International Trucks LT/RH/LoneStar RH613/LT625 Models Repair Service Manual

Catalog: 
Price: US$ 75.00

Complete service repair manual with Electrical Wiring Diagrams for International / Navistar Trucks LT/RH/LoneStar RH613 4x2, RH613 6x4, RH613 6x2, LT625 4x2, LT625 6x4, LT625 6x2, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

International / Navistar Trucks LT / RH/ LoneStar RH613 4x2, RH613 6x4, RH613 6x2, LT625 4x2, LT625 6x4, LT625 6x2 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 5,157 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

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MAIN SECTIONS
  Table of Contents.......3
  Safety Terminology.......6
  Safety Instructions.......6
  Work Area.......6
  Safety Equipment.......6
  Protective Measures.......6
  Vehicle.......6
  Engine.......7
  Fire Prevention.......7
  Batteries.......7
  Compressed Air.......7
  Tools.......7
  Fluids Under Pressure.......8
  Fuel.......8
  Removal of Tools, Parts, and Equipment.......8
    Frame.......9
      1. Frame and Bumper.......11
        Deck Plate.......11
        Overview.......11
        Front Bumper.......12
        Overview.......12
        One-piece Stationary Bumper.......13
        Three-piece Stationary Bumper.......13
          Removal.......14
          Overview.......14
          Special Tools.......14
          Equipment Conditions.......14
          Removal Procedure.......14
          Follow-On Procedure.......14
          Installation.......15
          Overview.......15
          Special Tools.......15
          Equipment Conditions.......15
          Installation Procedure.......15
          Follow-On Procedure.......16
        Tool Box.......17
        Overview.......17
        Tow Hook.......18
        Overview.......18
      2. Frame and Bumper - LoneStar.......20
        Front Bumper.......20
        Overview.......20
    Front Axle.......21
      1. Front Non-Driving Axle.......23
        Dana Spicer.......23
        Overview.......23
          Kingpin.......25
          Removal.......25
          Overview.......25
          Special Tools.......25
          Equipment Conditions.......25
          Removal Procedure.......26
          Follow-On Procedure.......27
          Installation.......28
          Overview.......28
          Special Tools.......28
          Torque Specifications.......28
          Equipment Conditions.......28
          Installation Procedure.......29
          Follow-On Procedure.......30
          Kingpin.......31
          Removal.......31
          Overview.......31
          Special Tools.......31
          Equipment Conditions.......31
          Removal Procedure.......32
          Follow-On Procedure.......33
          Installation.......34
          Overview.......34
          Special Tools.......34
          Torque Specifications.......34
          Equipment Conditions.......34
          Installation Procedure.......35
          Follow-On Procedure.......36
          Wheel Seals.......36
          Removal.......36
          Overview.......36
          Special Tools.......36
          Equipment Conditions.......37
          Removal Procedure.......38
          Follow-On Procedure.......39
          Installation.......40
          Overview.......40
          Special Tools.......40
          Equipment Conditions.......40
          Installation Procedure.......41
          Follow-On Procedure.......43
        Hendrickson.......45
        Overview.......45
        Meritor.......47
        Overview.......47
    Front Suspension.......49
      1. Suspension Systems.......51
        Air Ride.......51
        Overview.......51
        Mono Leaf Spring.......53
        Overview.......53
        Parabolic Taper Leaf Spring.......54
        Overview.......54
    Brakes.......57
      1. Air Brakes.......59
        Bendix ABS Air Brakes.......59
          4-Channel.......59
          Overview.......59
          4-Channel with Automatic Traction Control.......62
          Overview.......62
          4-Channel with Electronic Stability and Automatic Traction Control.......64
          Overview.......64
          6-Channel.......66
          Overview.......66
          6-Channel with Automatic Traction Control.......69
          Overview.......69
          6-Channel with Electronic Stability and Automatic Traction Control.......71
          Overview.......71
          ABS Module.......73
          Removal.......73
          Overview.......73
          Special Tools.......73
          Equipment Conditions.......73
          Removal Procedure.......74
          Follow-On Procedure.......75
          Installation.......76
          Overview.......76
          Special Tools.......76
          Torque Specifications.......76
          Equipment Conditions.......76
          Installation Procedure.......77
          Follow-On Procedure.......78
          Steering Angle Sensor.......79
          Removal.......79
          Overview.......79
          Special Tools.......79
          Equipment Conditions.......79
          Removal Procedure.......80
          Follow-On Procedure.......82
          Installation.......83
          Overview.......83
          Special Tools.......83
          Torque Specifications.......83
          Equipment Conditions.......83
          Installation Procedure.......84
          Follow-On Procedure.......86
          Wheel Speed Sensor.......87
          Removal.......87
          Overview.......87
          Special Tools.......87
          Equipment Conditions.......87
          Removal Procedure.......88
          Follow-On Procedure.......88
          Installation.......89
          Overview.......89
          Special Tools.......89
          Torque Specifications.......89
          Equipment Conditions.......89
          Installation Procedure.......90
          Follow-On Procedure.......90
          Yaw Rate Sensor.......91
          Removal.......91
          Overview.......91
          Special Tools.......91
          Equipment Conditions.......91
          Removal Procedure.......92
          Follow-On Procedure.......92
          Installation.......93
          Overview.......93
          Special Tools.......93
          Equipment Conditions.......93
          Installation Procedure.......94
          Follow-On Procedure.......94
        Meritor Wabco ABS Air Brakes.......95
          4-Channel.......95
          Overview.......95
          4-Channel with Automatic Traction Control.......97
          Overview.......97
          4-Channel with Electronic Stability and Automatic Traction Control.......98
          Overview.......98
          6-Channel.......100
          Overview.......100
          6-Channel with Automatic Traction Control.......102
          Overview.......102
          6-Channel with Electronic Stability and Automatic Traction Control.......103
          Overview.......103
        Air Brake Systems.......105
          Hand Control Valve.......105
          Overview.......105
          Spring Brake Modulator Valve.......106
          Overview.......106
          Tractor.......107
          Overview.......107
          Air Modulator Valve.......108
          Removal.......108
          Overview.......108
          Special Tools.......108
          Equipment Conditions.......108
          Removal Procedure.......109
          Follow-On Procedure.......109
          Installation.......110
          Overview.......110
          Special Tools.......110
          Torque Specifications.......110
          Equipment Conditions.......110
          Installation Procedure.......111
          Follow-On Procedure.......111
          ATR-6 Valve.......112
          Removal.......112
          Overview.......112
          Special Tools.......112
          Equipment Conditions.......112
          Removal Procedure.......113
          Follow-On Procedure.......113
          Installation.......114
          Overview.......114
          Special Tools.......114
          Torque Specifications.......114
          Equipment Conditions.......114
          Installation Procedure.......115
          Follow-On Procedure.......115
          Foot Valve.......116
          Removal.......116
          Overview.......116
          Special Tools.......116
          Equipment Conditions.......116
          Removal Procedure.......117
          Follow-On Procedure.......117
          Installation.......118
          Overview.......118
          Special Tools.......118
          Torque Specifications.......118
          Equipment Conditions.......118
          Installation Procedure.......119
          Follow-On Procedure.......119
          R-12 Relay Valve.......120
          R-12 Relay Valve Removal.......120
          Overview.......120
          Special Tools.......120
          Equipment Conditions.......120
          Removal Procedure.......121
          Follow-On Procedure.......121
          R-12 Relay Valve Installation.......122
          Overview.......122
          Special Tools.......122
          Torque Specifications.......122
          Equipment Conditions.......122
          Installation Procedure.......123
          Follow-On Procedure.......123
          Quick Release Valve.......124
          Removal.......124
          Overview.......124
          Special Tools.......124
          Equipment Conditions.......124
          Removal Procedure.......125
          Follow-On Procedure.......125
          Installation.......126
          Overview.......126
          Special Tools.......126
          Torque Specifications.......126
          Equipment Conditions.......126
          Installation Procedure.......127
          Follow-On Procedure.......127
        Disc Brakes.......128
          Front .......128
          Overview.......128
          Caliper Removal.......129
          Overview.......129
          Special Tools.......129
          Equipment Condition.......129
          Removal Procedure.......129
          Follow-On Procedure.......129
          Caliper Installation.......130
          Overview.......130
          Special Tools.......130
          Equipment Condition.......130
          Installation Procedure.......130
          Follow-On Procedure.......130
          Rear.......132
          Overview.......132
          Caliper Removal.......133
          Overview.......133
          Special Tools.......133
          Equipment Condition.......133
          Removal Procedure.......133
          Follow-On Procedure.......133
          Caliper Installation.......134
          Overview.......134
          Special Tools.......134
          Equipment Condition.......134
          Installation Procedure.......134
          Follow-On Procedure.......134
        Slack Adjusters.......136
          Front Axle.......136
          Overview.......136
          Rear Axle.......138
          Overview.......138
      2. Air Systems.......140
        Air Compressors.......140
          Cummins 18.7 CFM.......140
          Overview.......140
          Knorr-Bremse 31.8 CFM.......141
          Overview.......141
          Wabco 37.4 CFM.......142
          Overview.......142
          Air Compressor 21.0 CFM.......143
          Overview.......143
          Bendix 15.9 CFM.......144
          Overview.......144
        Air Dryer  Bendix AD-IS.......145
        Overview.......145
        Air Dryer  Meritor Wabco System Save 1200 Plus.......146
        Overview.......146
        Air Dryer  Auxiliary Bendix Air Dryer.......147
        Overview.......147
        Air Tank.......148
        Overview.......148
          Standard Location.......149
          Overview.......149
        Drain Valves.......150
          Heated Drain Valves.......150
          Overview.......150
      3. Trailer.......151
        Trailer Connections.......151
          Air Brakes - Trailer Connections.......151
          Overview.......151
          Electrical Connection.......153
          Overview.......153
    Steering.......155
      1. Steering Column and Steering Wheel.......157
        Steering Column - Tilting.......157
        Overview.......157
        Steering Column - Tilting and Telescoping.......158
        Overview.......158
        Steering Wheel.......159
        Overview.......159
        Special Tools.......160
          Removal.......161
          Overview.......161
          Special Tools.......161
          Equipment Conditions.......161
          Removal Procedure.......161
          Follow-On Procedure.......162
          Installation.......163
          Overview.......163
          Special Tools.......163
          Equipment Conditions.......163
          Installation Procedure.......163
          Follow-On Procedure.......164
        Steering Wheel Switches.......165
          Removal.......165
          Overview.......165
          Special Tools.......165
          Equipment Conditions.......165
          Removal Procedure.......165
          Follow-On Procedure.......166
          Installation.......167
          Overview.......167
          Special Tools.......167
          Equipment Conditions.......167
          Installation Procedure.......167
          Follow-On Procedure.......168
      2. Power Steering System.......169
        Oil Cooler.......169
          Remote Mounted Power Steering Oil Cooler.......169
          Overview.......169
        Power Steering Gear.......170
          Ross PCF60.......170
          Overview.......170
          Ross THP60.......171
          Overview.......171
          Sheppard HD94.......172
          Overview.......172
          Reservoir.......174
          Removal.......174
          Overview.......174
          Special Tools.......174
          Equipment Conditions.......174
          Removal Procedure.......174
          Follow-On Procedure.......175
          Installation.......176
          Overview.......176
          Special Tools.......176
          Torque Specifications.......176
          Equipment Conditions.......176
          Installation Procedure.......176
          Follow-On Procedure.......177
          Power Steering Pump Bleed.......178
          Overview.......178
          Special Tools.......178
          Equipment Conditions.......178
          System Bleed Procedure.......178
          Follow-on Procedure.......179
          Power Steering Pump Flow Test.......180
          Overview.......180
          Special Tools.......180
          Equipment Condition.......180
          Test Setup.......180
          Test Procedure.......180
          Follow-On Procedure.......181
    Drivelines.......183
      1. Drive Shaft.......185
        Dana Spicer.......185
        Overview.......185
          Universal Joint.......187
          Removal.......187
          Overview.......187
          Special Tools.......187
          Equipment Conditions.......187
          Removal Procedure.......188
          Follow-On Procedure.......188
          Installation.......189
          Overview.......189
          Special Tools.......189
          Equipment Conditions.......189
          Installation Procedure.......190
          Follow-On Procedure.......190
        Driveline Service & Troubleshooting.......191
          Operational Checkout Procedure.......192
          Overview.......192
          Center Bearing Inspection.......195
          Overview.......195
          Special Tools.......195
          Equipment Condition.......195
          Inspection Procedure.......195
          Follow-On Procedure.......195
          Driveline Angle Measurement.......196
          Overview.......196
          Special Tools.......196
          Equipment Conditions.......196
          Measurement Procedure.......196
          Follow-On Procedure.......198
          Driveline Vibration Diagnostics.......199
          Overview.......199
          Special Tools.......199
          Equipment Condition.......199
          Procedure.......199
          Follow-On Procedure.......200
    Exhaust.......201
      1. Exhaust Systems.......203
        Day Cab .......203
          Horizontal.......203
          Overview.......203
          Horizontal with Vertical Tips.......204
          Overview.......204
          Vertical .......205
          Overview.......205
        Short Sleeper .......206
          Horizontal.......206
          Overview.......206
          Vertical.......207
          Overview.......207
          Removal.......208
          Overview.......208
          Special Tools.......208
          Equipment Conditions.......208
          Removal Procedure.......208
          Follow-On Procedure.......209
          Installation.......210
          Overview.......210
          Special Tools.......210
          Equipment Conditions.......210
          Installation Procedure.......211
          Follow-On Procedure.......211
        Long Sleeper.......212
          Horizontal.......212
          Overview.......212
          Vertical.......213
          Overview.......213
        Inhibit Regen Switch.......214
        Overview.......214
      2. Exhaust Systems - LoneStar.......215
        Horizontal.......215
        Overview.......215
      3. Engine Brake.......216
        Engine Compression Brake.......216
          Cummins.......216
          Overview.......216
          Jacobs (A26).......217
          Overview.......217
        Engine Brake Switch.......218
        Overview.......218
    Electrical / Software.......219
      1. Diagnostic Trouble Code (DTC) List.......225
      2. 12 Volt System.......229
      Overview.......229
        Auto Start Stop.......230
        Overview.......230
        Overview.......231
        Battery Box.......232
        Overview.......232
          Battery Box Locations.......234
          Left Side Battery Box (Standard).......234
          Auxiliary Battery Box (Between the Frame Rails).......235
          Auxiliary Battery Box (Left Side Mounted).......236
          Battery Disconnect.......237
          Overview.......237
          Special Tools.......237
          Equipment Conditions.......237
          Disconnect Procedure.......237
          Follow-On Procedure.......238
          Battery Reconnect.......239
          Overview.......239
          Special Tools.......239
          Equipment Conditions.......239
          Reconnect Procedure.......240
          Follow-On Procedure.......240
        Battery Disconnect Switch.......241
        Overview.......241
        Body Control Module.......242
          Diagnostics.......242
          Overview.......242
          SPN 520274 FMI 6 - Ignition Grid: Current Above Normal or Grounded Circuit.......244
          Overview.......244
          Associated Faults.......244
          Fault Facts.......244
          Special Tools.......244
          Possible Causes.......244
          Body Control Module Electrical Test.......246
          Overview.......246
          Special Tools.......246
          Equipment Conditions.......246
          Test Setup.......246
          Diamond Logic Builder.......252
          Overview.......252
          Selecting an Interface Cable.......253
          Overview.......253
          Special Tools.......253
          Equipment Conditions.......253
          Selection Procedure.......253
          Follow-On Procedure.......254
          Connecting to a Vehicle.......255
          Overview.......255
          Special Tools.......255
          Equipment Conditions.......255
          Connection Procedure.......255
          Follow-On Procedure.......256
          Activating Diagnostic Mode.......257
          Overview.......257
          Special Tools.......257
          Equipment Conditions.......257
          Activation Procedure.......257
          Follow-On Procedure.......258
          Starting a Session.......259
          Overview.......259
          Special Tools.......259
          Equipment Conditions.......259
          Starting Procedure.......259
          Follow-On Procedure.......260
          Viewing Fault Codes.......261
          Overview.......261
          Special Tools.......261
          Equipment Conditions.......261
          Viewing Procedure.......261
          Follow-On Procedure.......261
          Clearing Fault Codes.......262
          Overview.......262
          Special Tools.......262
          Equipment Conditions.......262
          Clearing Procedure.......262
          Follow-On Procedure.......262
          Modifying Signals Tab.......263
          Overview.......263
          Special Tools.......263
          Equipment Conditions.......263
          Modify Watched Signal Columns.......263
          Modify Watched Signals.......264
          Follow-On Procedure.......264
          Programming Modules.......265
          Overview.......265
          Special Tools.......265
          Equipment Conditions.......265
          Programming Procedure.......265
          Follow-On Procedure.......268
          Input Not Recognized by Body Control Module.......269
          Overview.......269
          Special Tools.......269
          Equipment Conditions.......269
          Troubleshooting Procedure.......269
          Follow-On Procedure.......270
          Output Not Commanded by Body Control Module.......271
          Overview.......271
          Special Tools.......271
          Equipment Conditions.......271
          Troubleshooting Procedure.......271
          Follow-On Procedure.......272
        CAN Systems.......273
        Overview.......273
          Faults.......275
          Short.......275
          Terminating Resistor Failure.......275
          Backbone Open.......275
          Node Open.......276
          Operational Checkout Procedure.......277
          125K Low Speed.......278
          Overview.......278
          Overview.......278
          Diagnostics.......280
          250K Body.......282
          Overview.......282
          Diagnostics.......283
          250K Cab.......285
          Overview.......285
          Diagnostics.......287
          500K Powertrain.......289
          Overview.......289
          Diagnostics.......291
          Tests.......293
          Power and Ground Test.......293
          Overview.......293
          Tools Required.......293
          Equipment Condition.......293
          Test Setup.......293
          Test Procedure.......293
          Follow-On Procedure.......293
          Module Communication Test.......294
          Overview.......294
          Tools Required.......294
          Equipment Condition.......294
          Test Setup.......294
          Test Procedure.......294
          Follow-On Procedure.......295
          CAN Voltage Test.......296
          Tools Required.......296
          Equipment Condition.......296
          Test Setup.......296
          Test Procedure.......296
          Follow-On Procedure.......296
          CAN Resistance Test.......297
          Tools Required.......297
          Equipment Condition.......297
          Test Setup.......297
          Test Procedure.......297
          Follow-On Procedure.......297
        Clutch Switch.......298
        Overview.......298
        Electrical Load Control.......304
        Overview.......304
        Hood Switch.......308
        Overview.......308
        Key Switch.......311
        Overview.......311
        Starting and Charging System.......316
          Operational Checkout Procedure.......317
          Starting System.......318
          Overview.......318
          Battery Pack.......318
          Starter.......318
          Control.......318
          No Click No Crank.......320
          Overview.......320
          Possible Causes.......320
          Click No Crank.......322
          Overview.......322
          Possible Causes.......322
          Low Cranking Speed.......324
          Overview.......324
          Possible Causes.......324
          Starter Input Signal Not Sent.......325
          Overview.......325
          Key Switch and Grid Control.......325
          Crank Inhibit.......325
          GridCtrl_CrankInhibit.......325
          Crank_Inhibit_Reason.......325
          Lower_Clutch_Signal.......326
          Neutral_Status_TCM.......326
          Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal).......326
          Hood_Switch.......326
          Operational Checkout Procedure.......328
          Overview.......328
          Charging System.......332
          Overview.......332
          Battery Pack.......332
          Alternator.......332
          Red Battery Warning Light.......334
          Overview.......334
          Possible Causes.......334
          Repeated Jump Starts.......336
          Overview.......336
          Possible Causes.......336
          Voltmeter Reading High.......338
          Overview.......338
          Possible Causes.......338
          Voltmeter Reading Low / Fluctuating.......339
          Overview.......339
          Possible Causes.......339
          Tests.......341
          Battery Test.......341
          Overview.......341
          Tools Required.......341
          Equipment Condition.......341
          Test Setup.......341
          Test Procedure.......341
          Expected Outcome.......342
          Follow-On Procedure.......343
          Electrical System Test.......344
          Overview.......344
          Tools Required.......344
          Equipment Condition.......344
          Test Setup.......344
          Test Procedure.......344
          Starter System Test Procedure.......347
          Charging System Test Procedure.......348
          Expected Outcome.......349
          Follow-On Procedure.......349
          Cable Drop Test.......350
          Overview.......350
          Tools Required.......350
          Equipment Condition.......350
          Test Setup.......350
          Test Procedure.......350
          Expected Outcome.......351
          Follow-On Procedure.......351
          Parasitic Draw Test.......352
          Overview.......352
          Tools Required.......352
          Equipment Condition.......352
          Test Setup.......352
          Test Procedure.......353
          Expected Outcome.......355
          Follow-On Procedure.......355
          Manual Engine Bar Test.......356
          Overview.......356
          Tools Required.......356
          Equipment Condition.......356
          Test Setup.......356
          Test Procedure.......356
          Expected Outcome.......356
          Follow-On Procedure.......356
          Starter Control Circuit Test.......357
          Overview.......357
          Tools Required.......357
          Equipment Condition.......357
          Test Setup.......357
          Test Procedure.......357
          Expected Outcome.......357
          Follow-On Procedure.......357
          Inspections.......358
          Ring Gear Inspection.......358
          Overview.......358
          Tools Required.......358
          Equipment Condition.......358
          Inspection Procedure.......358
          Expected Outcome.......359
          Follow-On Procedure.......359
          Electrical System Inspection.......360
          Overview.......360
          Tools Required.......360
          Equipment Condition.......360
          Inspection Procedure.......361
          Expected Outcome.......363
          Follow-On Procedure.......363
        Neutral Confirmation.......364
        Overview.......364
          Automatic.......366
          Overview.......366
          Manual.......367
          Overview.......367
        Jump Start Stud.......369
        Overview.......369
        Power Inverter.......371
        Overview.......371
        Inverter Diagnostics.......371
          Operational Checkout Procedure.......373
          Inverter Inoperative.......375
          Symptom Overview.......375
          Symptom Facts.......375
          Possible Causes.......375
          Pin-Point Test - Inverter Inoperative.......377
          Tools Required.......377
          E01 - DC Input Under-Voltage Shutdown.......379
          Fault Code Overview.......379
          Fault Facts.......379
          Possible Causes.......379
          Pin-Point Test - E01.......381
          Tools Required.......381
          E02 - DC Input Over-Voltage Shutdown.......383
          Fault Code Overview.......383
          Fault Facts.......383
          Possible Causes.......383
          Pin-Point Test - E02.......385
          Tools Required.......385
          E03 - Inverter Output Overload.......386
          Fault Code Overview.......386
          Fault Facts.......386
          Possible Causes.......386
          E04 - Inverter Over-Temperature Shutdown.......388
          Fault Code Overview.......388
          Fault Facts.......388
          Possible Causes.......388
          E05 - DC Input Under-Voltage Warning.......390
          Fault Code Overview.......390
          Fault Facts.......390
          Possible Causes.......390
          Pin-Point Test - E05.......392
          Tools Required.......392
          E06 - Inverter Output Overload Warning.......394
          Fault Code Overview.......394
          Fault Facts.......394
          Possible Causes.......394
          E07 - Inverter Over-Temperature Warning.......396
          Fault Code Overview.......396
          Fault Facts.......396
          Possible Causes.......396
          E10 - Charger Output Over-Voltage Shutdown.......398
          Fault Code Overview.......398
          Fault Facts.......398
          Possible Causes.......398
          E11 - Battery Not Accepting Charge.......400
          Fault Code Overview.......400
          Fault Facts.......400
          Possible Causes.......400
          Pin-Point Test - E11.......402
          Tools Required.......402
          E12 - Transfer Relay Over-Temperature Shutdown.......404
          Fault Code Overview.......404
          Fault Facts.......404
          Possible Causes.......404
      3. Accessories.......406
        Air Solenoid Pack.......406
        Overview.......406
        Cruise Control.......407
        Overview.......407
          Predictive Cruise Control.......411
          Overview.......411
          Operational Checkout Procedure.......415
          Overview.......415
          Predictive Cruise Control Module Diagnostics.......417
          Pin-Point Tests - Predictive Cruise Control .......420
          Tools Required.......420
          Predictive Cruise Control GPS Antenna Diagnostics.......428
        Differential Locking.......430
        Overview.......430
        Power Windows, Door Locks and Mirrors.......431
          Power Door Locks and Windows.......431
          Overview.......431
          Heated Mirrors.......435
          Overview.......435
          Power Mirrors.......437
          Overview.......437
          Remote Keyless Entry.......439
          Overview.......439
          Remote Keyless Entry Fob Programming.......441
          Overview.......441
          Tools Required.......441
          Equipment Condition.......441
          Procedure.......441
          Follow On Procedure.......441
        Satellite Communication System.......442
        Overview.......442
        Steering Wheel Switches.......443
          Left POD.......443
          Overview.......443
          Right POD.......445
          Overview.......445
        Theft Deterrent System.......447
        Overview.......447
          Operational Checkout Procedure.......450
          Theft Deterrent System Not Responding.......451
          Overview.......451
          Fault Facts.......451
          Possible Causes.......451
        USB Receptacle.......453
        Overview.......453
      4. Brakes.......454
        Bendix Air Brake System.......455
          Anti-Lock Brake System (ABS).......455
          Overview.......455
          Inputs.......457
          Outputs.......457
          Operational Checkout Procedure.......459
          Overview.......459
          ABS Module Loss of Communication.......460
          Overview.......460
          Fault Facts.......460
          Tools Required.......460
          Possible Causes.......460
          Automatic Traction Control (ATC) System.......463
          Overview.......463
          Inputs.......464
          Outputs.......465
          Electronic Stability Control (ESC) System.......466
          Overview.......466
          Inputs.......467
          Outputs.......468
        Meritor Wabco Air Brake System.......470
          Anti-Lock Brake System (ABS).......470
          Overview.......470
          Inputs.......472
          Outputs.......472
          Automatic Traction Control (ATC) System.......474
          Overview.......474
          Inputs.......475
          Outputs.......476
          Electronic Stability Control (ESC) System.......477
          Overview.......477
          Inputs.......478
          Outputs.......479
      5. Collision Avoidance Systems.......480
        Collision Mitigation System.......480
          Bendix Wingman Advanced.......480
          Overview.......480
          Adaptive Cruise Control (ACC).......482
          Alerts.......482
          Collision Mitigation Braking.......482
          Tech Tips.......484
          Operational Checkout Procedure.......485
          Overview.......485
          Radar Sensor Loss of Communication.......487
          Overview.......487
          Fault Facts.......487
          Tools Required.......487
          Possible Causes.......487
          Radar Sensor Removal.......490
          Special Tools.......490
          Torque Specifications.......490
          Equipment Conditions.......490
          Removal Procedure.......490
          Follow-On Procedure.......491
          Radar Sensor Installation.......492
          Special Tools.......492
          Torque Specifications.......492
          Equipment Conditions.......492
          Installation Procedure.......492
          Follow-On Procedure.......493
          Radar Sensor Adjustment.......494
          Special Tools.......494
          Equipment Conditions.......494
          Lateral Adjustment Procedure (Radar or Mounting Plate Not Replaced).......494
          Lateral Adjustment Procedure (Radar or Mounting Plate Replaced).......496
          Vertical Adjustment Procedure.......498
          Follow-On Procedure.......500
          Bendix Wingman Fusion.......501
          Overview.......501
          Adaptive Cruise Control (ACC).......503
          Alerts.......503
          Collision Mitigation Braking.......504
          SafetyDirect Capability.......504
          Stationary Vehicle Braking (SVB).......504
          Tech Tips.......506
          Operational Checkout Procedure.......507
          Overview.......507
          Camera Sensor Loss of Communication.......510
          Overview.......510
          Fault Facts.......510
          Tools Required.......510
          Possible Causes.......510
          SafetyDirect Module Loss of Communication.......513
          Overview.......513
          Fault Facts.......513
          Tools Required.......513
          Possible Causes.......513
          Camera Removal.......516
          Special Tools.......516
          Torque Specifications.......516
          Equipment Conditions.......516
          Removal Procedure.......516
          Follow-On Procedure.......517
          Camera Installation.......518
          Special Tools.......518
          Torque Specifications.......518
          Equipment Conditions.......518
          Installation Procedure.......518
          Follow-On Procedure.......519
          SafetyDirect Module High Roof Removal.......520
          Special Tools.......520
          Torque Specifications.......520
          Equipment Conditions.......520
          Removal Procedure.......520
          Follow-On Procedure.......522
          SafetyDirect Module High Roof Installation.......523
          Special Tools.......523
          Equipment Conditions.......523
          Installation Procedure.......523
          Follow-On Procedure.......525
          SafetyDirect Module Low Roof Removal.......526
          Special Tools.......526
          Torque Specifications.......526
          Equipment Conditions.......526
          Removal Procedure.......526
          Follow-On Procedure.......526
          SafetyDirect Module Low Roof Installation.......527
          Special Tools.......527
          Torque Specifications.......527
          Equipment Conditions.......527
          Installation Procedure.......527
          Follow-On Procedure.......527
        Lane Departure System.......528
          Bendix AutoVue 3G.......528
          Overview.......528
      6. Engine.......530
        Cummins Diagnostics.......530
          Table Of Contents.......530
          Fault Code Diagnostics.......531
          Fault Code List.......531
          SPN 110 FMI 0 (Cummins FC 151) - Engine Coolant Temperature - Data Valid But Above Normal Operating Range - Most Severe Level.......533
          Fault Overview.......533
          Lamp Reaction.......533
          Fault Fact.......533
          Cummins Solutions.......533
          Engine component coolant leaks.......533
          Externally obstructed radiator.......533
          Radiator shutters malfunctioning (If Equipped).......533
          Fan Clutch operates incorrectly.......533
          Stuck in - range Engine Coolant Temperature Sensor.......533
          Thermostat is stuck open or closed.......533
          Combustion gasses entering the cooling system.......533
          Internally leaking EGR Cooler.......533
          Engine Control Module (ECM) calibration revision history check.......533
          SPN 111 FMI 3 (Cummins FC 195) - Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source.......534
          Fault Overview.......534
          Lamp Reaction.......534
          Fault Fact.......534
          Cummins Solutions.......534
          Fault Code 195 triggered by another Fault Code.......534
          Engine Coolant Level sensor voltage circuit check (3 - wire sensor).......534
          Malfunctioning Engine Coolant Level sensor circuit response (3 - wire).......534
          Malfunctioning Engine Coolant Level sensor circuit response (2 - wire).......534
          Engine Coolant Level sensor signal or return open circuit.......534
          Engine Coolant Level sensor signal pin shorted to another pin.......534
          SPN 111 FMI 18 (Cummins FC 197) - Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level.......535
          Fault Overview.......535
          Lamp Reaction.......535
          Fault Fact.......535
          Cummins Solutions.......535
          Verify coolant loss complaint.......535
          Missing or damaged Coolant Level Sensor.......535
          Engine component coolant leaks.......535
          Internally leaking EGR Cooler.......535
          Engine Control Module (ECM) calibration revision history check.......535
          SPN 111 FMI 1 (Cummins FC 235) - Coolant Level - Data Valid But Below Normal Operating Range - Most severe Level .......536
          Fault Overview.......536
          Lamp Reaction.......536
          Fault Fact.......536
          Cummins Solutions.......536
          Verify coolant loss complaint.......536
          Missing or damaged Coolant Level Sensor.......536
          Engine component coolant leaks.......536
          Internally leaking EGR Cooler.......536
          Malfunctioning cooling system Pressure Cap.......536
          Engine Control Module (ECM) calibration revision history check.......536
          SPN 629 FMI 12 (Cummins FC 343) - Engine Control Module Warning Internal Hardware Failure - Bad Intelligent Device or Component.......537
          Fault Overview.......537
          Lamp Reaction.......537
          Fault Fact.......537
          Cummins Solutions.......537
          Malfunctioning battery or battery cables.......537
          Battery circuit fuse has open circuit.......537
          Keyswitch input circuit check.......537
          Malfunctioning charging system alternator.......537
          Engine Control Module (ECM) calibration history check.......537
          SPN 639 FMI 9 (Cummins FC 427) - J1939 Data Link - Abnormal Update Rate .......538
          Fault Overview.......538
          Lamp Reaction.......538
          Fault Fact.......538
          Cummins Solutions.......538
          Incorrect ECM data link communications.......538
          Engine Control Module (ECM) calibration revision history check.......538
          SPN 168 FMI 16 (Cummins FC 442) - Battery 1 Voltage - Data Valid But Above Normal Operating Range - Moderately Severe Level.......539
          Fault Overview.......539
          Lamp Reaction.......539
          Fault Fact.......539
          Cummins Solutions.......539
          Malfunctioning battery or battery cables.......539
          Malfunctioning charging system alternator.......539
          Engine Control Module (ECM) calibration revision history check.......539
          SPN 3597 FMI 2 (Cummins FC 1117) - ECM Low Battery Voltage.......540
          Fault Overview.......540
          Lamp Reaction.......540
          Fault Fact.......540
          Cummins Solutions.......540
          Battery Power Removed by Battery Power Disconnect Switch.......540
          Low Battery Voltage.......540
          Malfunctioning Battery or Battery Cables.......540
          Battery Circuit Fuse has Open Circuit.......540
          Keyswitch Input Circuit Check.......540
          Intermittent Ground Connection.......540
          Engine Control Module (ECM) Calibration Revision History Check.......540
          ECM is Malfunctioning.......540
          SPN 1761 FMI 1 (Cummins FC 1673) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Most Severe Level.......541
          Fault Overview.......541
          Associated Faults.......541
          Fault Facts.......541
          Possible Causes.......541
          SPN 1761 FMI 3 (Cummins FC 1669) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Above Normal or Shorted to High Source.......542
          Fault Overview.......542
          Associated Faults.......542
          Fault Facts.......542
          Possible Causes.......542
          SPN 1761 FMI 4 (Cummins FC 1668) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Below Normal or Shorted to Low Source.......543
          Fault Overview.......543
          Associated Faults.......543
          Fault Facts.......543
          Possible Causes.......543
          SPN 1761 FMI 9 (Cummins FC 4677) Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Abnormal Update Rate .......544
          Fault Overview.......544
          Associated Faults.......544
          Fault Facts.......544
          Possible Cause.......544
          Pin-Point Tests (SPN 1761 FMI 9).......547
          Tools Required.......547
          SPN 1761 FMI 10 (Cummins FC 4769) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal Rate of Change.......552
          Fault Overview.......552
          Associated Faults.......552
          Fault Facts.......552
          Possible Causes.......552
          SPN 1761 FMI 11 (Cummins FC 4739) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Root Cause Not Known.......553
          Fault Overview.......553
          Associated Faults.......553
          Fault Facts.......553
          Possible Causes.......553
          SPN 1761 FMI 13 (Cummins FC 4732) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of Calibration.......554
          Fault Overview.......554
          Associated Faults.......554
          Fault Facts.......554
          Possible Causes.......554
          SPN 1761 FMI 17 (Cummins FC 3497) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Least Severe Level.......555
          Fault Overview.......555
          Associated Faults.......555
          Fault Facts.......555
          Possible Causes.......555
          SPN 1761 FMI 18 (Cummins FC 3498) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range -Moderately Severe Level .......556
          Fault Overview.......556
          Associated Faults.......556
          Fault Facts.......556
          Possible Causes.......556
          SPN 3031 FMI 2 (Cummins FC 1679) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic, Intermittent, or Incorrect.......557
          Fault Overview.......557
          Associated Faults.......557
          Fault Facts.......557
          Possible Causes.......557
          SPN 3031 FMI 3 (Cummins FC 1678) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Above Normal or Shorted to High Source .......558
          Fault Overview.......558
          Associated Faults.......558
          Fault Facts.......558
          Possible Causes.......558
          SPN 3031 FMI 4 (Cummins FC 1677) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Below Normal or Shorted to Low Source.......559
          Fault Overview.......559
          Associated Faults.......559
          Fault Facts.......559
          Possible Causes.......559
          SPN 3031 FMI 9 (Cummins FC 4572) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal Update Rate.......560
          Fault Overview.......560
          Associated Faults.......560
          Fault Facts.......560
          Possible Cause.......560
          Pin-Point Tests (SPN 3031 FMI 9).......563
          Tools Required.......563
          SPN 3031 FMI 11 (Cummins FC 4737) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause Not Known.......568
          Fault Overview.......568
          Associated Faults.......568
          Fault Facts.......568
          Possible Causes.......568
          SPN 3031 FMI 13 (Cummins FC 4731) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out of Calibration.......569
          Fault Overview.......569
          Associated Faults.......569
          Fault Facts.......569
          Possible Causes.......569
          SPN 3364 FMI 2 (Cummins FC 3878) - Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or Incorrect.......570
          Fault Overview.......570
          Associated Faults.......570
          Fault Facts.......570
          Possible Causes.......570
          SPN 3364 FMI 3 (Cummins FC 1686) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Above Normal or Shorted to High Source.......571
          Fault Overview.......571
          Associated Faults.......571
          Fault Facts.......571
          Possible Cause.......571
          SPN 3364 FMI 4 (Cummins 1685) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Below Normal or Shorted to Low Source.......573
          Fault Overview.......573
          Associated Faults.......573
          Fault Facts.......573
          Possible Cause.......573
          SPN 3364 FMI 9 (Cummins FC 3868) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate.......575
          Fault Overview.......575
          Associated Faults.......575
          Fault Facts.......575
          Possible Cause.......575
          Pin-Point Tests (SPN 3364 FMI 9).......578
          Tools Required.......578
          SPN 3364 FMI 10 (Cummins FC 4277) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate of Change .......583
          Fault Overview.......583
          Associated Faults.......583
          Fault Facts.......583
          Possible Causes.......583
          SPN 3364 FMI 11 (Cummins FC 1715) - Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known.......585
          Fault Overview.......585
          Associated Faults.......585
          Fault Facts.......585
          Possible Causes.......585
          SPN 3364 FMI 13 (Cummins FC 1714) - Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration.......586
          Fault Overview.......586
          Associated Faults.......586
          Fault Facts.......586
          Possible Causes.......586
          SPN 3364 FMI 15 (Cummins FC 4842) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal Operating Range - Least Severe Level.......587
          Fault Overview.......587
          Associated Faults.......587
          Fault Facts.......587
          Possible Causes.......587
          SPN 3364 FMI 18 (Cummins FC 3867) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal Operating Range - Moderately Severe Level.......589
          Fault Overview.......589
          Associated Faults.......589
          Fault Facts.......589
          Possible Causes.......589
          SPN 3521 FMI 11 (Cummins FC 4768) - Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known.......591
          Fault Overview.......591
          Associated Faults.......591
          Fault Facts.......591
          Possible Causes.......591
          SPN 3521 FMI 16 (Cummins FC 6765) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above Normal Operating Range - Moderately Severe Level.......592
          Fault Overview.......592
          Associated Faults.......592
          Fault Facts.......592
          Possible Causes.......592
          SPN 3521 FMI 18 (Cummins FC 6766) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below Normal Operating Range - Moderately Severe Level.......594
          Fault Overview.......594
          Associated Faults.......594
          Fault Facts.......594
          Possible Causes.......594
          SPN 3521 FMI 31 (Cummins FC 4235) - Aftertreatment 1 Diesel Exhaust Fluid Property- Condition Exists.......596
          Fault Overview.......596
          Associated Faults.......596
          Fault Facts.......596
          Possible Causes.......596
          SPN 4096 FMI 31 (Cummins FC 3547) - Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition Exists.......598
          Fault Overview.......598
          Associated Faults.......598
          Fault Facts.......598
          Possible Causes.......598
          Tests and Inspections.......600
          Overview.......600
          DEF Head Unit Coolant Line Routing Inspection.......601
          Overview.......601
          Tools Required.......601
          Equipment Condition.......601
          Inspection Procedure.......601
          Expected Outcome.......602
          DEF Quality Test.......603
          Overview.......603
          Tools Required.......603
          Equipment Condition.......603
          Test Procedure.......603
          Expected Outcome.......603
          DEFTHV Coolant Flow Test.......604
          Overview.......604
          Tools Required.......604
          Equipment Condition.......604
          Test Setup.......604
          Test Procedure.......604
          Expected Outcome.......604
          Engine Coolant Level Circuit Test.......605
          Overview.......605
          Tools Required.......605
          Equipment Condition.......605
          Test Setup.......605
          Test Procedure.......605
          ECM Battery Voltage Supply Test.......615
          Overview.......615
          Tools Required.......615
          Equipment Condition.......615
          Test Setup.......615
          Test Procedure.......616
      7. Exterior Lighting.......625
        Air Cleaner Lighting - LoneStar.......625
        Overview.......625
        Air Shield Lighting.......626
        Overview.......626
        Brake Switch.......627
        Overview.......627
          Operational Checkout Procedure.......629
          Overview.......629
          Brake Switch Not Working.......631
          Overview.......631
          Fault Facts.......631
          Possible Causes.......631
          Pin-Point Test - Feature Code 0004092.......634
          Tools Required.......634
          SPN 597 FMI 0 - Brake Switch Input short to Power.......638
          Overview.......638
          Associated Faults.......638
          Fault Facts.......638
          Possible Causes.......638
          Pin-Point Test - SPN 597 FMI 0 with Air Brakes 0004092.......640
          Tools Required.......640
          SPN 597 FMI 1 - Brake Switch Reading Below Normal Range.......644
          Overview.......644
          Associated Faults.......644
          Fault Facts.......644
          Possible Causes.......644
          SPN 597 FMI 2 - Analog Brake Switch signal does not agree with Digital brake switch signal.......646
          Overview.......646
          Associated Faults.......646
          Fault Facts.......646
          Possible Causes.......646
        Fog Lights.......648
        Overview.......648
          Operational Checkout Procedure.......650
          Overview.......650
          Input Diagnostics.......653
          Overview.......653
          Fault Facts.......653
          Possible Causes.......653
          Output Diagnostics - Not Illuminating.......655
          Overview.......655
          Fault Facts.......655
          Possible Causes.......655
          Pin-Point Test - Output Diagnostics - Not Illuminating.......660
          Tools Required.......660
          Output Diagnostics - Illuminating When Not Requested.......664
          Overview.......664
          Fault Facts.......664
          Possible Causes.......664
          Pin-Point Test - Output Diagnostics - Illuminating When Not Requested.......667
          Tools Required.......667
          SPN 2388 FMI 5 - Left Fog Light Open Circuit.......669
          Overview.......669
          Associated Faults.......669
          Fault Facts.......669
          Possible Causes.......669
          Pin-Point Test - SPN 2388 FMI 5.......671
          Tools Required.......671
          SPN 2388 FMI 6 - Left Fog Light Short to Ground.......673
          Overview.......673
          Associated Faults.......673
          Fault Facts.......673
          Possible Causes.......673
          Pin-Point Test - SPN 2388 FMI 6.......675
          Tools Required.......675
          SPN 4008 FMI 5 - Right Fog Light Open Circuit.......677
          Overview.......677
          Associated Faults.......677
          Fault Facts.......677
          Possible Causes.......677
          Pin-Point Test - SPN 4008 FMI 5.......679
          Tools Required.......679
          SPN 4008 FMI 6 - Right Fog Light Short to Ground.......681
          Overview.......681
          Associated Faults.......681
          Fault Facts.......681
          Possible Causes.......681
          Pin-Point Test - SPN 4008 FMI 6.......683
          Tools Required.......683
        Headlights.......685
        Overview.......685
          Operational Checkout Procedure.......687
          Overview.......687
          Special Tools.......690
          Low Beam Diagnostics.......693
          Overview.......693
          Low Beam Input Diagnostics.......695
          Overview.......695
          Fault Facts.......695
          Special Tools.......695
          Possible Causes.......695
          Low Beam Output Diagnostics - Not illuminating.......697
          Overview.......697
          Fault Facts.......697
          Special Tools.......697
          Possible Causes.......697
          Low Beam Output Diagnostics - Illuminating When Not Requested.......702
          Overview.......702
          Fault Facts.......702
          Special Tools.......702
          Possible Causes.......702
          SPN 2653 FMI 5 - Left Low Beam Open Circuit.......704
          Overview.......704
          Associated Faults.......704
          Fault Facts.......704
          Special Tools.......704
          Possible Causes.......704
          SPN 2653 FMI 6 - Left Low Beam Short to Ground.......706
          Overview.......706
          Associated Faults.......706
          Fault Facts.......706
          Special Tools.......706
          Possible Causes.......706
          SPN 2655 FMI 5 - Right Low Beam Open Circuit.......708
          Overview.......708
          Associated Faults.......708
          Fault Facts.......708
          Special Tools.......708
          Possible Causes.......708
          SPN 2655 FMI 6 - Right Low Beam Short to Ground.......710
          Overview.......710
          Associated Faults.......710
          Fault Facts.......710
          Special Tools.......710
          Possible Causes.......710
          High Beam Diagnostics.......711
          Overview.......711
          High Beam Input Diagnostics.......713
          Overview.......713
          Fault Facts.......713
          Special Tools.......713
          Possible Causes.......713
          High Beam Output Diagnostics - Not Illuminating.......716
          Overview.......716
          Fault Facts.......716
          Tools Required.......716
          Possible Causes.......716
          High Beam Output Diagnostics - Illuminating When Not Requested.......721
          Overview.......721
          Fault Facts.......721
          Special Tools.......721
          Possible Causes.......721
          SPN 4011 FMI 5 - Left High Beam Open Circuit.......724
          Overview.......724
          Associated Faults.......724
          Fault Facts.......724
          Special Tools.......724
          Possible Causes.......724
          SPN 4011 FMI 6 - Left High Beam Short to Ground.......726
          Overview.......726
          Associated Faults.......726
          Fault Facts.......726
          Special Tools.......726
          Possible Causes.......726
          SPN 4012 FMI 5 - Right High Beam Open Circuit.......727
          Overview.......727
          Associated Faults.......727
          Fault Facts.......727
          Special Tools.......727
          Possible Causes.......727
          SPN 4012 FMI 6 - Right High Beam Short to Ground.......729
          Overview.......729
          Associated Faults.......729
          Fault Facts.......729
          Special Tools.......729
          Possible Causes.......729
        Lighting Control Module.......730
        Overview.......730
          Operational Checkout Procedure.......731
          Overview.......731
          Pin-Point Test - Operational Checkout Procedure.......733
          Tools Required.......733
        Marker / Park Lights.......734
        Overview.......734
          Operational Checkout Procedure.......738
          Overview.......738
          Park Light Input Diagnostics.......742
          Overview.......742
          Fault Facts.......742
          Possible Causes.......742
          Park Light Output Diagnostics - Not Illuminating.......744
          Overview.......744
          Fault Facts.......744
          Possible Causes.......744
          Pin-Point Test - Park Light Output - Not Illuminating.......747
          Tools Required.......747
          Park Light Output Diagnostics - Illuminating When Not Requested.......749
          Overview.......749
          Fault Facts.......749
          Possible Causes.......749
          Pin-Point Test - Park Light Output - Illuminating When Not Requested.......751
          Tools Required.......751
          SPN 2378 FMI 5 - Park Light Underccurrent.......753
          Overview.......753
          Associated Faults.......753
          Fault Facts.......753
          Possible Causes.......753
          Pin-Point Test - SPN 2378 FMI 5.......755
          Tools Required.......755
          SPN 2378 FMI 6 - Park Light Overcurrent.......757
          Overview.......757
          Associated Faults.......757
          Fault Facts.......757
          Possible Causes.......757
          Pin-Point Test - SPN 2378 FMI 6.......759
          Tools Required.......759
          SPN 4024 FMI 2 - Marker Light Interrupt Switch Failure.......761
          Overview.......761
          Associated Faults.......761
          Fault Facts.......761
          Possible Causes.......761
        Stop / Turn Lights.......763
        Overview.......763
          Operational Checkout Procedure.......770
          Overview.......770
          Hazard Input Diagnostics.......775
          Overview.......775
          Possible Causes.......775
          Pin-Point Test - Hazard Input Diagnostics.......778
          Tools Required.......778
          Turn Signal Input Diagnostics.......780
          Overview.......780
          Possible Causes.......780
          Pin-Point Test - Turn Signal Input Diagnostics.......784
          Tools Required.......784
          Front Turn Lamps Not Illuminating.......792
          Overview.......792
          Possible Causes.......792
          Pin-Point Test- Front Turn Lamp Output Not Illuminating.......796
          Tools Required.......796
          Front Turn Lamps Illuminating When Not Requested.......799
          Overview.......799
          Possible Causes.......799
          Pin-Point Test - Front Turn Lamps Illuminating When Not Requested.......801
          Tools Required.......801
          Rear Turn Lamp Not Illuminating.......803
          Overview.......803
          Possible Causes.......803
          Pin-Point Test - Stop and Turn Lamps- Rear Turn Lamp Not Illuminating.......806
          Tools Required.......806
          Rear Turn Lamps Illuminating When Not Requested.......809
          Overview.......809
          Possible Causes.......809
          Pin-Point Test - Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested.......811
          Tools Required.......811
          SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps.......813
          Overview.......813
          Associated Faults.......813
          Fault Facts.......813
          Possible Causes.......813
          Pin-Point Test SPN 2368 FMI 5.......815
          Tools Required.......815
          SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps.......817
          Overview.......817
          Associated Faults.......817
          Fault Facts.......817
          Possible Causes.......817
          Pin-Point Test SPN 2368 FMI 6.......819
          Tools Required.......819
          SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps.......821
          Overview.......821
          Associated Faults.......821
          Fault Facts.......821
          Possible Causes.......821
          Pin-Point Test SPN 2370 FMI 5.......823
          Tools Required.......823
          SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps.......825
          Overview.......825
          Associated Faults.......825
          Fault Facts.......825
          Possible Causes.......825
          Pin-Point Test SPN 2370 FMI 6.......827
          Tools Required.......827
          SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent .......829
          Overview.......829
          Associated Fault.......829
          Fault Facts.......829
          Possible Causes.......829
          Pin-Point Test SPN 2372 FMI 5.......831
          Tools Required.......831
          SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent .......833
          Overview.......833
          Associated Faults.......833
          Fault Facts.......833
          Possible Causes.......833
          Pin-Point Test SPN 2372 FMI 6.......835
          Tools Required.......835
          SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent .......837
          Overview.......837
          Associated Faults.......837
          Fault Facts.......837
          Possible Causes.......837
          Pin-Point Test SPN 2374 FMI 5.......839
          Tools Required.......839
          SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent .......841
          Overview.......841
          Associated Faults.......841
          Fault Facts.......841
          Possible Causes.......841
          Pin-Point Test SPN 2374 FMI 6.......843
          Tools Required.......843
      8. HVAC.......845
        On-Highway HVAC System.......845
          Front HVAC System.......846
          Overview.......846
          A/C Refrigerant Flow.......848
          General Operation of HVAC Electrical System.......850
          Air Distribution.......851
          Defrost.......851
          Temperature.......851
          Recirculation.......852
          Panel / Floor.......852
          Operational Checkout Procedure.......854
          Overview.......854
          Blower Not Working Properly.......857
          Overview.......857
          Fault Facts.......857
          Special Tools.......857
          Possible Causes.......857
          HVAC System Air Not Cool After A/C Turned ON.......862
          Overview.......862
          Fault Facts.......862
          Possible Causes.......862
          HVAC System Air Not Warm After Heat Turned ON.......867
          Overview.......867
          Possible Causes.......867
          SPN 876 FMI 5 - HVAC Compressor Clutch Engagement Undercurrent.......869
          Overview.......869
          Associated Faults.......869
          Fault Facts.......869
          Possible Causes.......869
          SPN 876 FMI 6 - HVAC Compressor Clutch Engagement Overcurrent.......870
          Overview.......870
          Associated Faults.......870
          Fault Facts.......870
          Possible Causes.......870
          SPN 1552 FMI 2 - Temperature Door Actuator Data Intermittent or Incorrect.......871
          Overview.......871
          Associated Faults.......871
          Fault Facts.......871
          Possible Causes.......871
          SPN 2609 FMI 0 - PT Sensor - HVAC Pressure Sensor Reading Above Normal Range.......872
          Overview.......872
          Associated Faults.......872
          Fault Facts.......872
          Tools Required.......872
          Possible Causes.......872
          SPN 2609 FMI 1 - PT Sensor - HVAC Pressure Sensor Reading Below Normal Range.......874
          Overview.......874
          Associated Faults.......874
          Fault Facts.......874
          Tools Required.......874
          Possible Causes.......874
          SPN 2609 FMI 15 - PT Sensor - HVAC Low Pressure Protection (A/C Compressor Lockout).......877
          Overview.......877
          Associated Faults.......877
          Fault Facts.......877
          SPN 2609 FMI 16 - PT Sensor - HVAC High Pressure Protection.......878
          Overview.......878
          Associated Faults.......878
          Fault Facts.......878
          Possible Causes.......878
          SPN 3981 FMI 2 - Defrost Door Actuator Data Intermittent or Incorrect.......880
          Overview.......880
          Associated Faults.......880
          Fault Facts.......880
          Possible Causes.......880
          SPN 3984 FMI 2 - Recirculation Door Actuator Data Intermittent or Incorrect.......881
          Overview.......881
          Associated Faults.......881
          Fault Facts.......881
          Possible Causes.......881
          SPN 3985 FMI 9 - HVAC Control Module Circuit Failed To Communicate With the Body Control Module.......882
          Overview.......882
          Associated Faults.......882
          Fault Facts.......882
          Possible Causes.......882
          SPN 516636 FMI 19 - Error or Not Available is transmitted from Front HVAC Control Module.......883
          Overview.......883
          Associated Faults.......883
          Fault Facts.......883
          Tools Required.......883
          Possible Causes.......883
          SPN 516778 FMI 5 - Freeze Probe Open Circuit.......885
          Overview.......885
          Associated Faults.......885
          Fault Facts.......885
          Tools Required.......885
          Possible Causes.......885
          SPN 516778 FMI 6 - Freeze Probe Short to Ground.......886
          Overview.......886
          Associated Faults.......886
          Fault Facts.......886
          Tools Required.......886
          Possible Causes.......886
          SPN 516825 FMI 2 - Panel Door Actuator Data Intermittent or Incorrect.......888
          Overview.......888
          Associated Faults.......888
          Fault Facts.......888
          Possible Causes.......888
          SPN 516826 FMI 2 - Floor Door Actuator Data Intermittent or Incorrect.......889
          Overview.......889
          Associated Faults.......889
          Fault Facts.......889
          Possible Causes.......889
          SPN 516827 FMI 3 - Blower Motor Under Voltage Protection.......890
          Overview.......890
          Associated Faults.......890
          Fault Facts.......890
          Tools Required.......890
          Possible Causes.......890
          SPN 516827 FMI 4 - Blower Over Voltage Protection.......892
          Overview.......892
          Associated Faults.......892
          Fault Facts.......892
          Tools Required.......892
          Possible Causes.......892
          SPN 516827 FMI 7 - Blower Motor Not Responding (Blocked Rotor).......894
          Overview.......894
          Associated Faults.......894
          Fault Facts.......894
          Tools Required.......894
          Possible Causes.......894
          SPN 516827 FMI 31 - Blower Motor Over Temperature.......896
          Overview.......896
          Associated Faults.......896
          Fault Facts.......896
          Tools Required.......896
          Possible Causes.......896
          SPN 520465 FMI 2 - HVAC Control Module - Multiple Actuator Faults.......898
          Overview.......898
          Associated Faults.......898
          Fault Facts.......898
          Tools Required.......898
          Possible Causes.......898
          Sleeper / Rear HVAC System.......900
          Overview.......900
          A/C Refrigerant Flow.......903
          Rear Air Distribution.......904
          Sleeper HVAC Operational Checkout Procedure.......905
          Overview.......905
          Rear HVAC System Air Not Cool After A/C Turned ON.......910
          Overview.......910
          Fault Facts.......910
          Possible Causes.......910
          HVAC Tests.......912
          Overview.......912
          A/C Compressor Clutch Electrical Test.......914
          Overview.......914
          Tools Required.......914
          Equipment Condition.......914
          Test Setup.......914
          Test Procedure.......914
          Expected Outcome.......916
          Follow On Procedure.......916
          A/C System Restriction Test.......917
          Overview.......917
          Tools Required.......917
          Equipment Condition.......917
          Test Setup.......917
          Test Procedure.......917
          Expected Outcome.......917
          Charge Quantity Measurement Test.......918
          Overview.......918
          Tools Required.......918
          Equipment Condition.......918
          Test Setup.......918
          Test Procedure.......918
          Expected Outcome.......918
          Refrigerant Leak Test.......919
          Overview.......919
          Tools Required.......919
          Equipment Condition.......919
          Test Procedure Refrigerant Present.......920
          No Refrigerant Present.......921
          No Refrigerant Present - High Pressure Nitrogen.......922
          Expected Outcome.......923
          Follow-On Procedure.......923
          Refrigerant Identification Test.......924
          Overview.......924
          Tools Required.......924
          Equipment Condition.......924
          Test Setup.......924
          Test Procedure.......924
          Expected Outcome.......924
          Follow-On Procedure.......924
          Static Refrigerant Pressure Test.......925
          Overview.......925
          Tools Required.......925
          Equipment Condition.......925
          Test Setup.......925
          Test Procedure.......925
          Expected Outcome.......926
          Follow On Procedure.......926
          Dynamic Refrigerant Pressure Test.......927
          Overview.......927
          Tools Required.......927
          Equipment Condition.......927
          Test Setup.......928
          Test Procedure.......928
          Expected Outcome.......930
          Follow-On Procedure.......930
          A/C Pressure Readings Indicating Problems.......931
          Overview.......931
          Tools Required.......931
          Equipment Condition.......931
          Low-Side Pressure Low, High-Side Pressure Low.......932
          Possible Causes.......932
          Low-Side Pressure Low, High-Side Pressure Normal or High.......933
          Possible Causes.......933
          High-Side and Low-Side Pressures Normal or Slightly Low, Duct Output Not Cold.......934
          Possible Causes.......934
          Low-Side Pressure Normal, High-Side Pressure High.......935
          Possible Causes.......935
          Low-Side Pressure High, High-Side Pressure Low.......936
          Possible Causes.......936
          Low-Side Pressure High, High-Side Pressure Normal.......937
          Possible Causes.......937
          Low-Side Pressure High, High-Side Pressure High.......938
          Possible Causes.......938
          High-Side Pressure Excessively High or Low.......938
          A/C Compressor Compression Test.......939
          Overview.......939
          Tools Required.......939
          Equipment Condition.......939
          Test Procedure.......939
          Expected Outcome.......939
          HVAC Control Module and Actuator Calibration.......940
          Overview.......940
          Defrost Actuator Electrical Test.......941
          Overview.......941
          Fault Facts.......941
          Possible Causes.......941
          Pin-Point Test - Defrost Actuator Electrical Test.......944
          Tools Required.......944
          Floor Actuator Electrical Test.......949
          Overview.......949
          Fault Facts.......949
          Possible Causes.......949
          Pin-Point Test - Floor Actuator Electrical Test.......952
          Tools Required.......952
          Panel Actuator Electrical Test.......957
          Overview.......957
          Fault Facts.......957
          Possible Causes.......957
          Pin-Point Test - Panel Actuator Electrical Test.......960
          Tools Required.......960
          Recirculation Actuator Electrical Test.......965
          Overview.......965
          Fault Facts.......965
          Possible Causes.......965
          Pin-Point Test - Recirculation Actuator Electrical Test.......968
          Tools Required.......968
          Temperature Actuator Electrical Test.......973
          Overview.......973
          Fault Facts.......973
          Possible Causes.......973
          Pin-Point Test - Temperature Actuator Electrical Test.......976
          Tools Required.......976
          Blower Motor Electrical Input Test.......981
          Overview.......981
          Tools Required.......981
          Equipment Condition.......981
          Test Setup.......981
          Test Procedure.......981
          Expected Outcome.......981
          Follow On Procedure.......981
          HVAC Control Module Electrical Tests.......982
          Overview.......982
          Tools Required.......982
          Equipment Condition.......982
          Test Setup.......982
          Test Procedure.......982
          Expected Outcome.......984
          Follow On Procedure.......984
          Freeze Probe Electrical Test.......985
          Overview.......985
          Tools Required.......985
          Equipment Condition.......985
          Test Setup.......985
          Test Procedure.......985
          Expected Outcome.......986
          Follow-On Procedure.......986
          Heater Core Seal Leak Test.......987
          Overview.......987
          Tools Required.......987
          Equipment Condition.......987
          Test Setup.......987
          Test Procedure.......988
          Expected Outcome.......989
          Follow On Procedure.......989
          Low A/C Pressure Sensor Electrical Test.......990
          Overview.......990
          Tools Required.......990
          Equipment Condition.......990
          Test Setup.......990
          Test Procedure.......990
          Expected Outcome.......990
          Follow On Procedure.......990
          HVAC Pressure / Temperature Sensor Electrical Test.......991
          Overview.......991
          Tools Required.......991
          Equipment Condition.......991
          Test Setup.......991
          Pressure / Temperature Test Procedure.......991
          Expected Outcome.......993
          Follow On Procedure.......993
          HVAC Pressure / Temperature Sensor Functional Test.......994
          Overview.......994
          Tools Required.......994
          Equipment Condition.......994
          Test Setup.......994
          Procedure.......994
          Expected Outcome.......995
          Sleeper HVAC Input Test.......996
          Overview.......996
          Tools Required.......996
          Equipment Condition.......996
          Test Setup.......996
          Test Procedure.......997
          Expected Outcome.......998
          Follow On Procedure.......998
          Rear A/C Request Test.......999
          Overview.......999
          Tools Required.......999
          Equipment Condition.......999
          Test Setup.......999
          Test Procedure.......999
          Expected Outcome.......1000
          Follow On Procedure.......1000
          Rear HVAC Control Module and Blend Door Actuator Calibration.......1001
          Overview.......1001
          Tools Required.......1001
          Equipment Condition.......1001
          Test Setup.......1001
          Test Procedure.......1001
          Expected Outcome.......1002
          Follow-On Procedure.......1002
          Rear Blend Door Actuator Electrical Test.......1003
          Overview.......1003
          Tools Required.......1003
          Equipment Condition.......1003
          Test Setup.......1003
          Test Procedure.......1003
          Expected Outcome.......1004
          Follow-On Procedure.......1004
          Rear Blend Door Movement Test.......1005
          Overview.......1005
          Tools Required.......1005
          Equipment Condition.......1005
          Test Setup.......1005
          Test Procedure.......1005
          Expected Outcome.......1005
          Follow-On Procedure.......1005
          Sleeper HVAC Blower Speed Switch Electrical Test.......1006
          Overview.......1006
          Tools Required.......1006
          Equipment Condition.......1006
          Test Setup.......1006
          Test Procedure.......1006
          Expected Outcome.......1008
          Follow-On Procedure.......1008
          Rear Blower Motor Electrical Test.......1009
          Overview.......1009
          Tools Required.......1009
          Equipment Condition.......1009
          Test Setup.......1009
          Test Procedure.......1009
          Expected Outcome.......1011
          Follow-On Procedure.......1011
          Rear HVAC Control Module Electrical Test.......1012
          Overview.......1012
          Tools Required.......1012
          Equipment Condition.......1012
          Test Setup.......1012
          Test Procedure.......1012
          Expected Outcome.......1013
          Follow-On Procedure.......1013
          Sleeper HVAC Temperature Control Switch Electrical Tests.......1014
          Overview.......1014
          Tools Required.......1014
          Equipment Condition.......1014
          Test Setup.......1014
          Test Procedure.......1014
          Expected Outcome.......1016
          Rear Discharge Duct Temperature Sensor Electrical Test.......1017
          Overview.......1017
          Tools Required.......1017
          Equipment Condition.......1017
          Test Setup.......1017
          Test Procedure.......1017
          Expected Outcome.......1017
          Follow-On Procedure.......1017
          HVAC Inspections.......1018
          Overview.......1018
          HVAC System Inspection.......1019
          Overview.......1019
          Tools Required.......1019
          Equipment Condition.......1019
          Inspection Procedure.......1019
          Expected Outcome.......1020
          A/C System Internal Damage Inspection.......1021
          Overview.......1021
          Tools Required.......1021
          Equipment Condition.......1021
          Inspection Procedure.......1021
          Expected Outcome.......1022
          Rear HVAC System Inspection.......1023
          Overview.......1023
          Tools Required.......1023
          Equipment Condition.......1023
          Inspection Procedure.......1023
          Expected Outcome.......1024
        No Idle HVAC.......1025
        Eberspaecher Auxiliary Heater.......1026
          Overview.......1026
          Regular Maintenance.......1027
          Monthly.......1027
          Every 1000 operating hours.......1028
          Connecting EDiTH to heater.......1029
          Starting and using EDiTH software.......1029
          Reading fault codes.......1035
          Clearing fault codes.......1035
          Removing controller lock.......1036
          Symptom Diagnostics.......1037
          Overview.......1037
          Fault Code Diagnostics.......1039
          Overview.......1039
          10 - Overvoltage / Shutdown.......1041
          Fault Code Overview.......1041
          11 - Undervoltage / Shutdown.......1042
          Fault Code Overview.......1042
          Pin-Point Tests.......1044
          Tools Required.......1044
          12 - Overheating.......1045
          Fault Code Overview.......1045
          14 - Possible Overheating Detected (Differential Evaluation).......1046
          Fault Code Overview.......1046
          15 - Operation Lock - Heater has Overheated More than 10 Times.......1047
          Fault Code Overview.......1047
          17 - Overheating - Emergency Off.......1048
          Fault Code Overview.......1048
          20 - Glow Plug - Interruption.......1049
          Fault Code Overview.......1049
          Pin-Point Tests.......1050
          Tools Required.......1050
          21 - Glow Plug Output: Short Circuit, Overload or Accidental Ground.......1051
          Fault Code Overview.......1051
          30 - Speed of Combustion Fan motor Outside Tolerance Range.......1052
          Fault Code Overview.......1052
          31 - Combustion Fan Motor Open Circuit.......1053
          Fault Code Overview.......1053
          Pin-Point Tests.......1054
          Tools Required.......1054
          32 - Combustion Fan Motor Short Circuit, Overload or Accidental Ground.......1055
          Fault Code Overview.......1055
          39 - Vehicle Blower Relay Control - Short Circuit, Overload or Earth Short.......1056
          Fault Code Overview.......1056
          41 - Water Pump - Interruption.......1057
          Fault Code Overview.......1057
          Pin-Point Tests.......1058
          Tools Required.......1058
          42 - Water Pump - Short Circuit, Overload or Earth Short.......1059
          Fault Code Overview.......1059
          Pin-Point Tests.......1060
          Tools Required.......1060
          47 - Metering Pump - Short Circuit, Overload or Earth Short.......1061
          Fault Code Overview.......1061
          Pin-Point Tests.......1063
          Tools Required.......1063
          48 - Metering Pump  Interruption.......1064
          Fault Code Overview.......1064
          50 - Operation Lock Because of Too Many Failed Starting Attempts.......1065
          Fault Code Overview.......1065
          51 - Time Exceeded - Blowing Cold.......1066
          Fault Code Overview.......1066
          52 - Safety Time Exceeded.......1067
          Fault Code Overview.......1067
          53 - Flame Aborted from Control Stage Large.......1069
          Fault Code Overview.......1069
          54 - Flame Aborted from Control Stage Boost.......1070
          Fault Code Overview.......1070
          56 - Flame Aborted from Control Stage Small.......1071
          Fault Code Overview.......1071
          60 - Temperature Sensor - Interruption.......1072
          Fault Code Overview.......1072
          61 - Temperature Sensor - Short-Circuit, Overload or Accidental Ground.......1073
          Fault Code Overview.......1073
          64 - Flame Sensor - Interruption.......1074
          Fault Code Overview.......1074
          65 - Flame Sensor - Short-Circuit, Overload or Accidental Ground.......1075
          Fault Code Overview.......1075
          71 - Overheating Sensor - Interruption.......1076
          Fault Code Overview.......1076
          72 - Overheating Sensor - Short-Circuit, Overload or Accidental Ground.......1077
          Fault Code Overview.......1077
          90 - Controller Defect.......1078
          Fault Code Overview.......1078
          91 - External Interference Voltage.......1079
          Fault Code Overview.......1079
          92 - Controller Defect.......1080
          Fault Code Overview.......1080
          93 - Controller Defect.......1081
          Fault Code Overview.......1081
          94 - Controller Defect.......1082
          Fault Code Overview.......1082
          95 - Controller Defect.......1083
          Fault Code Overview.......1083
          96 - Controller Defect.......1084
          Fault Code Overview.......1084
          97 - Controller Defect.......1085
          Fault Code Overview.......1085
          98 - Controller Defect.......1086
          Fault Code Overview.......1086
          99 - Controller Defect.......1087
          Fault Code Overview.......1087
          100 - Controller Defect.......1088
          Fault Code Overview.......1088
          101 - Controller Defect.......1089
          Fault Code Overview.......1089
          Tests and Inspections.......1090
          Blower Motor Test.......1090
          Tools Required.......1090
          Test Setup.......1090
          Test Procedure.......1090
          Expected Outcome.......1090
          Coolant Circuit Inspection.......1091
          Inspection Setup.......1091
          Inspection Procedure.......1091
          Expected Outcome.......1091
          Connector Inspection.......1092
          Inspection Setup.......1092
          Inspection Procedure.......1092
          Expected Outcome.......1092
          Flame Sensor Test.......1093
          Tools Required.......1093
          Test Setup.......1093
          Test Procedure.......1093
          Expected Outcome.......1093
          Fuel Intake Inspection.......1095
          Inspection Setup.......1095
          Inspection Procedure.......1095
          Expected Outcome.......1095
          Fuel Pump Quantity Test.......1096
          Tools Required.......1096
          Test Setup.......1096
          Test Procedure.......1096
          Expected Outcome.......1097
          Glow Pin Test.......1098
          Tools Required.......1098
          Test Setup.......1098
          Test Procedure.......1098
          Expected Outcome.......1098
          Glow Plug Filter Inspection.......1099
          Inspection Setup.......1099
          Inspection Procedure.......1099
          Expected Outcome.......1099
          Follow-on Procedure.......1099
          Intake and exhaust air Inspection.......1100
          Inspection Setup.......1100
          Inspection Procedure.......1100
          Expected Outcome.......1100
          Integrated Fuel Filter Inspection.......1101
          Inspection Setup.......1101
          Inspection Procedure.......1101
          Expected Outcome.......1101
          Overheat Sensor Test.......1102
          Tools Required.......1102
          Test Setup.......1102
          Test Procedure.......1102
          Expected Outcome.......1103
          Temperature Sensor Test.......1104
          Tools Required.......1104
          Test Setup.......1104
          Test Procedure.......1104
          Expected Outcome.......1104
          Removal and Install Procedures.......1106
          Blower motor.......1106
          Removal.......1106
          Installation.......1107
          Blower Motor Cover.......1108
          Removal.......1108
          Installation.......1108
          Controller.......1109
          Removal.......1109
          Installation.......1110
          Flame Sensor.......1111
          Removal.......1111
          Installation.......1111
          Fuel Pump.......1112
          Removal.......1112
          Installation.......1113
          Torque Specifications.......1113
          Glow Pin Screen.......1114
          Removal.......1114
          Installation.......1114
          Torque Specifications.......1114
          Glow Plug.......1115
          Removal.......1115
          Installation.......1115
          Heat Exchanger Cover.......1116
          Removal.......1116
          Installation.......1116
          Overheat / Temperature Sensor Assembly.......1117
          Removal.......1117
          Installation.......1117
          Torque Specifications.......1117
          Water Pump.......1118
          Removal.......1118
          Installation.......1118
          Diagnostic Tools and Accessories.......1119
          ESP2029007050280Z - Y Adapter.......1119
          ESP2215241890000Z - ISO Adapter.......1119
          TXT126870334  Terminal release tool.......1120
          TXT126870335  Terminal release tool.......1120
          ZTSE4357  Digital Multimeter (DMM).......1121
          ZTSE4435C - International Electronic Engine Terminal Test Kit.......1122
          ZTSE44983 - Banana Plug Harness.......1122
          ZTSE4871 - Breakout Harness 4871.......1123
      9. Instrumentation / Gauges.......1124
      Overview.......1124
      Gauge Cluster.......1126
      EGC Fault Reaction.......1126
      Virtual Gauges.......1126
      Auxiliary Gauges.......1126
        Operational Checkout Procedure.......1130
        Gauges.......1131
          Air Pressure Gauges.......1131
          Overview.......1131
          Air Application Gauge.......1135
          Overview.......1135
          Axle Temperature Gauge.......1139
          Overview.......1139
          DEF Gauges.......1143
          Overview.......1143
          Engine Coolant Temperature.......1145
          Overview.......1145
          Engine Manifold Pressure .......1147
          Overview.......1147
          Engine Oil Pressure.......1149
          Overview.......1149
          Engine Oil Temperature .......1151
          Overview.......1151
          Fuel Level Gauge .......1153
          Overview.......1153
          Outside Temperature Monitor.......1157
          Overview.......1157
          PTO Indicator.......1159
          Overview.......1159
          Rear Axle Load Monitor.......1160
          Overview.......1161
          Speedometer.......1165
          Overview.......1165
          Tachometer.......1167
          Overview.......1167
          Transmission Oil Temp Gauge.......1168
          Manual.......1168
          Overview.......1168
          Automatic.......1172
          Overview.......1172
          Voltmeter.......1173
          Overview.......1173
        Instrumentation.......1175
          ABS Indicator .......1175
          Air Cleaner Restriction.......1176
          Overview.......1176
          Brake Warning Indicator.......1180
          Overview.......1180
          DPF Indicator.......1181
          Overview.......1181
          Electronic Stability Control (ESC) Indicator.......1183
          Overview.......1183
          High Exhaust System Temperature Indicator.......1184
          Overview.......1184
          Park Brake Indicator.......1186
          Overview.......1186
          Tire Pressure Monitor System.......1190
          Overview.......1190
          Traction Control Indicator.......1192
          Overview.......1193
          Trailer ABS Indicator.......1196
          Overview.......1196
          Transmission Indicator.......1197
          Overview.......1197
          Up-Shift Indicator.......1198
          Overview.......1198
        Driver Information Display.......1200
        Overview.......1200
      10. Seats.......1202
        RollTek Supplemental Restraint System (SRS).......1202
        Overview.......1202
          Operational Check.......1205
          Symptoms.......1206
          Diagnostics.......1207
      11. Trailer.......1208
        Trailer Lighting.......1208
          Overview.......1208
          Operational Checkout Procedure.......1210
          Overview.......1210
          Fault Facts.......1210
          Special Tools.......1211
          Trailer Marker Lights - Not Illuminating.......1214
          Overview.......1214
          Fault Facts.......1214
          Special Tools.......1214
          Possible Causes.......1214
          Trailer Tail Lights - Not Illuminating.......1216
          Overview.......1216
          Fault Facts.......1216
          Special Tools.......1216
          Possible Causes.......1216
          Trailer Left Turn Lights - Not Illuminating.......1218
          Overview.......1218
          Fault Facts.......1218
          Special Tools.......1218
          Possible Causes.......1218
          Trailer Right Turn Lights - Not Illuminating.......1220
          Overview.......1220
          Fault Facts.......1220
          Special Tools.......1220
          Possible Causes.......1220
          Trailer Stop Lights - Not Illuminating.......1222
          Overview.......1222
          Fault Facts.......1222
          Special Tools.......1222
          Possible Causes.......1222
      12. Transmission.......1226
        Shifter.......1226
          Stalk Shifter.......1226
          Overview.......1226
          Engine Brake Control.......1226
          Manual Mode.......1226
          Range Selection.......1226
          Tech Tips.......1227
          Operational Checkout Procedure.......1228
          Overview.......1228
          Special Tools.......1228
          Stalk Shifter Electrical Test.......1229
          Overview.......1229
          Special Tools.......1229
          Equipment Conditions.......1229
          Test Setup.......1229
          SPN 525 FMI 3 - Stalk Shifter Shorted High.......1231
          Overview.......1231
          Associated Faults.......1231
          Fault Facts.......1231
          Special Tools.......1231
          Possible Causes.......1231
          SPN 525 FMI 4 - Stalk Shifter Shorted Low.......1232
          Overview.......1232
          Associated Faults.......1232
          Fault Facts.......1232
          Special Tools.......1232
          Possible Causes.......1232
          SPN 2000 FMI 9 - Loss of Communication With ECM.......1233
          Overview.......1233
          Associated Faults.......1233
          Fault Facts.......1233
          Special Tools.......1233
          Possible Causes.......1233
          SPN 2003 FMI 9 - Loss of Communication With TCM.......1234
          Overview.......1234
          Associated Faults.......1234
          Fault Facts.......1234
          Special Tools.......1234
          Possible Causes.......1234
          SPN 2005 FMI 12 - Failure of Non-Volatile Memory or Checksum Fault.......1235
          Overview.......1235
          Associated Faults.......1235
          Fault Facts.......1235
          Special Tools.......1235
          Possible Causes.......1235
          SPN 2033 FMI 9 - Loss of Communication With BCM.......1236
          Overview.......1236
          Associated Faults.......1236
          Fault Facts.......1236
          Special Tools.......1236
          Possible Causes.......1236
      13. Windshield Wiper System.......1237
      Overview.......1237
        Operational Checkout Procedure.......1238
        Overview.......1238
        Windshield Wipers.......1243
          Wiper Overview.......1243
          Wiper Operation.......1243
          Wiper_0_Signal Not Working.......1246
          Overview.......1246
          Fault Fact.......1246
          Possible Causes.......1246
          Pin-Point Test - Wiper_0_Signal Circuit Not Working.......1249
          Tools Required.......1249
          Wiper_1_Signal Not Working.......1253
          Overview.......1253
          Fault Fact.......1253
          Possible Causes.......1253
          Pin-Point Test - Wiper Input 1 Not Working.......1255
          Tools Required.......1255
          Wiper_2_Signal Not Working.......1259
          Overview.......1259
          Fault Fact.......1259
          Possible Causes.......1259
          Pin-Point Test - Wiper Input 2 Not Working.......1262
          Tools Required.......1262
          Wiper Low Speed Not Functioning.......1266
          Overview.......1266
          Fault Facts.......1266
          Possible Causes.......1266
          Pin-Point Test - Wiper Low Speed Not Functioning.......1271
          Tools Required.......1271
          Wiper High Speed Not Functioning........1277
          Overview.......1277
          Fault Facts.......1277
          Possible Causes.......1277
          Pin-Point Test - Wiper High Speed Not Functioning.......1282
          Tools Required.......1282
          SPN 2636 FMI 5 - Wiper Motor Relay Under Current or Open Circuit.......1288
          Overview.......1288
          Associated Faults.......1288
          Fault Facts.......1288
          Possible Causes.......1288
          Pin-Point Test - SPN 2636 FMI 5.......1290
          Tools Required.......1290
          SPN 2636 FMI 6 - Wipe Motor Relay Over Current.......1292
          Overview.......1292
          Associated Faults.......1292
          Fault Facts.......1292
          Possible Causes.......1292
          Pin-Point Test - SPN 2636 FMI 6.......1293
          Tools Required.......1293
          SPN 2637 FMI 5 - Wiper Variable Speed Relay Under Current or High Resistance.......1295
          Overview.......1295
          Associated Faults.......1295
          Fault Facts.......1295
          Possible Causes.......1295
          Pin-Point Test - SPN 2637 FMI 5.......1297
          Tools Required.......1297
          SPN 2637 FMI 6 - Wiper Variable Relay Over Current.......1299
          Overview.......1299
          Associated Faults.......1299
          Fault Facts.......1299
          Possible Causes.......1299
          Pin-Point Test - SPN 2637 FMI 6.......1301
          Tools Required.......1301
          SPN 4057 FMI 5 - Wiper Motor Under Current.......1302
          Overview.......1302
          Associated Faults.......1302
          Fault Facts.......1302
          Possible Causes.......1302
          Pin-Point Test - SPN 4057 FMI 5.......1307
          Tools Required.......1307
          SPN 4057 FMI 6 - Wiper Motor Over Current.......1313
          Overview.......1313
          Associated Faults.......1313
          Fault Facts.......1313
          Possible Causes.......1313
          Pin-Point Test - SPN 4057 FMI 6.......1317
          Tools Required.......1317
        Windshield Washer Pump.......1320
        Overview.......1320
          Washer Pump and / or Wipers Not Working.......1321
          Overview.......1321
          Fault Fact.......1321
          Possible Causes.......1321
          Pin-Point Test - Wiper and Washer Pump Not Working.......1324
          Tools Required.......1324
    Front End.......1327
      1. Bug Deflector / Screen.......1329
      Overview.......1329
      2. Fender Extensions.......1330
        Fender Extensions.......1330
        Overview.......1330
          Removal.......1331
          Overview.......1331
          Special Tools.......1331
          Equipment Conditions.......1331
          Removal Procedure.......1331
          Follow-On Procedure.......1331
          Installation.......1332
          Overview.......1332
          Special Tools.......1332
          Equipment Conditions.......1332
          Installation Procedure.......1332
          Follow-On Procedure.......1332
        Quarter Fenders.......1333
        Overview.......1333
          Removal.......1334
          Overview.......1334
          Special Tools.......1334
          Equipment Conditions.......1334
          Removal Procedure.......1335
          Follow-On Procedure.......1335
          Installation.......1336
          Overview.......1336
          Special Tools.......1336
          Torque Specifications.......1336
          Equipment Conditions.......1336
          Installation Procedure.......1337
          Follow-On Procedure.......1337
      3. Fender Extensions - LoneStar.......1338
        Fender Extensions.......1338
        Overview.......1338
          Removal.......1339
          Overview.......1339
          Special Tools.......1339
          Equipment Conditions.......1339
          Removal Procedure.......1340
          Follow-On Procedure.......1341
          Installation.......1342
          Overview.......1342
          Special Tools.......1342
          Equipment Conditions.......1342
          Installation Procedure.......1342
          Follow-On Procedure.......1344
      4. Hood and Grille.......1345
        Hood (Tilting Front End).......1345
        Overview.......1345
          Removal.......1347
          Overview.......1347
          Special Tools.......1347
          Equipment Conditions.......1347
          Removal Procedure.......1348
          Follow-On Procedure.......1349
          Installation.......1350
          Overview.......1350
          Special Tools.......1350
          Equipment Conditions.......1350
          Installation Procedure.......1351
          Follow-On Procedure.......1351
          Hood Alignment.......1352
          Hood Removed / Hinge Disturbed.......1352
          Overview.......1352
          Special Tools.......1352
          Equipment Conditions.......1352
          Alignment Procedure.......1352
          Follow-On Procedure.......1354
          Hood Realignment.......1355
          Overview.......1355
          Special Tools.......1355
          Equipment Conditions.......1355
          Alignment Procedure.......1355
          Follow-On Procedure.......1357
          Headlight.......1358
          Removal.......1358
          Overview.......1358
          Special Tools.......1358
          Equipment Conditions.......1359
          Procedure.......1360
          Follow-on Procedure.......1362
          Installation.......1363
          Special Tools.......1363
          Torque Specifications.......1363
          Procedure.......1364
          Follow-on Procedure.......1366
          Adjustment.......1367
          Overview.......1367
          Special Tools.......1367
          Equipment Conditions.......1367
          Adjustment Procedure.......1367
          Follow-On Procedure.......1368
        Grille.......1369
        Overview.......1369
          Removal.......1370
          Overview.......1370
          Special Tools.......1370
          Equipment Conditions.......1370
          Removal Procedure.......1370
          Follow-On Procedure.......1371
          Installation.......1372
          Overview.......1372
          Special Tools.......1372
          Equipment Conditions.......1372
          Installation Procedure.......1372
          Follow-On Procedure.......1373
      5. Hood and Grille - LoneStar.......1374
        Hood (Tilting Front End).......1374
        Overview.......1374
          Removal.......1376
          Overview.......1376
          Special Tools.......1376
          Equipment Conditions.......1376
          Removal Procedure.......1376
          Follow-On Procedure.......1381
          Installation.......1382
          Overview.......1382
          Special Tools.......1382
          Equipment Conditions.......1382
          Installation Procedure.......1382
          Follow-On Procedure.......1388
          Hood Alignment.......1389
          Overview.......1389
          Special Tools.......1389
          Equipment Conditions.......1389
          Alignment Procedure.......1389
          Follow-On Procedure.......1390
          Headlight Adjustment Procedure.......1391
          Overview.......1391
          Special Tools.......1391
          Equipment Conditions.......1391
          Adjustment Procedure.......1391
          Follow-On Procedure.......1391
        Grille.......1392
        Overview.......1392
          Removal.......1393
          Overview.......1393
          Special Tools.......1393
          Equipment Conditions.......1393
          Removal Procedure.......1394
          Follow-On Procedure.......1396
          Installation.......1397
          Overview.......1397
          Special Tools.......1397
          Equipment Conditions.......1397
          Procedure.......1397
          Follow-On Procedure.......1400
      6. Splash Shields.......1401
      Overview.......1401
    Fifth Wheel and Misc........1403
      1. Fifth Wheel.......1405
        Fontaine.......1405
        Overview.......1405
        Holland.......1411
        Overview.......1411
        Jost.......1415
        Overview.......1415
      2. Keys.......1418
      Overview.......1418
      3. GPS.......1420
        Prewire.......1420
        Overview.......1420
    Clutch.......1421
      1. Systems.......1423
        Clutch.......1423
          Eaton.......1423
          Overview.......1423
          ZF Sachs.......1425
          Overview.......1425
        Clutch Actuation System.......1426
          Air Assist Hydraulic Clutch Master Cylinder.......1426
          Overview.......1426
          Standard Hydraulic Clutch Master Cylinder.......1427
          Overview.......1427
        Clutch Brake.......1428
        Overview.......1428
        Remote Clutch Grease Fitting.......1429
        Overview.......1429
      2. Hydraulic Clutch Reservoir.......1430
        Removal.......1430
        Overview.......1430
        Special Tools.......1430
        Equipment Conditions.......1430
        Removal Procedure.......1430
        Follow-On Procedure.......1430
        Installation.......1431
        Overview.......1431
        Special Tools.......1431
        Equipment Conditions.......1431
        Installation Procedure.......1431
        Follow-On Procedure.......1431
      3. Master Cylinder.......1432
        Remove.......1432
        Overview.......1432
        Special Tools.......1432
        Equipment Conditions.......1432
        Removal Procedure.......1432
        Follow-On Procedure.......1432
        Install.......1433
        Overview.......1433
        Special Tools.......1433
        Equipment Conditions.......1433
        Installation Procedure.......1433
        Follow-On Procedure.......1434
      4. Slave Cylinder.......1435
        Remove.......1435
        Overview.......1435
        Special Tools.......1435
        Equipment Conditions.......1435
        Removal Procedure.......1435
        Follow-On Procedure.......1435
        Install.......1435
        Overview.......1435
        Special Tools.......1436
        Equipment Conditions.......1436
        Installation Procedure.......1436
        Follow-On Procedure.......1436
      5. Clutch Pedal.......1437
        Removal.......1437
        Overview.......1437
        Special Tools.......1437
        Equipment Conditions.......1437
        Removal Procedure.......1438
        Follow-On Procedure.......1438
        Installation.......1439
        Overview.......1439
        Special Tools.......1439
        Torque Specification.......1439
        Equipment Conditions.......1439
        Installation Procedure.......1440
        Follow-On Procedure.......1440
        Hydraulic Clutch Bleed Procedure.......1441
        Overview.......1441
        Special Tools.......1441
        Equipment Condition.......1441
        Procedure.......1441
        Follow-On Procedure.......1443
    Engines.......1445
      1. Air Cleaner.......1449
        Air Cleaner - LT / RH.......1449
        Overview.......1449
        Air Cleaner - LoneStar.......1451
        Overview.......1451
      2. Block Heater.......1452
      Overview.......1452
      3. Cold Start Assist.......1454
        Cummins X15 Ether Cold Start.......1454
        Overview.......1454
        A26 Intake Heater Cold Start.......1455
        Overview.......1455
      4. Cooling System.......1456
        Cooling Package.......1456
        Overview.......1456
          Coolant System External Cleaning.......1457
          Overview.......1457
          Special Tools.......1457
          Equipment Conditions.......1457
          Air Deflector Removal.......1457
          External Cleaning Procedures.......1457
          HVAC Condenser Clean.......1457
          Charge Air Cooler (CAC) Clean.......1457
          Front of Radiator Clean.......1458
          Follow-On Procedure.......1458
          Air Deflector Installation.......1458
        Test, Inspections, and Cleaning.......1460
          Deaeration Tank Inspection.......1461
          Overview.......1461
          Special Tools.......1461
          Equipment Conditions.......1461
          Inspection Procedure.......1462
          Follow-On Procedure.......1463
          Check Coolant Condition.......1464
          Overview.......1464
          Special Tools.......1464
          Equipment Conditions.......1464
          Setup.......1464
          Procedure.......1465
          Expected Outcome.......1465
          Follow-on Procedure.......1465
          Coolant Pressure Check Procedure.......1466
          Overview.......1466
          Special Tools.......1466
          Equipment Conditions.......1466
          Setup.......1467
          Procedure.......1467
          Expected Outcome.......1468
          Follow-on Procedure.......1468
          Coolant Package Flush Procedure.......1469
          Overview.......1469
          Special Tools.......1470
          Equipment Conditions.......1470
          Preparation.......1470
          Coolant Filter Flush, if Equipped.......1470
          Flush Thermostat Housing.......1471
          Front Heater Core Flush.......1471
          Rear Heater Core Flush, if Equipped.......1471
          DEF Heater Core Flush.......1472
          Front and Rear, if Equipped, Heater Core Rinse.......1472
          DEF Heater Rinse.......1473
          Radiator and Engine Rinse.......1474
          Final Rinse.......1474
          Expected Outcome.......1475
          Follow-on Procedure.......1475
          Coolant Drain Procedure.......1476
          Overview.......1476
          Special Tools.......1476
          Equipment Conditions.......1476
          Setup.......1477
          Pressurized Drain Procedure.......1477
          Expected Outcome.......1478
          Follow-on Procedure.......1479
          Coolant Fill Procedure.......1480
          Overview.......1480
          Special Tools.......1480
          Equipment Conditions.......1480
          Vacuum Fill Procedure.......1481
          Expected Outcome.......1483
          Follow-on Procedure.......1483
        Engine Component Maintenance.......1484
          HVAC Condenser.......1484
          Relocate.......1484
          Overview.......1484
          Special Tools.......1485
          Equipment Conditions.......1485
          Procedure.......1485
          Expected Outcome.......1486
          Follow-on Procedure.......1486
          Reinstallation.......1487
          Overview.......1487
          Special Tools.......1487
          Equipment Conditions.......1487
          Procedure.......1487
          Expected Outcome.......1488
          Follow-on Procedure.......1488
          Deaeration Tank.......1489
          Removal.......1489
          Overview.......1489
          Required Tools.......1489
          Equipment Conditions.......1489
          Procedure.......1489
          Expected Outcome.......1489
          Follow-on Procedure.......1489
          Installation.......1490
          Overview.......1490
          Required Tools.......1490
          Equipment Conditions.......1490
          Procedure.......1490
          Expected Outcome.......1490
          Follow-on Procedure.......1490
          Power Steering Reservoir.......1491
          Relocate.......1491
          Overview.......1491
          Required Tools.......1491
          Equipment Conditions.......1491
          Procedure.......1491
          Expected Outcome.......1492
          Follow-on Procedure.......1492
          Reinstallation.......1493
          Overview.......1493
          Required Tools.......1493
          Equipment Conditions.......1493
          Procedure.......1493
          Expected Outcome.......1494
          Follow-on Procedure.......1494
          Radiator Hose.......1495
          Remove.......1495
          Overview.......1495
          Required Tools.......1495
          Equipment Conditions.......1495
          Procedure.......1495
          Heat Shrink Clamp - Remove.......1495
          Radiator Hose - Remove.......1496
          Expected Outcome.......1496
          Follow-on Procedure.......1496
          Installation.......1497
          Overview.......1497
          Required Tools.......1497
          Torque Specifications.......1497
          Equipment Conditions.......1497
          Procedure.......1497
          Radiator Hose - Install.......1497
          Heat Shrink Clamp - Install.......1498
          Expected Outcome.......1500
          Follow-on Procedure.......1500
          Coolant Package.......1501
          Removal.......1501
          Overview.......1501
          Required Tools.......1501
          Equipment Conditions.......1501
          Procedure.......1502
          Expected Outcome.......1502
          Follow-on Procedure.......1502
          Installation.......1503
          Overview.......1503
          Required Tools.......1503
          Equipment Conditions.......1503
          Procedure.......1503
          Expected Outcome.......1504
          Follow-on Procedure.......1504
          Radiator.......1505
          Remove.......1505
          Overview.......1505
          Required Tools.......1505
          Equipment Conditions.......1505
          Procedure.......1505
          Expected Outcome.......1506
          Follow-on Procedure.......1506
          Installation.......1507
          Overview.......1507
          Required Tools.......1507
          Equipment Conditions.......1507
          Procedure.......1507
          Expected Outcome.......1508
          Follow-on Procedure.......1508
        Charge Air Cooler (CAC).......1509
        Overview.......1509
          Charge Air Cooler (CAC) Maintenance.......1510
          Removal.......1510
          Overview.......1510
          Special Tools.......1510
          Equipment Conditions.......1510
          Procedure.......1511
          Follow-On Procedure.......1511
          Installation.......1512
          Overview.......1512
          Required Tools.......1512
          Equipment Conditions.......1512
          Procedure.......1512
          Follow-on Procedure.......1512
          Cleaning.......1514
          Overview.......1514
          Required Tools.......1514
          Equipment Conditions.......1514
          Off-chassis Pressure Test.......1515
          Cleaning Management System (CMS) - Installation.......1516
          Cleaning Procedure.......1517
          Flush.......1518
          Cleaning Management System (CMS) - Removal.......1518
          Expected Outcome.......1518
          Follow-on Procedure.......1518
        Coolant Filter.......1519
        Overview.......1519
        Service Information.......1519
        In-transit (UTi Transport Solutions) Heat Plumbing.......1520
        Overview.......1520
      5. Cooling System - LoneStar.......1521
        Cooling Package.......1521
        Overview.......1521
          Cooling System Maintenance.......1522
          External Cleaning.......1522
          Special Tools.......1522
          Equipment Conditions.......1522
          Air Deflector Removal.......1523
          HVAC Condenser Cleaning.......1523
          Charge Air Cooler (CAC) Cleaning.......1523
          Front of Radiator Cleaning.......1523
          Air Deflector Installation.......1524
          Follow-On Procedure.......1524
          Deaeration Tank Inspection.......1525
          Overview.......1525
          Special Tools.......1525
          Equipment Conditions.......1525
          Setup.......1525
          Inspection Procedure.......1526
          Follow-On Procedure.......1528
          Check Coolant Condition.......1529
          Overview.......1529
          Special Tools.......1529
          Equipment Conditions.......1529
          Setup.......1530
          Coolant Check Procedure.......1530
          Follow-On Procedure.......1531
          Coolant Pressure Check Procedure.......1532
          Special Tools.......1532
          Equipment Conditions.......1532
          Setup.......1532
          Pressure Check Procedure.......1533
          Follow-On Procedure.......1535
          Coolant Package Flush Procedure.......1536
          Special Tools.......1536
          Equipment Conditions.......1536
          Preparation.......1537
          Coolant Filter Flush, if Equipped.......1537
          Flush Thermostat Housing.......1538
          Front Heater Core Flush.......1538
          Rear Heater Core Flush, if Equipped.......1538
          DEF Heater Core Flush.......1539
          Front and Rear, if Equipped, Heater Core Rinse.......1540
          DEF Heater Rinse.......1540
          Radiator and Engine Rinse.......1541
          Final Rinse Procedure.......1541
          Follow-On Procedure.......1542
          Coolant Drain procedure.......1543
          Special Tools.......1543
          Equipment Conditions.......1543
          Coolant Drain Procedure.......1544
          Follow-On Procedure.......1546
          Deaeration Tank.......1547
          Removal.......1547
          Special Tools.......1547
          Equipment Conditions.......1547
          Removal Procedure.......1547
          Follow-On Procedure.......1548
          Power Steering Reservoir.......1550
          Relocation.......1550
          Special Tools.......1550
          Specifications.......1550
          Equipment Conditions.......1550
          Reservoir Relocation Procedure.......1551
          Follow-On Procedure.......1551
          Reinstallation.......1552
          Special Tools.......1552
          Equipment Conditions.......1552
          Reinstallation Procedure.......1553
          Follow-On Procedure.......1553
          Radiator Hose.......1554
          Removal.......1554
          Overview.......1554
          Special Tools.......1554
          Equipment Conditions.......1554
          Removal Procedure - With Heat Shrink Clamp.......1555
          Radiator Hose Removal Procedure - With Spring Clamp.......1556
          Follow-On Procedure.......1558
          Installation.......1559
          Special Tools.......1559
          Equipment Conditions.......1559
          Procedure - With Spring Clamp.......1559
          Procedure - With Heat Shrink Clamp.......1562
          Follow-On Procedure.......1564
          Cooling Package.......1565
          Removal.......1565
          Special Tools.......1565
          Equipment Conditions.......1565
          Removal Procedure.......1565
          Follow-On Procedure.......1574
          Installation.......1575
          Overview.......1575
          Special Tools.......1575
          Equipment Conditions.......1575
          Installation Procedure.......1575
          Follow-On Procedure.......1583
          Radiator Core.......1585
          Removal.......1585
          Special Tools.......1585
          Equipment Conditions.......1585
          Removal Procedure.......1585
          Follow-On Procedure.......1591
          Installation.......1592
          Overview.......1592
          Special Tools.......1592
          Equipment Conditions.......1592
          Installation Procedure.......1593
          Follow-On Procedure.......1598
          Coolant Fill Procedure.......1599
          Overview.......1599
          Special Tools.......1599
          Equipment Conditions.......1599
          Gravity Fill Procedure Cummins ISX 15 Engine.......1599
          Follow-On Procedure.......1601
          HVAC Condenser.......1602
          Removal.......1602
          Overview.......1602
          Special Tools.......1602
          Equipment Conditions.......1602
          Removal Procedure.......1603
          Follow-On Procedure.......1604
          Installation.......1605
          Overview.......1605
          Special Tools.......1605
          Equipment Conditions.......1605
          Installation Procedure.......1606
          Follow-On Procedure.......1607
          Relocation.......1608
          Special Tools.......1608
          Equipment Conditions.......1608
          Relocation Procedure.......1609
          Follow-On Procedure.......1609
          Reinstall .......1610
          Special Tools.......1610
          Equipment Conditions.......1610
          Reinstall Procedure.......1610
          Follow-On Procedure.......1611
        Charge Air Cooler (CAC).......1612
        Overview.......1612
          Remove.......1613
          Special Tools.......1613
          Equipment Conditions.......1613
          Removal Procedure.......1613
          Follow-On Procedure.......1614
          Clean.......1615
          Overview.......1615
          Special Tools.......1615
          Equipment Conditions.......1615
          Off-chassis Pressure Test.......1616
          Charge Air Cooler (CAC) Cleaning Management System (CMS) Install.......1617
          Cleaning Procedure.......1618
          Charge Air Cooler (CAC) Cleaning Management System (CMS) Removal.......1619
          Follow-On Procedure.......1619
          Flush.......1620
          Overview.......1620
          Special Tools.......1620
          Equipment Conditions.......1620
          Off-Chassis Pressure Test.......1621
          Charge Air Cooler (CAC) Cleaning Management System (CMS) Install.......1622
          Flush Procedure.......1623
          Charge Air Cooler (CAC) Cleaning Management System (CMS) Removal.......1624
          Follow-On Procedure.......1624
          Installation.......1625
          Special Tools.......1625
          Equipment Conditions.......1625
          Installation Procedure.......1625
          Follow-On Procedure.......1626
      6. Fan and Shroud.......1627
        Fan Override Switch.......1627
        Overview.......1627
        Fan and Shroud Replacement.......1628
          Shroud.......1628
          Disconnect.......1628
          Overview.......1628
          Special Tools.......1628
          Equipment Conditions.......1628
          Procedure.......1628
          Expected Outcome.......1629
          Follow-On Procedure.......1629
          Reconnect.......1630
          Overview.......1630
          Special Tools.......1630
          Equipment Conditions.......1630
          Procedure.......1630
          Follow-On Procedure.......1630
          Fan.......1631
          Removal.......1631
          Overview.......1631
          Special Tools.......1631
          Equipment Conditions.......1631
          Procedure.......1631
          Follow-On Procedure.......1632
          Installation.......1633
          Overview.......1633
          Special Tools.......1633
          Equipment Conditions.......1633
          Procedure.......1633
          Follow-On Procedure.......1633
      7. Engine Features.......1634
        Accelerator Interlock.......1634
        Overview.......1634
        Idle Shutdown Timer.......1635
        Overview.......1635
        Predictive Cruise Control.......1636
        Overview.......1636
          Antenna Harness.......1638
          Removal.......1638
          Installation.......1639
          Predictive Cruise Control Module.......1640
          Removal.......1640
          Installation.......1642
        A26 Neutral Coast.......1644
        Overview.......1644
        A26 Multi-torque.......1645
        Overview.......1645
        Cummins X15 SmartCoast.......1646
        Overview.......1646
        Cummins X15 SmartTorque2.......1647
        Overview.......1647
        Vehicle Speed Limiter.......1648
        Overview.......1648
      8. Fan Drive.......1649
        Fan Drive - Borg-Warner K32.......1649
        Overview.......1649
          Operational Check.......1650
          Overview.......1650
          Clutch Will Not Engage.......1652
          Overview.......1652
          Possible Causes.......1652
          Clutch Will Not Disengage.......1653
          Overview.......1653
          Possible Causes.......1653
          Air Leak In Drive.......1655
          Overview.......1655
          Possible Causes.......1655
          Excessive Noise From Fan Drive.......1656
          Overview.......1656
          Possible Causes.......1656
          Fan Drive Test.......1659
          Overview.......1659
          Tools Required.......1659
          Equipment Condition.......1659
          Test Procedure.......1659
          Expected Outcome.......1659
          Follow-on Procedure.......1659
          Navistar Engine Diagnostic Software Engine Fan Test.......1660
          Overview.......1660
          Tools Required.......1660
          Equipment Conditions.......1660
          Test Setup.......1660
          Test Procedure.......1660
          Expected Outcome.......1661
          Follow-on Procedure.......1661
          Fan Drive Clutch Lining.......1662
          Removal.......1662
          Overview.......1662
          Required Tools.......1662
          Equipment Conditions.......1662
          Procedure.......1663
          Follow-on Procedure.......1663
          Installation.......1664
          Overview.......1664
          Required Tools.......1664
          Equipment Conditions.......1664
          Procedure.......1665
          Expected Outcome.......1665
          Follow-on Procedure.......1665
          Fan Drive Assembly.......1666
          Removal.......1666
          Overview.......1666
          Required Tools.......1666
          Equipment Conditions.......1666
          Procedure.......1667
          Follow-on Procedure.......1667
          Installation.......1668
          Overview.......1668
          Required Tools.......1668
          Equipment Conditions.......1668
          Procedure.......1669
          Follow-on Procedure.......1669
        Fan Drive - Horton Drivemaster.......1670
        Overview.......1670
          Operational Checkout Procedure.......1672
          Fan Always ON.......1674
          Overview.......1674
          Fault Facts.......1674
          Special Tools.......1674
          Possible Causes.......1674
          Fan Always OFF.......1681
          Overview.......1681
          Fault Facts.......1681
          Special Tools.......1681
          Possible Causes.......1681
          Fan Cycles Too Frequently.......1686
          Overview.......1686
          Fault Facts.......1686
          Special Tools.......1686
          Possible Causes.......1686
          Excessive Noise From Fan Drive.......1689
          Overview.......1689
          Fault Facts.......1689
          Special Tools.......1689
          Possible Causes.......1689
          Air Cartridge.......1691
          Removal.......1691
          Overview.......1691
          Required Tools.......1691
          Equipment Conditions.......1691
          Procedure.......1692
          Follow-on Procedure.......1693
          Installation.......1694
          Overview.......1694
          Required Tools.......1694
          Torque Specifications.......1694
          Equipment Conditions.......1694
          Procedure.......1695
          Follow-on Procedure.......1696
          Clutch Pack Seal Face.......1697
          Removal.......1697
          Overview.......1697
          Required Tools.......1697
          Equipment Conditions.......1697
          Procedure.......1698
          Follow-on Procedure.......1698
          Installation.......1699
          Overview.......1699
          Required Tools.......1699
          Equipment Condition.......1699
          Procedure.......1700
          Follow-on Procedure.......1700
          Cummins Fan.......1701
          Removal.......1701
          Overview.......1701
          Required Tools.......1701
          Equipment Condition.......1701
          Procedure.......1702
          Follow-on Procedure.......1702
          Installation.......1703
          Overview.......1703
          Required Tools.......1703
          Equipment Condition.......1703
          Procedure.......1704
          Follow-on Procedure.......1704
          Cummins Fan Drive Assembly.......1705
          Removal.......1705
          Overview.......1705
          Required Tools.......1705
          Equipment Condition.......1705
          Procedure.......1706
          Follow-on Procedure.......1706
          Installation.......1707
          Overview.......1707
          Required Tools.......1707
          Equipment Condition.......1707
          Procedure.......1708
          Follow-on Procedure.......1708
          Navistar Fan Drive Assembly.......1709
          Removal.......1709
          Overview.......1709
          Required Tools.......1709
          Equipment Condition.......1709
          Procedure.......1710
          Follow-on Procedure.......1710
          Installation.......1711
          Overview.......1711
          Required Tools.......1711
          Equipment Condition.......1711
          Procedure.......1712
          Follow-on Procedure.......1713
          Pulley Bearing.......1714
          Removal.......1714
          Overview.......1714
          Required Tools.......1714
          Equipment Conditions.......1714
          Procedure.......1715
          Follow-on Procedure.......1715
          Installation.......1716
          Overview.......1716
          Required Tools.......1716
          Torque Specifications.......1716
          Equipment Condition.......1716
          Procedure.......1717
          Follow-on Procedure.......1717
      9. Oil System.......1718
        Oil Level Sensor.......1718
        Overview.......1718
        Oil Recovery System.......1719
        Overview.......1719
    Transmissions.......1721
      1. PTO.......1723
        Transmission Mounted PTO .......1723
        Overview.......1723
        Dash-Mounted PTO Controls.......1725
        Overview.......1725
        Thru-Shaft PTO.......1726
        Overview.......1726
      2. Shifter.......1727
        Navistar Stalk Shifter.......1727
          Removal.......1728
          Overview.......1728
          Special Tools.......1728
          Equipment Condition.......1728
          Procedure.......1728
          Follow-on Procedure.......1729
          Installation.......1730
          Overview.......1730
          Special Tools.......1730
          Torque Specification.......1730
          Equipment Condition.......1730
          Procedure.......1730
          Follow-on Procedure.......1731
      3. Transmissions.......1732
        Allison Automatic Transmission (TC10).......1732
        Overview.......1732
          Allison Automatic Transmission with Auto Neutral .......1733
          Overview.......1733
        Manual Transmissions.......1734
          Fuller.......1734
          Overview.......1734
          Tremec.......1736
          Overview.......1736
          Eaton.......1737
          Overview.......1737
          Fully Automated Manual With Hill Start Aid.......1739
          Overview.......1739
          Service Information.......1741
      4. Transmission Oil Cooler.......1742
        Automatic Transmission Oil Cooler.......1742
        Overview.......1742
        Manual Transmission Oil Cooler.......1744
          Water to Oil Type Cooler.......1744
          Overview.......1744
          Air to Oil Type Cooler.......1745
          Overview.......1745
    Rear Axle and Suspension.......1747
      1. Axle Controls.......1749
        Differential Lock Controls.......1749
        Overview.......1749
        Power Divider Lock.......1750
        Overview.......1750
          PDL Warning Buzzer.......1751
          Overview.......1751
      2. Rear Axle.......1752
        Meritor.......1752
          Single Axle.......1752
          Single Reduction.......1753
          Two-Speed.......1753
          Tandem Axle.......1754
          Single Reduction.......1755
          Two-Speed.......1755
      3. Rear Suspensions.......1756
        Air Suspension Pressure Release Valve.......1756
        Overview.......1756
        Bias Air Control Valve.......1757
        Overview.......1757
        Air Suspensions.......1758
          Single.......1758
          Overview.......1758
          Tandem.......1760
          Overview.......1760
          Air Bag.......1762
          Removal.......1762
          Overview.......1762
          Required Tools.......1762
          Equipment Condition.......1762
          Procedure.......1763
          Follow-on Procedure.......1763
          Installation.......1764
          Overview.......1764
          Required Tools.......1764
          Equipment Condition.......1764
          Procedure.......1765
          Follow-on Procedure.......1765
          Air Ride Spring.......1766
          Removal.......1766
          Overview.......1766
          Required Tools.......1766
          Equipment Condition.......1766
          Procedure.......1767
          Follow-on Procedure.......1767
          Installation.......1768
          Overview.......1768
          Required Tools.......1768
          Equipment Condition.......1768
          Procedure.......1769
          Follow-on Procedure.......1770
          Ride Height Control Valve.......1771
          Removal.......1771
          Overview.......1771
          Required Tools.......1771
          Equipment Condition.......1771
          Procedure.......1772
          Follow-on Procedure.......1772
          Installation.......1773
          Overview.......1773
          Required Tools.......1773
          Equipment Condition.......1773
          Procedure.......1774
          Follow-on Procedure.......1774
          Torque Rod.......1775
          Removal.......1775
          Overview.......1775
          Required Tools.......1775
          Equipment Condition.......1775
          Procedure.......1776
          Follow-on Procedure.......1776
          Installation.......1777
          Overview.......1777
          Required Tools.......1777
          Torque Specifications.......1777
          Equipment Condition.......1777
          Procedure.......1778
          Follow-on Procedure.......1778
          Ride Height Measurement.......1779
          Overview.......1779
          Required Tools.......1779
          Equipment Condition.......1779
          Test Setup.......1779
          Test Procedure.......1780
          Follow-on Procedure.......1781
          Ride Height Adjustment.......1782
          Overview.......1782
          Specifications.......1782
          Equipment Condition.......1782
          Procedure.......1782
          Travel exceeds specification:.......1782
          Travel is less than specification:.......1782
          Expected Outcome.......1782
          Follow-On Procedure.......1783
    Fuel System.......1785
      1. DEF Tank.......1787
      Overview.......1787
      DEF.......1787
      DEF Tank.......1787
      DEF Supply Module.......1788
      DEF Tank Pickup Assembly.......1788
      DEF Lines.......1788
      DEF Coolant Lines.......1788
      DEF Tank Heater Valve.......1788
      DEF Line Heater.......1788
        DEF Tank.......1789
          Removal.......1789
          Overview.......1789
          Required Tools.......1789
          Equipment Conditions.......1789
          Procedure.......1790
          Follow-on Procedure.......1792
          Installation.......1793
          Overview.......1793
          Required Tools.......1793
          Equipment Condition.......1793
          Procedure.......1794
          Follow-on Procedure.......1796
          DEF Supply Module Filter.......1797
          Removal.......1797
          Overview.......1797
          Overview.......1798
          Required Tools.......1798
          Equipment Conditions.......1798
          Procedure.......1799
          Follow-on Procedure.......1799
          Installation.......1800
          Overview.......1800
          Required Tools.......1800
          Equipment Condition.......1800
          Procedure.......1801
          Follow-on Procedure.......1801
        DEF Head .......1802
          Removal.......1802
          Overview.......1802
          Required Tools.......1802
          Equipment Conditions.......1802
          Procedure.......1803
          Follow-on Procedure.......1803
          Installation.......1804
          Overview.......1804
          Required Tools.......1804
          Equipment Conditions.......1804
          Procedure.......1805
          Follow-on Procedure.......1805
      2. Fuel Heater.......1806
        Arctic Fox.......1806
        Overview.......1806
        Cummins - Fuel Heater.......1807
        Overview.......1807
          Removal.......1808
          Overview.......1808
          Required Tools.......1808
          Equipment Conditions.......1808
          Procedure.......1809
          Follow-on Procedure.......1809
          Installation.......1810
          Overview.......1810
          Required Tools.......1810
          Torque Specifications.......1810
          Equipment Conditions.......1810
          Procedure.......1811
          Follow-on Procedure.......1811
      3. Fuel / Water Separator.......1812
        Davco.......1812
        Overview.......1812
          Removal.......1815
          Overview.......1815
          Required Tools.......1815
          Equipment Conditions.......1815
          Procedure.......1816
          Follow-on Procedure.......1816
          Installation.......1817
          Overview.......1817
          Required Tools.......1817
          Torque Specification.......1817
          Equipment Conditions.......1817
          Procedure.......1818
          Follow-on Procedure.......1818
          Bleed Procedure.......1819
          Overview.......1819
          Required Tools.......1819
          Equipment Condition.......1819
          Procedure.......1819
          Follow-on Procedure.......1819
        Racor.......1820
        Overview.......1820
      4. Fuel Tanks.......1822
      Overview.......1822
        Fuel Tanks.......1823
          Removal.......1823
          Overview.......1823
          Required Tools.......1823
          Equipment Conditions.......1823
          Procedure.......1824
          Expected Outcome.......1824
          Follow-on Procedure.......1825
          Installation.......1826
          Overview.......1826
          Required Tools.......1826
          Equipment Conditions.......1826
          Procedure.......1827
          Expected Outcome.......1828
          Follow-on Procedure.......1828
        Fuel Tank Sender.......1829
          Removal.......1829
          Overview.......1829
          Required Tools.......1829
          Equipment Conditions.......1829
          Procedure.......1830
          Expected Outcome.......1830
          Follow-on Procedure.......1831
          Installation.......1832
          Overview.......1832
          Required Tools.......1832
          Equipment Conditions.......1832
          Procedure.......1833
          Expected Outcome.......1834
          Follow-on Procedure.......1834
    Cab.......1835
      1. Accessories.......1841
        Antenna Mounting.......1841
        Overview.......1841
          TV Antenna Mounting.......1843
          Overview.......1843
          Satellite Antenna Mounting.......1844
          Overview.......1844
        GPS.......1846
        Overview.......1846
        Keyless Entry System.......1847
        Overview.......1847
        Programming Key Fob.......1848
        Exiting Learning Process.......1848
        Mirrors.......1849
          Power Mirrors.......1849
          Overview.......1849
          Service Information.......1851
          Heated Mirrors.......1852
          Overview.......1852
          Service Information.......1853
          Mirror Assembly.......1853
          Removal.......1853
          Overview.......1853
          Required Tools.......1854
          Equipment Condition.......1854
          Procedure.......1854
          Follow-on Procedure.......1855
          Installation.......1856
          Overview.......1856
          Required Tools.......1856
          Equipment Condition.......1856
          Procedure.......1857
          Follow-on Procedure.......1858
          Mirror.......1859
          Removal.......1859
          Overview.......1859
          Required Tools.......1859
          Equipment Condition.......1859
          Procedure.......1860
          Follow-on Procedure.......1860
          Installation.......1861
          Overview.......1861
          Required Tools.......1861
          Torque Specification.......1861
          Equipment Condition.......1861
          Procedure.......1862
          Follow-on Procedure.......1862
          Ambient Temperature Sensor.......1863
          Removal.......1863
          Overview.......1863
          Required Tools.......1863
          Equipment Condition.......1863
          Procedure.......1863
          Follow-on Procedure.......1863
          Installation.......1864
          Overview.......1864
          Required Tools.......1864
          Equipment Condition.......1864
          Procedure.......1864
          Follow-on Procedure.......1864
          Hood Mounted Mirrors.......1865
          Overview.......1865
          Mirror Assembly.......1866
          Removal.......1866
          Overview.......1866
          Required Tools.......1866
          Equipment Condition.......1866
          Procedure.......1867
          Follow-on Procedure.......1867
          Installation.......1868
          Overview.......1868
          Required Tools.......1868
          Equipment Condition.......1868
          Procedure.......1869
          Follow-on Procedure.......1869
          Mirror.......1870
          Removal.......1870
          Overview.......1870
          Required Tools.......1870
          Equipment Condition.......1870
          Procedure.......1871
          Follow-on Procedure.......1871
          Installation.......1872
          Overview.......1872
          Required Tools.......1872
          Torque Specifications.......1872
          Equipment Condition.......1872
          Procedure.......1873
          Follow-on Procedure.......1873
        Power Door Locks / Windows.......1874
        Overview.......1874
          Door Panel.......1876
          Removal.......1876
          Overview.......1876
          Required Tools.......1876
          Equipment Conditions.......1876
          Procedure.......1876
          Follow-On Maintenance.......1877
          Installation.......1878
          Overview.......1878
          Required Tools.......1878
          Torque Specifications.......1878
          Equipment Conditions.......1878
          Procedure.......1878
          Follow-On Maintenance.......1879
        Tire Pressure Monitor.......1880
        Overview.......1880
      2. Cab.......1881
        Cab Glass.......1881
          Sleeper Vent Window.......1881
          Removal.......1881
          Overview.......1881
          Special Tools.......1881
          Equipment Conditions.......1882
          Procedure.......1882
          Follow-On Procedure.......1882
          Installation.......1883
          Overview.......1883
          Special Tools.......1883
          Equipment Conditions.......1883
          Procedure.......1884
          Follow-On Procedure.......1884
          Sleeper Vent Window Handle.......1885
          Removal.......1885
          Overview.......1885
          Special Tools.......1885
          Equipment Conditions.......1885
          Procedure.......1885
          Follow-On Procedure.......1886
          Installation.......1887
          Overview.......1887
          Special Tools.......1887
          Equipment Conditions.......1887
          Procedure.......1888
          Follow-On Procedure.......1888
        Cab Interior.......1889
          Dog House.......1889
          Removal.......1889
          Overview.......1889
          Required Tools.......1889
          Equipment Conditions.......1889
          Procedure.......1889
          Follow-On Maintenance.......1890
          Installation.......1891
          Overview.......1891
          Required Tools.......1891
          Equipment Conditions.......1891
          Procedure.......1891
          Follow-On Maintenance.......1892
          Center Column Electrical Cluster.......1893
          Removal.......1893
          Overview.......1893
          Required Tools.......1893
          Equipment Conditions.......1893
          Procedure.......1893
          Follow-On Maintenance.......1894
          Installation.......1895
          Overview.......1895
          Required Tools.......1895
          Equipment Conditions.......1895
          Procedure.......1895
          Follow-On Maintenance.......1896
          Dash.......1897
          Reposition.......1897
          Special Tools.......1897
          Torque Specifications.......1897
          Equipment Conditions.......1897
          Procedure.......1898
          Follow-On Procedure.......1903
          Reinstallation.......1904
          Special Tools.......1904
          Equipment Conditions.......1904
          Procedure.......1905
          Follow-On Procedure.......1910
          Flat Screen TV Mount.......1911
          Overview.......1911
          Removal.......1912
          Overview.......1912
          Required Tools.......1912
          Equipment Conditions.......1912
          Procedure.......1913
          Follow-On Maintenance.......1914
          Installation.......1915
          Overview.......1915
          Required Tools.......1915
          Equipment Conditions.......1915
          Procedure.......1916
          Follow-On Maintenance.......1917
          Switch Pack.......1918
          Removeal.......1918
          Overview.......1918
          Required Tools.......1919
          Equipment Conditions.......1919
          Procedure.......1920
          Follow-On Maintenance.......1922
          Installation.......1923
          Overview.......1923
          Required Tools.......1923
          Torque Specifications.......1923
          Equipment Conditions.......1923
          Procedure.......1924
          Follow-On Maintenance.......1925
          Switch.......1926
          Removal.......1926
          Overview.......1926
          Required Tools.......1926
          Equipment Conditions.......1926
          Procedure.......1926
          Follow-On Maintenance.......1927
          Installation.......1928
          Overview.......1928
          Required Tools.......1928
          Equipment Conditions.......1928
          Procedure.......1928
          Follow-On Maintenance.......1929
        Cab Interior - Day.......1930
        Trim Level 1 - Overview.......1930
          Sun Visor and Clip.......1931
          Removal.......1931
          Special Tools.......1931
          Equipment Conditions.......1931
          Procedure.......1931
          Follow-on Procedure.......1931
          Installation.......1932
          Special Tools.......1932
          Equipment Conditions.......1932
          Procedure.......1932
          Follow-on Procedure.......1932
          Header Console Panel.......1933
          Removal.......1933
          Overview.......1933
          Special Tools.......1933
          Equipment Conditions.......1933
          Procedure.......1934
          Follow-on Procedure.......1937
          Installation.......1938
          Overview.......1938
          Special Tools.......1938
          Equipment Conditions.......1938
          Procedure.......1939
          Follow-on Procedure.......1942
          Headliner Trim Panel (Standard Cab).......1943
          Removal.......1943
          Overview.......1943
          Special Tools.......1943
          Equipment Conditions.......1943
          Procedure.......1944
          Follow-on Procedure.......1945
          Installation.......1946
          Overview.......1946
          Special Tools.......1946
          Torque Specifications.......1946
          Equipment Conditions.......1946
          Procedure.......1947
          Follow-on Procedure.......1948
        Cab Interior - Sleeper.......1949
          Long Sleeper Cab.......1949
          Trim Level 1 - Overview.......1949
          Trim Level 2 - Overview.......1950
          Short Sleeper Cab.......1951
          Trim Level 1 - Overview.......1951
          Storage.......1952
          Cabinet Dresser - Overview.......1952
          Overhead Cabinet - Overview.......1953
          Overhead Sleeper Cabinet - Overview.......1954
          Refrigerator Cabinet - Overview.......1956
          Wardrobe Tower Lower Left and Right - Overview.......1957
          Wardrobe Tower Upper Left and Right - Overview.......1958
        Cab Rear Suspension.......1960
        Overview.......1960
          Air Spring Support Bracket.......1961
          Removal.......1961
          Overview.......1961
          Required Tools.......1961
          Equipment Conditions.......1961
          Procedure.......1961
          Follow-On Maintenance.......1963
          Installation.......1964
          Overview.......1964
          Required Tools.......1964
          Equipment Conditions.......1964
          Procedure.......1965
          Follow-On Maintenance.......1966
          Cab Suspension Air Springs.......1967
          Removal.......1967
          Overview.......1967
          Required Tools.......1967
          Equipment Conditions.......1967
          Procedure.......1967
          Follow-On Maintenance.......1968
          Installation.......1969
          Overview.......1969
          Required Tools.......1969
          Equipment Conditions.......1969
          Procedure.......1970
          Follow-On Maintenance.......1970
          Height Control Valve.......1971
          Removal.......1971
          Overview.......1971
          Required Tools.......1971
          Equipment Conditions.......1971
          Procedure.......1971
          Follow-On Maintenance.......1972
          Installation.......1973
          Overview.......1973
          Required Tools.......1973
          Equipment Conditions.......1973
          Procedure.......1974
          Expected Outcome.......1974
          Follow-On Maintenance.......1974
          Adjustment.......1976
          Overview.......1976
          Tools Required.......1976
          Equipment Condition.......1976
          Test Setup.......1976
          Test Procedure.......1976
          Expected Outcome.......1977
          Follow-on Procedure.......1977
          If ride height exceeds specification:.......1977
          If ride height is less than specification:.......1977
          Test.......1978
          Overview.......1978
          Tools Required.......1978
          Equipment Condition.......1978
          Test Setup.......1978
          Test Procedure.......1978
          Expected Outcome.......1979
          Follow-On Procedure.......1979
          Shock Absorber.......1980
          Removal.......1980
          Overview.......1980
          Required Tools.......1980
          Equipment Conditions.......1980
          Procedure.......1980
          Follow-On Maintenance.......1981
          Installation.......1982
          Overview.......1982
          Required Tools.......1982
          Equipment Conditions.......1982
          Procedure.......1983
          Expected Outcome.......1983
          Follow-On Maintenance.......1983
          Torque Rod.......1984
          Removal.......1984
          Overview.......1984
          Required Tools.......1984
          Equipment Conditions.......1984
          Procedure.......1984
          Follow-On Maintenance.......1985
          Installation.......1986
          Overview.......1986
          Required Tools.......1986
          Equipment Conditions.......1986
          Procedure.......1987
          Follow-On Maintenance.......1987
        Cab Side Extenders (Fairings).......1988
        Overview.......1988
          Removal.......1990
          Overview.......1990
          Required Tools.......1990
          Equipment Condition.......1990
          Procedure.......1990
          Follow-on Procedure.......1991
          Installation.......1992
          Overview.......1992
          Required Tools.......1992
          Equipment Condition.......1992
          Procedure.......1993
          Follow-on Procedure.......1995
        Cab Skirts.......1996
        Overview.......1996
        Cab Sunshade.......1997
        Overview.......1997
        Roof Air Deflector.......1998
        Overview.......1998
      3. HVAC.......1999
      Overview.......1999
        ESPAR.......2000
          ESPAR Programmable Parameter.......2000
          Overview.......2000
          ESPAR Auxiliary Heater (5 kW).......2001
          Overview.......2001
          ESPAR (AirTronic D2) Auxiliary Heater.......2002
          Overview.......2002
        General HVAC System Repair.......2003
        Safety Precautions.......2003
        General Precautions.......2003
        Refrigerant Precautions.......2003
          Recover HVAC System Refrigerant.......2007
          Overview.......2007
          Required Tools.......2007
          Equipment Conditions.......2007
          Recycling Mode.......2007
          Follow-On Maintenance.......2008
          Evacuate HVAC System (Vacuum Mode).......2009
          Overview.......2009
          Required Tools.......2009
          Equipment Conditions.......2009
          Evacuate HVAC System.......2009
          Follow-On Maintenance.......2010
          Charge HVAC System (Charge Mode).......2011
          Overview.......2011
          Required Tools.......2011
          Equipment Conditions.......2011
          Charge HVAC System.......2011
          Follow-On Maintenance.......2012
          Oil Fill.......2013
          Oil Fill Guidelines.......2013
          Overview.......2013
          Required Tools.......2013
          Equipment Conditions.......2013
          Oil Fill Guidelines.......2013
          Follow-On Maintenance.......2014
          Checking Compressor Oil Level.......2015
          Oil Separation During Refrigerant Recovery.......2018
          Excessive Oil Loss Due to Refrigerant Leak.......2019
          Vehicle HVAC Specifications.......2020
        HVAC System Maintenance.......2022
        HVAC Actuators - Overview.......2022
        Defrost Actuator.......2022
        Temperature Actuator.......2022
        Recirculation Actuator.......2023
        Panel Actuator / Floor Actuator.......2023
          Defrost Actuator.......2023
          Removal.......2023
          Special Tools.......2023
          Equipment Conditions.......2023
          Removal Procedure.......2023
          Follow-On Procedure.......2024
          Installation.......2025
          Special Tools.......2025
          Equipment Conditions.......2025
          Installation Procedure.......2025
          Follow-On Procedure.......2025
          Floor Actuator.......2026
          Removal.......2026
          Special Tools.......2026
          Equipment Conditions.......2026
          Removal Procedure.......2026
          Follow-On Procedure.......2026
          Installation.......2027
          Special Tools.......2027
          Equipment Conditions.......2027
          Installation Procedure.......2027
          Follow-On Procedure.......2027
          Panel Actuator.......2028
          Removal.......2028
          Special Tools.......2028
          Equipment Conditions.......2028
          Removal Procedure.......2028
          Follow-On Procedure.......2028
          Installation.......2029
          Special Tools.......2029
          Equipment Conditions.......2029
          Installation Procedure.......2029
          Follow-On Procedure.......2029
          Recirculation Actuator.......2030
          Removal.......2030
          Special Tools.......2030
          Equipment Conditions.......2030
          Removal Procedure.......2030
          Follow-On Procedure.......2030
          Installation.......2031
          Special Tools.......2031
          Equipment Conditions.......2031
          Installation Procedure.......2031
          Follow-On Procedure.......2031
          Temperature Actuator.......2032
          Removal.......2032
          Special Tools.......2032
          Equipment Conditions.......2032
          Removal Procedure.......2032
          Follow-On Procedure.......2032
          Installation.......2033
          Special Tools.......2033
          Equipment Conditions.......2033
          Installation Procedure.......2033
          Follow-On Procedure.......2033
          Blower Motor.......2034
          Removal.......2034
          Special Tools.......2034
          Equipment Conditions.......2034
          Removal Procedure.......2034
          Follow-On Procedure.......2034
          Installation.......2035
          Special Tools.......2035
          Equipment Conditions.......2035
          Installation Procedure.......2035
          Follow-On Procedure.......2035
          Cab Evaporator.......2036
          Removal.......2036
          Overview.......2036
          Required Tools.......2036
          Equipment Conditions.......2036
          Procedure.......2036
          Follow-On Maintenance.......2036
          Installation.......2037
          Overview.......2037
          Required Tools.......2037
          Equipment Conditions.......2037
          Procedure.......2037
          Expected Outcome.......2037
          Follow-On Maintenance.......2037
          Cab Thermal Expansion Valve (TXV).......2038
          Removal.......2038
          Overview.......2038
          Required Tools.......2038
          Equipment Conditions.......2038
          Procedure.......2038
          Expected Outcome.......2039
          Follow-On Maintenance.......2039
          Installation.......2040
          Overview.......2040
          Required Tools.......2040
          Torque Specifications.......2040
          Equipment Conditions.......2040
          Procedure.......2040
          Expected Outcome.......2041
          Follow-On Maintenance.......2041
          Compressor.......2042
          Removal.......2042
          Overview.......2042
          Required Tools.......2042
          Equipment Conditions.......2042
          Procedure.......2042
          Expected Outcome.......2042
          Follow-On Maintenance.......2042
          Installation.......2043
          Overview.......2043
          Required Tools.......2043
          Equipment Conditions.......2043
          Procedure.......2043
          Expected Outcome.......2043
          Follow-On Maintenance.......2043
          Condenser.......2044
          Removal.......2044
          Overview.......2044
          Required Tools.......2044
          Equipment Conditions.......2044
          Procedure.......2044
          Expected Outcome.......2044
          Follow-On Maintenance.......2044
          Installation.......2045
          Overview.......2045
          Required Tools.......2045
          Equipment Conditions.......2045
          Procedure.......2045
          Expected Outcome.......2045
          Follow-On Maintenance.......2045
          Freeze Probe.......2046
          Removal.......2046
          Special Tools.......2046
          Equipment Conditions.......2046
          Procedure.......2046
          Follow-On Procedure.......2046
          Installation.......2047
          Special Tools.......2047
          Equipment Conditions.......2047
          Procedure.......2047
          Follow-On Procedure.......2047
          Integrated Receiver Drier.......2048
          Removal.......2048
          Overview.......2048
          Required Tools.......2048
          Equipment Conditions.......2048
          Procedure.......2048
          Expected Outcome.......2049
          Follow-On Maintenance.......2049
          Installation.......2050
          Overview.......2050
          Required Tools.......2050
          Equipment Conditions.......2050
          Procedure.......2050
          Expected Outcome.......2050
          Follow-On Maintenance.......2051
        HVAC Flush and Purge Procedures.......2052
          Flush and Purge.......2052
          Overview.......2052
          Required Tools.......2052
          Equipment Conditions.......2052
          Discharge Barrel.......2053
          Fill Flush Tank.......2056
          Flush and Purge Procedure.......2056
          Expected Outcome.......2058
          Follow-On Maintenance.......2058
          Flush and Purge HVAC Condenser.......2059
          Overview.......2059
          Required Tools.......2059
          Equipment Conditions.......2059
          Procedure.......2059
          Expected Outcome.......2062
          Follow-On Maintenance.......2062
          Flush and Purge Cab Supply and Return Lines.......2063
          Overview.......2063
          Required Tools.......2063
          Equipment Conditions.......2063
          Procedure.......2064
          Expected Outcome.......2065
          Follow-On Maintenance.......2065
          Flush and Purge HVAC Cab Evaporator.......2066
          Overview.......2066
          Required Tools.......2066
          Equipment Conditions.......2066
          Procedure.......2066
          Expected Outcome.......2067
          Follow-On Maintenance.......2067
          Flush and Purge Sleeper Supply and Return Lines (If Applicable).......2068
          Overview.......2068
          Required Tools.......2068
          Equipment Conditions.......2068
          Procedure.......2068
          Expected Outcome.......2070
          Follow-On Maintenance.......2070
          Flush and Purge Sleeper Evaporator (If Applicable).......2071
          Overview.......2071
          Required Tools.......2071
          Equipment Conditions.......2071
          Procedure.......2071
          Expected Outcome.......2073
          Follow-On Maintenance.......2074
        No Idle System.......2075
        Overview.......2075
        Sleeper.......2077
        Blend-air with Integral Heater and Defroster.......2077
        Overview.......2077
          Sleeper Evaporator.......2078
          Removal.......2078
          Special Tools.......2078
          Equipment Conditions.......2078
          Procedure.......2078
          Follow-On Procedure.......2078
          Installation.......2078
          Special Tools.......2078
          Equipment Conditions.......2078
          Procedure.......2079
          Follow-On Procedure.......2079
          Sleeper Thermal Expansion Valve.......2080
          Removal.......2080
          Special Tools.......2080
          Equipment Conditions.......2080
          Procedure.......2080
          Follow-On Procedure.......2080
          Installation.......2081
          Special Tools.......2081
          Equipment Conditions.......2081
          Procedure.......2081
          Follow-On Procedure.......2081
          Sleeper Circulating Fan.......2082
          Overview.......2082
          Sleeper Control Panel.......2083
          Overview.......2083
          Automatic Climate Control (With Auto Start and Stop).......2084
        Webasto (Airtop 2000) Auxiliary Heater.......2085
        Overview.......2085
      4. Instrumentation.......2086
        Driver Information Display.......2086
        Overview.......2086
        Gauge Cluster.......2088
        Overview.......2088
        Gauges.......2091
          Air Application.......2091
          Overview.......2091
          Engine Oil Temperature.......2092
          Overview.......2092
          Engine Manifold Pressure (Boost).......2093
          Overview.......2093
          Rear Axle Oil Temperature.......2094
          Overview.......2094
          Seat Belt Warning Lamp.......2095
          Overview.......2095
          Transmission Oil Temperature.......2096
          Overview.......2096
          Voltmeter (Auxiliary Gauge).......2097
          Overview.......2097
        Virtual Gauges.......2098
          Air Application.......2098
          Overview.......2098
          Air Cleaner Restriction.......2099
          Overview.......2099
          Ambient Temperature.......2100
          Overview.......2100
          Engine Oil Temperature.......2101
          Overview.......2101
          Engine Manifold Pressure (Boost).......2102
          Overview.......2102
          Load Indicating Rear Suspension.......2103
          Overview.......2103
          Low Washer Fluid.......2104
          Overview.......2104
          PTO Hourmeter.......2105
          Overview.......2105
          Rear Axle Oil Temperature.......2106
          Overview.......2106
          Transmission Oil Temperature.......2107
          Overview.......2107
      5. Seats.......2108
        Isringhausen (ISRI).......2108
        Overview.......2108
        National.......2110
        Overview.......2110
        National with RollTek.......2111
          Drivers.......2111
          Overview.......2111
          Passenger.......2113
          Overview.......2113
          RollTek Seat with Supplemental Restraint System (SRS).......2115
          Removal.......2115
          Overview.......2115
          Required Tools.......2115
          Equipment Conditions.......2115
          Procedure.......2115
          Expected Outcome.......2119
          Follow-On Maintenance.......2119
          Installation.......2120
          Overview.......2120
          Required Tools.......2120
          Equipment Conditions.......2120
          Procedure.......2120
          Expected Outcome.......2124
          Follow-On Maintenance.......2124
          RollTek Side Roll Airbag (SRA).......2125
          Removal.......2125
          Overview.......2125
          Required Tools.......2126
          Equipment Conditions.......2126
          Procedure.......2126
          Expected Outcome.......2129
          Follow-On Maintenance.......2129
          Installation.......2130
          Overview.......2130
          Required Tools.......2131
          Torque Specifications.......2131
          Equipment Conditions.......2131
          Procedure.......2131
          Unpacking Replacement SRA Unit.......2131
          Product Identification.......2132
          RollTek Side Roll Air Bag (SRA) - Installation.......2133
          Expected Outcome.......2135
          Follow-On Maintenance.......2135
          RollTek Supplemental Restraint System (SRS) Module.......2136
          Removal.......2136
          Overview.......2136
          Required Tools.......2137
          Equipment Conditions.......2137
          Procedure.......2137
          Expected Outcome.......2142
          Follow-On Maintenance.......2142
          Installation.......2143
          Overview.......2143
          Required Tools.......2144
          Equipment Conditions.......2144
          Procedure.......2144
          Expected Outcome.......2151
          Follow-On Maintenance.......2151
        Sears Atlas.......2152
        Overview.......2152
      6. Windshield Wipers.......2153
        Windshield Wiper System.......2153
        Overview.......2153
          Windshield Wiper Motor.......2155
          Removal.......2155
          Overview.......2155
          Required Tools.......2155
          Equipment Conditions.......2155
          Procedure.......2156
          Expected Outcome.......2156
          Follow-On Maintenance.......2156
          Installation.......2157
          Overview.......2157
          Required Tools.......2157
          Equipment Conditions.......2157
          Procedure.......2158
          Expected Outcome.......2158
          Follow-On Maintenance.......2158
tables.......13
  Service Procedures.......13
  Torque Specifications.......15
  Service Procedures.......24
  Torque Specifications.......40
  Service Procedures.......61
  Service Procedures.......63
  Service Procedures.......65
  Service Procedures.......68
  Service Procedures.......70
  Service Procedures.......72
  Torque Specifications.......93
  Service Procedures.......107
  Service Procedures.......128
  Torque Specifications.......130
  Service Procedures.......132
  Torque Specifications.......134
  Service Procedures.......160
  Torque Specifications.......163
  Torque Specifications.......167
  Service Procedures.......170
  Service Procedures.......171
  Service Procedures.......173
  Specifications.......178
  Service Procedures.......186
  Torque Specifications.......189
  Service Procedures.......191
  Service Procedures.......203
  Service Procedures.......204
  Service Procedures.......206
  Torque Specifications.......210
  Service Procedures.......212
  Service Procedures.......215
  Torque Specifications.......233
  Torque Specifications.......239
  Diagnostics.......243
  Procedures.......252
  CAN Modules Table.......274
  Approximate DC voltage readings (Key ON).......296
  Approximate Resistance (batteries disconnected).......297
  Released.......299
  Intermediate.......299
  Fully depressed.......299
  Diagnostic Section.......316
  Diagnostic Section.......319
  Starter Input Diagnostic Section.......327
  Diagnostic Section.......333
  AC Output Ratings.......386
  AC Output Ratings.......394
  Service Information.......458
  Service Information.......465
  Service Information.......469
  Service Information.......473
  Service Information.......476
  Service Information.......479
  Service Information.......483
  Specifications.......494
  Service Information.......505
  Torque Specifications.......523
  Service Information.......529
  5.......565
  Tech Tips.......628
  Base HVAC Tests.......912
  Front HVAC Tests.......912
  Sleeper / Rear HVAC Tests.......913
  R-134a Static Temperature / Pressure Table.......926
  A/C System Dynamic Pressures and Temperatures.......929
  Freeze Probe Resistance Chart.......986
  Specification.......1093
  Specification.......1097
  Specification.......1098
  Specification.......1102
  Specification.......1104
  Torque Specifications.......1108
  Torque Specifications.......1111
  Torque Specifications.......1115
  Torque Specifications.......1116
  Torque Specifications.......1118
  Sensor Values.......1156
  Service Information.......1201
  Check Communication.......1205
  Test 1  Power Circuit Check.......1205
  Test 2 Ground Circuit Check.......1205
  PWM Outputs to TCM.......1227
  Windshield Wiper Input Switch.......1244
  Service Procedures.......1330
  Torque Specifications.......1332
  Service Procedures.......1333
  Service Procedures.......1338
  Torque Specifications.......1342
  Service Procedures.......1346
  Torque Specifications.......1350
  Service Procedures.......1369
  Torque Specifications.......1372
  Service Procedures.......1375
  Torque Specifications.......1382
  Torque Specifications.......1389
  Service Procedures.......1392
  Torque Specifications.......1397
  Torque Specifications.......1431
  Reservoir Nuts .......1431
  7  8 lbf-ft (9  11 Nm).......1431
  Torque Specifications.......1433
  Master Cylinder Bolts.......1433
  15  18 lbf-ft (20  25 Nm).......1433
  Adjustment Nut.......1433
  6  9 lbf-ft (8  12 Nm).......1433
  Hydraulic Line.......1433
  15  18 lbf-ft (20  25 Nm).......1433
  Torque Specifications.......1436
  Clutch Housing Bolts.......1436
  11  15 lbf-ft (15  21 Nm).......1436
  Hydraulic Hose.......1436
  15  18 lbf-ft (20  25 Nm).......1436
  Torque Specification.......1441
  Bleeder Screw.......1441
  4 lbf-ft (5 Nm).......1441
  Torque Specification.......1487
  Torque Specification.......1490
  Torque Specification.......1493
  Torque Specifications.......1503
  Torque Specifications.......1507
  Torque Specifications.......1512
  Torque Specifications.......1524
  Torque Specifications.......1552
  Torque Specifications.......1559
  Torque Specifications.......1575
  Torque Specifications.......1592
  Torque Specifications.......1605
  Torque Specifications.......1610
  Torque Specification.......1625
  Torque Specification.......1630
  Torque Specification.......1633
  Torque Specifications.......1664
  Torque Specifications.......1668
  Torque Specifications.......1699
  Torque Specifications.......1703
  Torque Specifications.......1707
  Torque Specifications.......1711
  Torque Specifications.......1764
  Torque Specifications.......1768
  Torque Specification.......1773
  Torque Specification.......1793
  Torque Specification.......1800
  Torque Specifications.......1804
  Torque Specifications.......1826
  Torque Specifications.......1832
  Torque Specifications.......1856
  Torque Specifications.......1864
  Torque Specifications.......1868
  Torque Specifications.......1883
  Torque Specifications.......1887
  Torque Specifications.......1891
  Torque Specifications.......1895
  Torque Specifications.......1904
  Torque Specifications.......1915
  Torque Specification.......1928
  Torque Specifications.......1932
  Torque Specifications.......1938
  Torque Specifications.......1964
  Torque Specifications.......1969
  Torque Specifications.......1973
  Torque Specifications.......1982
  Torque Specifications.......1986
  Torque Specification.......1992
  Charge Quantities.......2020
  Oil Capacity by Component.......2020
  HVAC System Torque Chart.......2021
  Torque Specifications.......2025
  Torque Specifications.......2027
  Torque Specifications.......2029
  Torque Specifications.......2031
  Torque Specifications.......2033
  Torque Specifications.......2035
  Torque Specifications.......2037
  Torque Specifications.......2040
  Torque Specifications.......2043
  Torque Specifications.......2045
  Torque Specifications.......2047
  Torque Specifications.......2050
  Torque Specifications.......2078
  Torque Specifications.......2081
  Torque Specifications.......2120
  Torque Specifications.......2144
  Torque Specifications.......2157

International Trucks LT/RH/LoneStar RH613/LT625 Models Repair Service Manual

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