port 3 DOC Inlet Temperature Sens...

Page 121: ...rature Sensor 5 DOC Inlet Temperature Sensor 6 DOC Inlet Pressure Sensor 7 DPF Inlet Temperature Sensor 8 DPF Outlet Pressure Sensor 9 DPF Outlet Temperature Sensor 10 DPF Outlet NOx Sensor 11 SCR Out...

Page 122: ...F Outlet NOx Sensor 8 SCR Inlet Temperature Sensor 9 SCR Outlet Temperature Sensor 10 SCR Sensor Box 11 SCR Outlet NOx Sensor Fig 3 2HV Two Box ATS Sensor Locations EPA10 04 11 2012 f490470 1 1 1 1 2...

Page 123: ...Title of Maintenance Operation MOP MOP Number Aerodynamic Component Inspection 60 02 Mirror Folding Check 60 01 Cab 60 Index Alphabetical 122SD and Coronado 132 Maintenance Manual November 2014...

Page 124: ...affect the fold away feature of the mirror 60 02 Aerodynamic Component Inspection Inspect aerodynamic components if equipped for structural damage cracks or wear These may in clude Chassis fairings Ba...

Page 125: ...Title of Maintenance Operation MOP MOP Number Door Seal Door Latch and Door Check Lubrication 72 01 Doors 72 Index Alphabetical 122SD and Coronado 132 Maintenance Manual January 2010...

Page 126: ...tch 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...

Page 127: ...e Operation MOP MOP Number Air Conditioner Inspection 83 01 Air Filter Replacement 83 02 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical 122SD and Coronado 132 Maintenance Ma...

Page 128: ...e the results See Fig 1 4 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on the hoses Replace damaged hoses For re placement instructions see Group 83 of...

Page 129: ...holds the recirculation 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 asse...

Page 130: ...onsole Fig 3 Cab Recirculation Air Filter Location 02 26 2002 f831491 1 2 1 Retainer 2 Recirculation Air Filter Fig 4 Cab Recirculation Air Filter 02 26 2002 f831492 1 1 Air Filter Fig 5 Sleeper HVAC...

Page 131: ...Title of Maintenance Operation MOP MOP Number Hood Rear Support Lubrication 88 01 Hood Grille and Cab Fenders 88 Index Alphabetical 122SD and Coronado 132 Maintenance Manual November 2014...

Page 132: ...s 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 Supp...

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