International Engines MaxxForce 5/7/DT/9/10 models Diagnostics/Troubleshooting/Service/Repair Manuals

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Price: US$ 69.00

Complete service repair manual with Electrical Wiring Diagrams for International MaxxForce 5, MaxxForce 7, MaxxForce DT, MaxxForce 9, MaxxForce 10 Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

International / Navistar MF5, MF7, MF DT, MF 9, MF 10 Diesel Engines 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: 14,891 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

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EGES-455-1 - Diagnostic Trouble Code.pdf
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EGES-480-1 - MaxxForce 7 Diesel Engine Service Manual Model Year 2010 and Up.pdf
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EGES-540 -  2007-2009 Aftertreatment Unique Diagnostics And Service Information (MaxxForce 5, 7, DT, 9, 10, 11, and 13).pdf
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MAIN SECTIONS

0000001624 - 2010 MaxxForce DT, 9, and 10 Engines Diagnostic Manual..4
  toc..6
    Table of Contents..6
    Safety Terminology..10
    Safety Instructions..10
    Work Area..10
    Safety Equipment..10
    Protective Measures..10
    Vehicle..10
    Engine..11
    Fire Prevention..11
    Batteries..11
    Compressed Air..11
    Tools..11
    Fluids Under Pressure..12
    Fuel..12
    Removal of Tools, Parts, and Equipment..12
      Table of Contents..14
        Engine Identification..16
          Engine Serial Number..16
          Engine Serial Number Examples..16
          Engine Serial Number Codes..16
          Engine Emission Label..17
          Engine Accessory Labels..18
          Engine Description..18
            Standard Features..19
            Optional Features..20
            Optional Cold Climate Features..20
            Chassis Mounted Features..20
          Engine Component Locations (245 hp and above)..22
        Air Management System (AMS)..27
          Air Flow ? Pre Combustion..28
          Air Flow ? Post Combustion..28
          Air Management Components..28
            Turbochargers..28
            Interstage Cooler (ISC)..29
            High-pressure Charge Air Cooler (HPCAC)..30
            Turbocharger 2 Wastegate Control (TC2WC) Valve..30
            Exhaust Gas Recirculation (EGR) System..31
            EGR Flow..32
            EGR Valve..32
            EGR Closed Loop System..32
            Crankcase Ventilation System..34
          Aftertreatment (AFT) System..36
          AFT Control System..37
          Sensors..37
          Exhaust Back Pressure Valve..37
          Pre-Diesel Oxidation Catalyst (PDOC)..37
          Diesel Oxidation Catalyst (DOC)..37
          Diesel Particulate Filter (DPF)..37
          AFT Conditions and Responses..38
          Downstream Injection System..38
        Fuel Management System..39
          ICP System..41
            High-Pressure Oil Flow..42
            ICP Closed Loop System..42
            ICP Control System..43
            Fuel Injector..44
            Fuel Injector Features..44
            Injector Coils and Spool Valve..44
            Intensifier Piston and Plunger..44
            Plunger and Barrel..45
            Injector Needle..45
            Fuel Injector Operation..45
            Fill Stage..45
            Injection..46
            End of Injection..46
        Fuel Supply System..47
          Fuel Supply System Flow..48
        Engine Lubrication System..51
          Oil Flow..52
        Engine Cooling System..53
          Cooling System Description..53
          Cooling System Components..55
            Coolant Heater (optional)..55
            Thermostat Operation..55
            Low Temperature Radiator (LTR) Thermostat Operation..58
        Electronic Control System..59
          Electronic Control System Components..59
            Operation and Function..60
            Reference Voltage (VREF)..60
            Microprocessor..60
            Actuator Control..60
          Actuators..60
            Exhaust Gas Recirculation (EGR) Valve..61
            Intake Air Heater (IAH) Relay..61
            Engine Throttle Valve (ETV) and Position Sensor..61
            Turbocharger 2 Wastegate Control (TC2WC) valve (turbocharger wastegate actuator)..61
            Exhaust Back Pressure Valve (EBPV)..61
            Engine Compression Brake (ECB) valve..61
            Injection Pressure Regulator (IPR) valve..61
          Engine and Vehicle Sensors..62
            Temperature Sensors..62
            Thermistor Sensors..62
            ECT Sensor..62
            EOT Sensor..63
            AIT Sensor..63
            IMT Sensor..63
            CACOT Sensor..63
            TC2CIT Sensor..63
            Exhaust Gas Temperature (EGT) sensors..63
            Variable Capacitance Sensors..64
            FDP Sensor..64
            EOP Sensor..64
            EBP Sensor..64
            MAF Sensor..65
            IMP Sensor..65
            Magnetic Pickup Sensors..65
            CKP Sensor..65
            CMP Sensor..65
            VSS..66
            High-pressure Sensors..66
            DPFDP Sensor..66
            ECBP..66
            ICP..67
            Potentiometer..67
            APP..67
            Switches..68
            DDS..68
            ECL..68
            WIF..68
          Engine Throttle Valve Control System..69
        Exhaust and Engine Brake System..70
          Exhaust Brake..70
          Engine Brake..71
          ECBP..71
          ECB..71
          Brake Pressure Relief Valve..71
          EBP..72
          High-pressure Oil Manifold..72
            Operation..72
            Operation Modes..74
            Coast Mode..74
            Latched Mode..74
            Cruise Mode..74
      Table of Contents..76
        Standard Features..78
          Electronic Governor Control..78
          SAE J1939 Communication Datalink..78
          American Trucking Association (ATA) Datalink..78
          Service Diagnostics..78
          Event Logging System..79
          Electronic Speedometer and Tachometer..79
          Aftertreatment System..79
          Engine Fuel Pressure (EFP) Monitor..79
          Intake Air Heater (IAH)..79
          Fast Idle Advance..79
          Cold Ambient Protection (CAP)..79
          Coolant Temperature Compensation..80
          Engine Crank Inhibit (ECI)..80
        Optional Features..80
          Road Speed Limiting (RSL)..80
          Cruise Control..81
          Traction Control..81
          Exhaust Brake..81
          Engine Brake..81
          Engine Warning Protection System (EWPS)..81
          Idle Shutdown Timer (IST)..81
          IST for California ESS Compliant Engines..82
          Engine Idle Shutdown Timer (IST for Federal ? Optional)..82
          Electronic Fan (EFAN)..82
          Radiator Shutter Enable (RSE)..82
          In Cab Power Take Off (PTO) Control..82
          Remote Accelerator Pedal Position (RAPP)..83
          Change Engine Oil Interval Message..83
          Fuel Heater..83
      Table of Contents..84
        Session Files..86
        Diagnostic Trouble Codes (DTCs)..86
          Suspect Parameter Number (SPN) ..86
          Failure Mode Indicator (FMI)..86
          Active..86
          Previously Active..86
          Intermittent or Inactive Fault Diagnostic Procedure..86
          Overview..86
          Tools Required..87
            Equipment Condition..87
            Test Setup..87
            Test Procedure..87
            Expected Outcome..87
            Follow-On Procedure..87
        ECM Programmable Parameters..87
        Connecting EST with ServiceMaxx? Software to Engine..88
        Obtain Vehicle Health Report..88
          Overview..88
          Tools Required..88
          Equipment Condition..88
          Test Setup..88
          Test Procedure..88
          Expected Outcome..88
          Follow-On Procedure..88
        Record Snapshot of KOEO Data..89
          Overview..89
          Tools Required..89
          Equipment Condition..89
          Test Setup..89
          Test Procedure..89
          Expected Outcome..89
          Follow-On Procedure..89
        Record Snapshot of Engine Running Data..89
          Overview..89
          Tools Required..89
          Equipment Condition..90
          Test Setup..90
          Test Procedure..90
          Expected Outcome..92
          Follow-On Procedure..92
        Service Bay Tests..92
          Key On, Engine Off (KOEO) Tests..92
            KOEO Standard Test..94
            KOEO Injector Test..94
            KOEO Output State Low Test..94
            KOEO Output State High Test..94
            KOEO Output State Intake Air Heater Test..94
            KOEO Continuous Monitor Test..94
            KOEO Aftertreatment Tests ? Doser Actuator Test..95
            Tools..95
            KOEO Aftertreatment Test Pin-point Diagnostics..96
            KOEO Engine Cranking Test..97
            Overview..97
            Tools Required..97
            Equipment Condition..97
            Test Setup..97
            Procedure..98
            Expected Outcome..99
            Follow-on Procedure..99
            Relative Compression Test..99
            Fuel Pressure Adaptation Reset..99
            Overview..99
            Tools Required..99
            Equipment Condition..99
            Test Setup..100
            Test Procedure..100
            Follow-On Procedure..101
          Key On, Engine Running (KOER) Tests..101
          Overview..101
          Tools Required..102
            KOER Standard Test..102
            Test Setup..102
            Test Procedure..102
            Air Management Test..102
            Overview..102
            Tools Required..102
            Equipment Conditions..103
            Test Setup..103
            Test Procedure..103
            Signal Values:..103
            Follow-On Procedure..103
            Graph 1: Air Management System Test (Good)..104
            Colors in the graphs are used for clarity only and will not necessarily match the colors you will see in your ServiceMaxx? sna..104
            Graph Analysis:..104
            Actions:..105
            Graph 2: Air Management System Test (BAD) ..106
            Graph Analysis:..106
            Actions:..106
            Cylinder Cutout Test..108
            Onboard Filter Cleanliness Test..108
        Service Tool Procedures..108
          MAF Sensor Calibrate..108
      Table of Contents..110
        Description..112
          Engine Symptoms Diagnostics Description..112
        Coolant System..112
          Coolant Over Flow..112
          Overview..112
          Possible Causes..112
          Tools..112
          Test Procedure..113
          Coolant Leak to Exhaust/Intake..116
          Symptoms..116
          Tools..116
          Possible Causes..116
            Interstage Cooler Inspection..117
            Procedure..117
            EGR Cooler Inspection..117
            Cooling System Pressure Test..117
            In Vehicle EGR Cooler Test..118
            Equipment Condition..118
            EGR Cooler Test Procedure..119
            Decision..119
            Injector Sleeve Inspection..119
            Procedure..119
            Cylinder Head Leak Test..121
          Coolant in Lube Oil..122
          Symptom..122
          Tools..122
          Possible Causes..122
            Coolant System Inspection..123
            Procedure..123
            Front Cover Inspection..125
          Coolant Over-Temperature..126
          Symptoms..126
          Tools..126
          Possible Causes..126
            Coolant System Inspection..127
            Temperature Sensor Validation Test..129
            Cooling System Operating Pressure Test..129
        Lubrication System..130
          Low Oil Pressure..130
          Symptom..130
          Tools..130
          Possible Causes..130
            Lubrication System Inspection..130
            Oil Pressure Regulator Inspection..132
            Oil and Crankcase Inspection..133
            Oil Pump Inspection..135
            Front Cover Inspection..136
          Lube Oil in Coolant..137
          Symptom..137
          Tools..137
          Possible Causes..137
          Procedure..137
          Fuel in Lube..138
          Symptom..138
          Tools..138
          Possible Causes..138
          Procedure..138
        Engine Run / Start Symptoms..139
          1.0 - Preliminary Vehicle Operational Checkout Procedure..139
          2.0 - Engine Does Not Start Operational Checkout Procedure..142
          Overview..142
          3.0 - Engine Hard to Start Operational Checkout Procedure..145
          Overview..145
          4.0 - Engine Running, Engine Not Under Load Operational Checkout Procedure..149
          Overview..149
          5.0 - Engine Running, Engine Under Load Operational Checkout Procedure..151
          Overview..151
          6.0 - Fuel System Operational Checkout Procedure..153
          Engine Does Not Start Symptoms..153
            2.1 - Engine Cranks Slow or Does Not Crank..153
            Overview..153
            Possible Causes..153
            Test Procedure..154
            2.2 - Engine No Start, Cold Ambient Temperature..157
            Overview..157
            Possible Causes..157
            Test Procedure..157
            2.3 - Engine at Operating Temperature, No Re-Start..159
            Overview..159
            Possible Causes..159
            Test Procedure..159
            2.4 - Engine Never Starts..161
            Overview..161
            Possible Causes..161
            Test Procedure..161
          Engine Hard to Start Symptoms..164
            3.1 - Engine Hard to Start, Cold Ambient Temperature..164
            Overview..164
            Possible Causes..164
            Test Procedure..164
            3.2 - Engine at Operating Temperature, Hard to Re-Start..166
            Overview..166
            Possible Causes..166
            Test Procedure..166
            3.3 - Engine Starts, Then Stalls..168
            Overview..168
            Possible Causes..168
            Test Procedure..168
          Engine Running, Engine Not Under Load Symptoms..169
            4.1 - Rough Idle..169
            Overview..169
            Possible Causes..169
            Test Procedure..170
            4.2 - Engine Unable To Reach Rated Speed (No Load)..172
            Overview..172
            Possible Causes..172
            Test Procedure..172
            4.3 - Popping Noise from Intake..174
            Overview..174
            Possible Causes..174
            Test Procedure..174
          Engine Running, Engine Under Load Symptoms..176
            5.1 - Low Power (Slow Acceleration)..176
            Overview..176
            Possible Causes..176
            Test Procedure..176
            5.2 - Misfire (Stumble / Surge / Runs Rough)..182
            Overview..182
            Possible Causes..182
            Test Procedure..182
            5.3 - Engine Unable to Reach Desired Speed During PTO Operation..186
            Overview..186
            Possible Causes..186
            Test Procedure..186
          Fuel System Symptoms..188
            6.1 - Fuel Delivery Pressure..188
            Overview..188
            Possible Causes..188
            Test Procedure..189
      Table of Contents..194
        Required Test Procedures..196
          Initial Key On Check..196
          Purpose..196
          Tools..196
          Procedure..196
          Visual Inspection..197
          Purpose..197
          Tools..197
            Engine Oil..197
            Fuel Level..197
            Fuel Quality Check..198
            Purpose..198
            Tools..198
            Procedure..198
            Engine Coolant Level..200
            Charge Air Cooler (CAC) System..200
            Batteries and Electrical System Inspection..200
            Overview..200
            Tools Required..200
            Equipment Condition..200
            Inspection Procedure..201
            Expected Outcome..201
            Intake Air..201
            Exhaust System..201
          Electronic Service Tool (EST) with ServiceMaxx? software Connection..202
          Purpose ..202
          Tools..202
          Procedure..202
          Check for DTCs..204
          Purpose..205
          Tools..205
          Procedure..205
          KOER Standard Test..206
          Purpose..206
          Tools..206
          Procedure..206
          Engine Low Idle to High Idle..206
          Purpose..206
          Tools..206
          Procedure..206
          Torque Converter Stall Test (Automatic Transmission Only)..208
          Purpose..208
          Tools..208
          Procedure..208
          KOER Air Management Test..208
          Overview..208
          Tools Required..209
          Equipment Conditions..209
          Test Setup..209
          Test Procedure..210
          Expected Outcome..210
          Follow-On Procedure..210
          Air Management System Graph (GOOD)..210
          Overview..210
          Tools Required..211
          Equipment Condition..211
          Test Setup..211
          Test Procedure..212
          Expected Outcome..212
          Follow-On Procedure..212
          Air Management System Graph (BAD) ..213
          Overview..213
          Tools Required..213
          Equipment Condition..213
          Test Setup..213
          Test Procedure..214
          Expected Outcome..214
          Follow-On Procedure..214
          Turbocharger 2 Wastegate Control (TC2WC)..215
          Purpose..215
          Tools..215
            TC2WC Operational Test..215
            Procedure..215
            TC2WC System Leak Test..217
            TC2WC Valve Mechanical Test..217
            TC2WC Linkage Inspection..217
            Wastegate Actuator Rod Measurement Test..218
          Oil Breather Separator Test..218
          Purpose..218
          Tools..218
          Procedure..218
          Crankcase Pressure Test..219
          Purpose..219
          Tools..219
          Procedure..219
          Relative Compression Test..222
          Purpose..222
          Tools..222
          Procedure..222
          Relative Compression Test Interpretation..222
          Possible Causes..223
          Road Test (Full load, Rated Speed)..225
          Purpose..225
          Tools..225
          0 to 60 MPH Test..226
          Overview..226
          Tools Required..226
          Equipment Condition..226
          Test Setup..226
          Test Procedure..226
          Expected Outcome..229
          Follow-on Procedure..229
        Special Test Procedures..229
          Fuel System..231
            Fuel System Inspection..232
            Overview..232
            Tools Required..232
            Equipment Condition..232
            Inspection Procedure..232
            Expected Outcome..232
            Fuel Delivery Pressure (FDP) Test..232
            Purpose..232
            Tools..232
            Equipment Condition..233
            Test Setup..233
            Test Procedure..234
            Expected Outcome..234
            Follow-On Procedure..234
            Fuel Pressure Measurement..235
            Pump Voltage Measurement..235
            Overview..235
            Tools Required..235
            Equipment Condition..235
            Test Setup..235
            Test Procedure..236
            Expected Outcome..237
            Follow-On Procedure..237
            Clean Fuel Source Test..237
            Overview..237
            Tools Required..238
            Equipment Condition..238
            Test Setup..238
            Test Procedure..239
            Expected Outcome..239
            Follow-on Procedure..239
            Restriction / Aeration Test..240
            Overview..240
            Equipment Condition..240
            Test Setup..240
            Test Procedure..241
            Expected Outcome..241
            Follow-on Procedure..241
            Regulator Test..241
            Overview..241
            Tools Required..241
            Equipment condition..242
            Test Setup..242
            Test Procedure..243
            Expected Outcome..244
            Follow-On Procedure..244
            Strainer/Pump Inspection..244
            Final Pressure Test..244
            Return Line Restriction Test..245
            Fuel Filter Inspection..245
            Fuel Pump Voltage Test..245
            Overview..245
            Tools Required..245
            Equipment Condition..245
            Test Setup..245
            Test Procedure..246
            Expected Outcome..247
            Follow-On Procedure..247
          Exhaust Gas Recirculation (EGR) Valve Operational Test..247
          Overview..247
          Tool Required..248
            Equipment Condition..248
            Test Setup..248
            Test Procedure..248
            Expected Outcome..249
            Follow-On Maintenance..249
          Intake Air Heater (IAH) System Test..249
          Overview..249
          Tools Required..249
          Equipment Condition..249
          Test Setup..249
          Test Procedure..250
          Expected Outcome..250
          Follow-on Procedure..250
          Intake Air Heater (IAH) Current Draw Test..250
          Overview..250
          Tools Required..251
          Equipment Condition..251
          Test Setup..251
          Test Procedure..251
          Expected Outcome..253
           Intake Air Heater (IAH) Relay Test..253
          Overview..253
          Tools Required..253
          Equipment Condition..253
          Test Setup..253
          Test Procedure..254
          Expected Outcome..255
          Follow-On Procedure..255
          Coolant Quality Inspection..255
          Overview..255
          Tools Required..255
          Equipment Condition..255
          Inspection Procedure..255
          Expected Outcome..255
          Cylinder Sleeve Cavitation and Crack Inspection..256
          Overview..256
          Tools Required..256
          Equipment Condition..256
          Inspection Procedure..256
          Expected Outcome..256
          Coolant Heater Assembly Test..256
          Overview..256
          Tools Required..256
          Equipment Condition..256
          Test Setup..256
          Test Procedure..257
          Expected Outcome..258
          Follow-On Procedure..258
          Deaeration Tank Cap Test..258
          Overview..258
          Tools Required..258
          Equipment Condition..258
          Test Setup..258
          Test Procedure..259
          Expected Outcome..260
          Follow-on Procedure..260
          Coolant Over-Flow / Over-Temperature Test..260
          Overview..260
          Tools Required..260
          Equipment Condition..260
          Test Setup..260
          Test Procedure..260
          Expected Outcome..260
          Follow-On Procedure..261
          Air Compressor Overflow Test..261
          Overview..261
          Tools Required..261
          Equipment Condition..261
          Test Setup..261
          Test Procedure..261
          Expected Outcome..261
          Follow-on Procedure..261
          Oil Pan Heater Test..261
          Overview..261
          Tools Required..261
          Equipment Condition..261
          Test Setup..262
          Test Procedure..262
          Expected Outcome..263
          Follow-On Procedure..263
          Connect Cylinder Performance Analyzer (CPA) Tool..264
          Overview..264
          Tools Required..264
            Equipment Condition..264
            Test Setup..265
            Test Procedure..266
            Expected Outcome..267
            Follow-on Procedure..267
          Cylinder Performance Analyzer (CPA) Cold Idle Test..268
          Overview..268
          Tools Required..268
            Equipment Condition..268
            Test Setup..268
            Test Procedure..271
            Expected Outcome..272
            Follow-on Procedure..272
          Cylinder Performance Analyzer (CPA) Signal Check..273
          Overview..273
          Tools Required..273
            Equipment Condition..273
            Test Setup..273
            Test Procedure..275
            Expected Outcome..278
            Follow-On Procedure..278
          Cylinder Performance Analyzer (CPA) Hot Idle Test..278
          Overview..278
          Tools Required..278
            Equipment Condition..278
            Test Setup..279
            Test Procedure..282
            Expected Outcome..283
            Follow-On Procedure..283
          Cylinder Performance Analyzer (CPA) Road Test..284
          Overview..284
          Tools Required..284
            Equipment Condition..284
            Test Setup..284
            Test Procedure..287
            Expected Outcome..288
            Follow-On Procedure..288
          Cylinder Performance Analyzer (CPA) Advanced Testing..289
          Overview..289
          Tools Required..289
            Equipment Condition..289
            Test Setup..289
            Test Procedure..291
            Expected Outcome..293
            Follow-on Procedure..293
          Cylinder Performance Analyzer (CPA) ? High-Pressure Oil Pump (HPOP) Test..294
          Overview..294
          Tools Required..294
            Equipment Condition..294
            Test Setup..294
            Test Procedure..296
            Expected Outcome..297
            Follow-on Procedure..297
      Table of Contents..298
        Description..306
          Section Information..306
        Electronic Control System Diagnostics Form 0000003221..307
          Diagnostic Form Example..307
        Sensor and Actuator Locations..308
          Engine Mounted Components..308
          Vehicle Mounted Components..313
         Diagnostic Procedure Process..313
          Description..313
          Pin-grip Inspection..314
            Diagnostics with EST..314
            Diagnostics without EST..314
            Diagnostics with Step Based Diagnostics..314
          Sensor End Diagnostics (with ServiceMaxx? software)..315
            Sensor End Diagnostics (2-Wire)..315
            Sensor End Diagnostics (3-Wire)..316
          Pin-point Diagnostics (without ServiceMaxx? software)..320
          Actuator Operational Voltage Check ? Output State Test..320
          Harness Resistance Check..321
          Operational Voltage Check..322
        Circuit Diagnostics..323
          ACT PWR Relay (Actuator Power)..323
          Function..323
          ACT PWR Relay Location..323
          Tools..323
            ACT PWR Relay Pin-point Diagnostics..325
            ACT PWR Circuit Operation..327
            Fault Detection / Management..327
          AFTFD (Aftertreatment Fuel Doser)..328
            Overview..329
            Tools..330
            AFTFD Pin-point Diagnostics..330
            SPN 3479..331
            Malfunction Indicator Lamp (MIL) Reaction..331
            Associated Faults..332
            Drive Cycle to Determine Fault Status..332
            SPN 3479 FMI 6 ? AFT Fuel Doser Valve High Side Short Circuit..334
            Malfunction Indicator Lamp (MIL) Reaction..334
            Associated Faults..334
            Drive Cycle to Determine Fault Status..334
          Aftertreatment Fuel Inlet Sensor (AFTIS)..336
            Overview..337
            Tools..337
            AFTFIS Pin-point Diagnostics..338
            SPN 5456 FMI 2 ? AFTFIT Signal Erratic, Intermittent, or Incorrect..339
            Fault Overview..341
            Malfunction Indicator Lamp (MIL) Reaction..341
            Associated Faults..341
            Drive Cycle to Determine Fault Status..341
          Aftertreatment Fuel Pressure 2 Sensor (AFTFP2)..345
          Function..346
          Sensor Location..346
          Tools..346
            AFTFP2 Sensor End Diagnostics..347
            AFTFP2 Pin-point Diagnostics..348
            AFTFP2 Circuit Operation..348
          Aftertreatment Fuel Shutoff Valve (AFTFSV)..349
          Function..349
          Component Location..350
          Tools..350
            AFTFSV Connector End Diagnostics..351
          AFT System (Aftertreatment)..353
            Overview..357
            Tools..358
            Pin-point Diagnostics..359
            SPN 3246 FMI 21 ? DPFOT Signal Drifted LOW..362
            Fault Overview..363
            Malfunction Indicator Lamp (MIL) Reaction..363
            Associated Faults..363
            Drive Cycle to Determine Fault Status..363
            SPN 3251 FMI 0 ? DPFDP Excessively HIGH..366
            Malfunction Indicator Lamp (MIL) Reaction..366
            Associated Faults..366
            Drive Cycle to Determine Fault Status..366
            SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect..370
            Fault Overview..370
            Malfunction Indicator Lamp (MIL) Reaction..370
            Associated Faults..370
            Drive Cycle to Determine Fault Status..370
            Possible Causes..371
            SPN 3251 FMI 14 ? DPFDP sensor pressure hoses reversed..374
            Fault Overview..374
            Malfunction Indicator Lamp (MIL) Reaction..374
            Associated Faults..374
            Drive Cycle to Determine Fault Status..374
            SPN 3936 FMI 8 ? DPF Regenerations Are Occurring Too Frequently..377
            Fault Overview..378
            Malfunction Indicator Lamp (MIL) Reaction..378
            Associated Faults..378
            Drive Cycle to Determine Fault Status..378
            SPN 3936 FMI 20 ? DOC inlet unable to achieve light off temperature..382
            Fault Overview..382
            Malfunction Indicator Lamp (MIL) Reaction..383
            Associated Faults..383
            Drive Cycle to Determine Fault Status..383
            SPN 4766 FMI 10 ? DPF Catalyst System Efficiency Below Threshold..387
            Fault Overview..389
            Malfunction Indicator Lamp (MIL) Reaction..389
            Associated Faults..389
            Drive Cycle to Determine Fault Status..389
            SPN 5319 FMI 31 ? DPF incomplete regeneration..395
            Fault Overview..396
            Malfunction Indicator Lamp (MIL) Reaction..396
            Associated Faults..396
            Drive Cycle to Determine Fault Status..396
          AMS (Air Management System)..400
            Overview..401
            Tools..401
            Pin-point Diagnostics..402
            SPN 2659 FMI 10 - EGR Slow Response Fault..404
            Fault Overview..405
            Lamp Reaction..405
            Associated Faults..405
            Fault Facts..406
            Drive Cycle to Determine Fault Status..406
            Possible Causes..406
            SPN 2659 FMI 14 - EGR System Flow Rate Error During Air Management..410
            Possible Causes..410
            SPN 2659 FMI 20 - EGR High Flow Rate detected..411
            Fault Overview..412
            Lamp Reaction..412
            Associated Faults..412
            Fault Facts..412
            Drive Cycle to Determine Fault Status..412
            Possible Causes..412
            SPN 2659 FMI 21 ? EGR Low Flow Rate Detected..413
            Fault Overview..415
            Fault Detection / Management..415
            Malfunction Indicator Lamp (MIL) Reaction..415
            Associated Faults..415
            Drive Cycle to Determine Fault Status..415
          APP Sensor (Accelerator Pedal Position)..418
          Function..418
          Sensor Location..419
          Tools..419
            APP Sensor End Diagnostics..419
            APP Pin-point Diagnostics..422
            APP Circuit Operation..422
            APP..422
            APP Auto-calibration..422
            Fault Detection / Management..423
            SPN 91 FMI 3 - APP1 signal Out of Range HIGH..423
            Fault Overview..423
            Lamp Reaction..423
            Associated Faults..423
            Fault Facts..423
            Drive Cycle to Determine Fault Status..423
            Possible Causes..423
            Pin-Point Tests (SPN 91 FMI 3)..425
            Tools Required..425
            SPN 91 FMI 4 - APP1 signal Out of Range LOW..427
            Fault Overview..427
            Lamp Reaction..427
            Associated Faults..427
            Fault Facts..427
            Drive Cycle to Determine Fault Status..427
            Possible Causes..427
            Pin-Point Tests (SPN 91 FMI 4)..428
            Tools Required..429
            SPN 2623 FMI 3 - APP2 Signal Out of Range HIGH..432
            Fault Overview..432
            Lamp Reaction..432
            Associated Faults..432
            Fault Facts..432
            Drive Cycle to Determine Fault Status..432
            Possible Causes..432
            Pin-Point Tests (SPN 2623 FMI 3)..433
            Tools Required..433
            SPN 2623 FMI 4 - APP2 Signal Out of Range LOW..435
            Fault Overview..435
            Lamp Reaction..435
            Associated Faults..435
            Fault Facts..435
            Drive Cycle to Determine Fault Status..435
            Possible Causes..435
            Pin-Point Tests (SPN 2623 FMI 4)..436
            Tools Required..437
          ATA Datalink (American Trucking Association)..441
          Function..441
          Location..441
          Tools..441
            ATA Pin-point Diagnostics..442
            ATA Operation..443
            Diagnostic Connector..443
            EGC..443
            Fault Detection / Management..443
            Repair Information..443
          CACOT Sensor (Charge Air Cooler Outlet Temperature)..444
            Overview..445
            Tools..445
            SPN 2630 FMI 2 - CACOT signal erratic, intermittent, or incorrect..447
            Fault Overview..447
            Lamp Reaction..447
            Associated Faults..447
            Fault Facts..448
            Drive Cycle to Determine Fault Status..448
            Possible Causes..448
            SPN 2630 FMI 3 - CACOT Signal Out of Range HIGH..450
            Fault Overview..450
            Lamp Reaction..450
            Associated Faults..450
            Fault Facts..450
            Drive Cycle to Determine Fault Status..450
            Possible Causes..450
            Pin-Point Tests (SPN 2630 FMI 3)..451
            Tools Required..451
            SPN 2630 FMI 4 - CACOT Signal Out of Range LOW..456
            Fault Overview..456
            Lamp Reaction..456
            Associated Faults..456
            Fault Facts..456
            Drive Cycle to Determine Fault Status..456
            Possible Causes..456
            Pin-Point Tests (SPN 2630 FMI 4)..457
            Tools Required..457
            SPN 2630 FMI 16 ? CACOT Under cooling..459
            Fault Overview..460
            Malfunction Indicator Lamp (MIL) Reaction..460
            Associated Faults..460
            Drive Cycle to Determine Fault Status..460
          CCOSS Sensor (Crankcase Oil Seperator Speed)..463
          CCS (Cruise Control System)..464
          Function..465
          Location..465
          Tools..465
            CCS Pin-point Diagnostics ..466
          CKP Sensor (Crankshaft Position)..467
          Function..467
          Sensor Location..467
          Tools..467
            CKP Pin-point Diagnostics..468
            CKP Circuit Operation..469
            Fault / Detection Management..469
          CMP Sensor (Camshaft Position)..470
          Function..470
          Sensor Location..470
          Tools..470
            CMP Pin-point Diagnostics..471
            CMP Circuit Operation..472
            Fault / Detection Management..472
          Cylinder Balance..473
            Cylinder Balance Operation..473
            Cylinder Balance Diagnostics..474
          DCU Power (Doser Control Unit)..475
          Function..476
          Component Location..476
          Tools..476
            DCU PWR Pin-point Diagnostics..476
            SPN 609 FMI 3 - ACM (CES) Switched voltage too HIGH..478
            Fault Overview..478
            Lamp Reaction..478
            Associated Faults..478
            Fault Facts..478
            Drive Cycle to Determine Fault Status..479
            Possible Causes..479
            SPN 609 FMI 4 - ACM (CES) Switched voltage too LOW..480
            Fault Overview..481
            Lamp Reaction..481
            Associated Faults..481
            Fault Facts..481
            Drive Cycle to Determine Fault Status..481
            Possible Causes..481
            Pin-Point Tests (SPN 609 FMI 4)..482
            Tools Required..482
          DCU VREF Circuits..485
          Function..485
          Component Location..485
          Tools..485
            DCU VREF Circuit..486
          DOCIT Sensor (Diesel Oxidation Catalyst Inlet Temperature)..488
            Overview..489
            Tools..489
            DOCIT Pin-point Diagnostics..490
            SPN 4765 FMI 20 ? DOCIT Signal Drifted HIGH..492
            Fault Overview..493
            Malfunction Indicator Lamp (MIL) Reaction..493
            Associated Faults..493
            Drive Cycle to Determine Fault Status..493
            SPN 4765 FMI 21 ? DOCIT Signal Drifted LOW..496
            Fault Overview..497
            Malfunction Indicator Lamp (MIL) Reaction..497
            Associated Faults..497
            Drive Cycle to Determine Fault Status..497
          DPFDP Sensor (Diesel Particulate Filter Differential Pressure)..500
            Function..500
            Sensor Location..500
            Tools..500
            DPFDP Circuit Operation..502
            SPN 3251 FMI 3 ? DPFDP Signal Out of Range HIGH..503
            Fault Overview..503
            Malfunction Indicator Lamp (MIL) Reaction..503
            Associated Faults..503
            Drive Cycle to Determine Fault Status..503
            SPN 3251 FMI 4 ? DOCIT Signal Drifted LOW..506
            Fault Overview..506
            Malfunction Indicator Lamp (MIL) Reaction..506
            Associated Faults..506
            Drive Cycle to Determine Fault Status..506
          DPFIT Sensor (Diesel Particulate Filter Inlet Temperature)..509
            Overview..510
            Tools..510
            Pin-point Diagnostics..511
            SPN 3242 FMI 20 ? DPFIT Signal Drifted High..512
            Fault Overview..514
            Malfunction Indicator Lamp (MIL) Reaction..514
            Associated Faults..514
            Drive Cycle to Determine Fault Status..514
            SPN 3242 FMI 21 ? DPFIT Signal Drifted Low..518
            Fault Overview..519
            Malfunction Indicator Lamp (MIL) Reaction..519
            Associated Faults..519
            Drive Cycle to Determine Fault Status..519
          DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)..522
          Function..522
          Sensor Location..523
          Tools..523
            DPFOT Sensor End Diagnostics..523
            DPFOT Pin-point Diagnostics..525
            DPFOT Circuit Operation..525
          EBP Sensor (Exhaust Back Pressure)..526
          Function..526
          Sensor Location..526
          Tools..526
            EBP Sensor End Diagnostics..528
            EBP Pin-point Diagnostics..529
            EBP Circuit Operation..530
            Fault Detection / Management..530
            SPN 1209 FMI 2 - EBP Signal erratic, intermittent, or incorrect..531
            Fault Overview..531
            Lamp Reaction..531
            Associated Faults..531
            Fault Facts..531
            Drive Cycle to Determine Fault Status..531
            Possible Causes..531
            SPN 1209 FMI 3 - EBP Signal Out of Range HIGH..532
            Fault Overview..532
            Lamp Reaction..532
            Associated Faults..532
            Fault Facts..533
            Drive Cycle to Determine Fault Status..533
            Possible Causes..533
            Pin-Point Tests (SPN 1209 FMI 3)..534
            Tools Required..534
            SPN 1209 FMI 4 - EBP Signal Out of Range LOW..536
            Fault Overview..536
            Lamp Reaction..536
            Associated Faults..536
            Fault Facts..536
            Drive Cycle to Determine Fault Status..536
            Possible Causes..536
            Pin-Point Tests (SPN 1209 FMI 4)..537
            Tools Required..537
          EBPV (Exhaust Back Pressure Valve)..542
          Function..543
          Location..543
          Tools..543
            EBPV Pin-point Diagnostics..544
            EBPV Circuit Operation..545
            Fault Detection / Management..545
            SPN 5541 FMI 2 - TC1TOP Signal erratic, intermittent, or incorrect..545
            Function..545
            Lamp Reaction..546
            Associated Faults..546
            Fault Facts..546
            Drive Cycle to Determine Fault Status..546
            Possible Causes..546
            SPN 5541 FMI 3 ? TC1TOP signal Out of Range HIGH..547
            Malfunction Indicator Lamp (MIL) Reaction..547
            Associated Faults..547
            Drive Cycle to Determine Fault Status..547
            SPN 5541..549
            Malfunction Indicator Lamp (MIL) Reaction..549
            Associated Faults..549
            Drive Cycle to Determine Fault Status..549
            SPN 5543..551
            Malfunction Indicator Lamp (MIL) Reaction..551
            Associated Faults..551
            Drive Cycle to Determine Fault Status..551
            SPN 5543..553
            Malfunction Indicator Lamp (MIL) Reaction..553
            Associated Faults..553
            Drive Cycle to Determine Fault Status..553
            SPN 5543 FMI 5 - EBPC open load / circuit..555
            Fault Overview..555
            Lamp Reaction..555
            Associated Faults..555
            Fault Facts..555
            Drive Cycle to Determine Fault Status..555
            Possible Causes..555
            Pin-Point Tests (SPN 5543 FMI 5)..556
            Tools Required..556
          ECB Valve (Engine Compression Brake)..559
          Function..559
          Valve Location..560
          Tools..560
            ECB Pin-point Diagnostics..560
            ECB Circuit Operation..562
            Fault Detection / Management..562
          ECBP Sensor (Engine Compression Brake Pressure)..563
          Function..563
          Sensor Location..564
          Tools..565
            ECBP Sensor End Diagnostics..565
            ECBP Pin-point Diagnostics..566
            ECBP Circuit Operation..567
            Fault Detection / Management..567
            SPN 4287 FMI 0 - ECBP above desired level..568
            Fault Overview..568
            Lamp Reaction..568
            Associated Faults..568
            Fault Facts..568
            Drive Cycle to Determine Fault Status..568
            Possible Causes..568
            SPN 4287 FMI 1 - ECPB below desired level..570
            Fault Overview..570
            Lamp Reaction..570
            Associated Faults..570
            Fault Facts..570
            Drive Cycle to Determine Fault Status..570
            Possible Causes..570
            SPN 4287 FMI 4 - ECBP signal Out of Range LOW..571
            Fault Overview..571
            Lamp Reaction..572
            Associated Faults..572
            Fault Facts..572
            Drive Cycle to Determine Fault Status..572
            Possible Causes..572
            Tools Required..574
          ECI Circuit (Engine Crank Inhibit)..577
          Function..577
          Location..577
          Tools..577
            ECI Circuit Diagnostics..579
            ECI Circuit Operation..582
            DDS Circuit..582
            Ignition Switch..582
            ECI Circuit..582
            Engine Control Module (ECM)..582
            Starter Relay..582
            Clutch Switch..582
            Neutral Switch..582
            WTEC MD with Auto Neutral..582
            Fault Detection / Management..583
          ECL Switch (Engine Coolant Level)..584
          Function..584
          Location..584
          Tools..584
            ECL Switch Pin-point Diagnostics..585
            ECL Circuit Operation..586
            Fault Detection / Management..586
          ECM PWR (Engine Control Module Power)..587
          Function..587
          ECM Location..588
          Tools..588
            ECM PWR Pin-point Diagnostics..588
            ECM PWR Circuit Operation..591
            Fault Detection / Management..591
            SPN 158 FMI 15 - ECM Switched voltage too HIGH..592
            Fault Overview..592
            Lamp Reaction..592
            Associated Faults..592
            Fault Facts..592
            Drive Cycle to Determine Fault Status..592
            Possible Causes..592
          Engine Idle Speed..594
          Overview of Engine Sensor ..594
            SPN 188 FMI 0 - Engine unable to achieve desired idle speed (too high)..594
            Fault Overview..594
            Lamp Reaction..594
            Associated Faults..594
            Fault Facts..594
            Drive Cycle to Determine Fault Status..594
            Possible Causes..594
            SPN 188 FMI 1 - Engine Unable to Achieve Desired Idle Speed (Too Low)..596
            Fault Overview..596
            Lamp Reaction..596
            Associated Faults..596
            Fault Facts..596
            Drive Cycle to Determine Fault Status..596
            Possible Causes..596
          Transmission Output Shaft Speed (TOSS)..599
            Overview..599
            Tools..600
            Pin-point Diagnostics..601
            SPN 191..602
            Fault Overview..602
            Malfunction Indicator Lamp (MIL) Reaction..602
            Associated Faults..602
            Drive Cycle to Determine Fault Status..602
            SPN 191..605
            Fault Overview..605
            Malfunction Indicator Lamp (MIL) Reaction..605
            Associated Faults..605
            Drive Cycle to Determine Fault Status..605
          Torque Limitation..608
            Tools..608
            SPN 518..609
            Fault Overview..609
            Malfunction Indicator Lamp (MIL) Reaction..609
            Associated Faults..609
            Drive Cycle to Determine Fault Status..609
          Brake Switch..612
            Overview..612
            Tools..613
            Pin-point Diagnostics..614
            SPN 597..616
            Malfunction Indicator Lamp (MIL) Reaction..616
            Associated Faults..616
            Drive Cycle to Determine Fault Status..616
            SPN 597..618
            Malfunction Indicator Lamp (MIL) Reaction..618
            Associated Faults..618
            Drive Cycle to Determine Fault Status..618
          ECM Self Diagnostics (Engine Control Module)..621
            Overview..621
            Tools..621
            Pin-point ECM Self Diagnostic Fault..622
            SPN 108 FMI 2 - BARO Signal Erratic, Intermittent or Incorrect..623
            Fault Overview..623
            Lamp Reaction..623
            Associated Faults..623
            Fault Facts..623
            Drive Cycles..623
            Possible Cause..623
            SPN 108 FMI 3 - BARO signal Out of Range HIGH..624
            Fault Overview..624
            Lamp Reaction..624
            Associated Faults..624
            Fault Facts..624
            Drive Cycle to Determine Fault Status..624
            Possible Causes..624
            SPN 108 FMI 4 - BARO signal Out of Range LOW..624
            Fault Overview..625
            Lamp Reaction..625
            Associated Faults..625
            Fault Facts..625
            Drive Cycle to Determine Fault Status..625
            Possible Causes..625
            SPN 628 FMI 12 - ECM Memory Error..625
            Fault Overview..625
            Lamp Reaction..625
            Associated Faults..625
            Fault Facts..626
            Drive Cycle to Determine Fault Status..626
            Possible Causes..626
            SPN 629 FMI 0 - ECM Error - CPU Load Excessively HIGH..626
            Fault Overview..626
            Associated Faults..626
            Fault Facts..626
            Drive Cycle to Determine Fault Status..626
            Possible Causes..626
            SPN 629 FMI 8 - ECM Error - Engine Off Timer fault..628
            Fault Overview..628
            Lamp Reaction..628
            Associated Faults..628
            Fault Facts..628
            Drive Cycle to Determine Fault Status..628
            Possible Causes..628
            SPN 629 FMI 12 - ECM Internal chip Error..630
            Fault Overview..630
            Lamp Reaction..630
            Associated Faults..630
            Fault Facts..630
            Drive Cycle to Determine Fault Status..631
            Possible Causes..631
            SPN 1387..632
            Fault Overview..633
            Malfunction Indicator Lamp (MIL) Reaction..633
            Associated Faults..633
            Drive Cycle to Determine Fault Status..633
          ECT1 Sensor (Engine Coolant Temperature 1)..636
            Overview..637
            Tools..638
            Pin-point Diagnostics..639
            SPN 110 FMI 2 - ECT1 signal erratic, intermittent, or incorrect..641
            Fault Overview..641
            Lamp Reaction..641
            Associated Faults..642
            Fault Facts..642
            Drive Cycle to Determine Fault Status..642
            Possible Causes..642
            SPN 110 FMI 3 - ECT1 Signal Out of Range HIGH..643
            Fault Overview..643
            Lamp Reaction..643
            Associated Faults..643
            Fault Facts..643
            Drive Cycle to Determine Fault Status..643
            Possible Causes..643
            Pin-Point Tests (SPN 110 FMI 3)..644
            Tools Required..644
            SPN 110 FMI 4 - ECT1 signal Out of Range LOW..649
            Fault Overview..649
            Lamp Reaction..649
            Associated Faults..649
            Fault Facts..649
            Drive Cycle to Determine Fault Status..649
            Possible Causes..649
            Pin-Point Tests (SPN 110 FMI 4)..650
            Tools Required..650
            SPN 110 FMI 7 - ECT1 and EOT Temperature Conflict..651
            Malfunction Indicator Lamp (MIL) Reaction..651
            Associated Faults..651
            Drive Cycle to Determine Fault Status..651
            SPN 110 FMI 17 - Engine Coolant System below OBD monitoring temperature..655
            Fault Overview..656
            Lamp Reaction..656
            Associated Faults..656
            Fault Facts..656
            Drive Cycle to Determine Fault Status..656
            Possible Causes..656
            Pin-Point Tests (SPN 110 FMI 17)..657
            Tools Required..657
            SPN 110 FMI 18 - Engine Coolant System below closed loop minimum Temperature..659
            Fault Overview..660
            Lamp Reaction..660
            Associated Faults..660
            Fault Facts..660
            Drive Cycle to Determine Fault Status..660
            Possible Causes..660
            Pin-Point Tests (SPN 110 FMI 17)..661
            Tools Required..661
            SPN 1659 FMI 20 - ECT1 below expected: Check Thermostat..663
            Fault Overview..664
            Lamp Reaction..664
            Associated Faults..664
            Fault Facts..664
            Drive Cycle to Determine Fault Status..664
            Possible Causes..664
            Pin-Point Tests (SPN 1659 FMI 20)..665
            Tools Required..665
          EFC (Engine Fan Control)..667
          Function..667
          Location..667
          Tools..667
            EFC Circuit Diagnostics..669
            EFC Circuit Operation..671
            EFC Programmable Parameters..671
            Fault Detection / Management..671
          EFP (Electric Fuel Pump)..672
          Function..672
          EFP Location..673
          Tools..673
            EFP Pin-point Diagnostics..673
            EFP Circuit Operation..676
            Fault Detection / Management..676
            SPN 94 FMI 0 - Fuel Delivery Pressure above Critical..676
            Fault Overview..676
            Lamp Reaction..676
            Associated Faults..676
            Fault Facts..677
            Drive Cycle to Determine Fault Status..677
            Possible Causes..677
            SPN 94 FMI 1 - Fuel Delivery Pressure below Critical..677
            Fault Overview..677
            Lamp Reaction..678
            Associated Faults..678
            Fault Facts..678
            Drive Cycle to Determine Fault Status..678
            Possible Causes..678
            SPN 931 FMI 3 - EFP short to PWR..679
            Fault Overview..679
            Lamp Reaction..679
            Associated Faults..679
            Fault Facts..679
            Drive Cycle to Determine Fault Status..679
            Possible Causes..679
            SPN 931 FMI 4 - EFP open load / circuit or short to GND..680
            Fault Overview..680
            Lamp Reaction..680
            Associated Faults..680
            Fault Facts..680
            Drive Cycle to Determine Fault Status..680
            Possible Causes..680
          EGR Actuator (Exhaust Gas Recirculation)..682
            Overview..685
            Tools..685
            Pin-point Diagnostics With ServiceMaxx? Software..686
            Verification Testing..687
            SPN 27 FMI 0 - EGRP fault: over temperature..688
            Fault Overview..688
            Lamp Reaction..688
            Associated Faults..688
            Fault Facts..688
            Drive Cycle to Determine Fault Status..688
            Possible Causes..688
            SPN 27 FMI 14 - EGR internal circuit failure..689
            Fault Overview..689
            Lamp Reaction..689
            Associated Faults..689
            Fault Facts..689
            Drive Cycle to Determine Fault Status..689
            Possible Causes..689
            SPN 2791 FMI 2 - EGR valve communication fault..690
            Fault Overview..690
            Lamp Reaction..690
            Associated Faults..690
            Fault Facts..690
            Drive Cycle to Determine Fault Status..690
            Possible Causes..691
            Pin-Point Tests (SPN 2791 FMI 2)..692
            Tools Required..692
            SPN 2791 FMI 3 - EGRC short to PWR..699
            Fault Overview..699
            Lamp Reaction..699
            Associated Faults..699
            Fault Facts..699
            Drive Cycle to Determine Fault Status..699
            Possible Causes..699
            SPN 2791 FMI 4 - EGRC short to GND..700
            Fault Overview..700
            Lamp Reaction..700
            Associated Faults..700
            Fault Facts..700
            Drive Cycle to Determine Fault Status..700
            Possible Causes..700
            Pin-Point Tests (SPN 2791 FMI 4)..701
            Tools Required..701
            SPN 2791 FMI 7 - EGR Valve unable to achieve commanded position..703
            Fault Overview..703
            Lamp Reaction..703
            Associated Faults..703
            Fault Facts..703
            Drive Cycle to Determine Fault Status..703
            Possible Causes..703
            SPN 2791 FMI 8 - EGR valve not receiving ECM PWM signal..705
            Fault Overview..705
            Lamp Reaction..705
            Associated Faults..705
            Fault Facts..705
            Drive Cycle to Determine Fault Status..705
            Possible Causes..705
            SPN 2791 FMI 14 - EGR valve Initialization Fault..707
            Fault Overview..707
            Lamp Reaction..707
            Associated Fault..707
            Fault Facts..707
            Drive Cycle to Determine Fault Status..707
            Possible Causes..707
          EGR Cooler (Exhaust Gas Recirculation)..709
            Tools..710
            SPN 4752..711
            Fault Overview..713
            Malfunction Indicator Lamp (MIL) Reaction..713
            Associated Faults..713
            Drive Cycle to Determine Fault Status..713
          EGT Sensor (Exhaust Gas Temperature)..715
          Overview of EGT Sensor Group..716
          Overview..716
            SPN 173 FMI 2 - EGT signal erratic, intermittent, or incorrect..717
            Fault Overview..717
            Lamp Reaction..717
            Associated Faults..717
            Fault Facts..717
            Drive Cycle to Determine Fault Status..717
            Possible Causes..717
            SPN 173 FMI 3 - EGT Signal Out of Range HIGH..718
            Fault Overview..718
            Lamp Reaction..718
            Associated Faults..718
            Fault Facts..719
            Drive Cycle to Determine Fault Status..719
            Possible Causes..719
            Pin-Point Tests (SPN 173 FMI 3)..719
            Tools Required..720
            SPN 173 FMI 4 - EGT Signal Out of Range LOW..724
            Fault Overview..724
            Lamp Reaction..724
            Associated Faults..724
            Fault Facts..724
            Drive Cycle to Determine Fault Status..724
            Possible Causes..725
            Pin-Point Tests (SPN 173 FMI 4)..725
            Tools Required..725
          Engine Idle Torque..727
            Tools..727
            SPN 5395 FMI 0 Engine unable to achieve desired idle torque (too high)..728
            Fault Overview..728
            Time Requirement..728
            Lamp Reaction..728
            Associated Faults..728
            Fault Facts..728
            Drive Cycle to Determine Fault Status..729
            Possible Causes..729
            SPN 5395 FMI 1 Engine unable to achieve desired idle torque (too low)..731
            Fault Overview..731
            Lamp Reaction..731
            Associated Faults..731
            Fault Facts..731
            Drive Cycle to Determine Fault Status..731
            Possible Causes..731
          Engine Misfire..734
            Tools..736
            SPN 1322 ? 1328..737
            Fault Overview..740
            Malfunction Indicator Lamp (MIL) Reaction..740
            Associated Faults..740
            Drive Cycle to Determine Fault Status..740
          EOP Sensor (Engine Oil Pressure)..744
          Overview of EOP Sensor Group..744
          Overview..744
            SPN 100 FMI 3 - EOP signal Out of Range HIGH..745
            Fault Overview..745
            Lamp Reaction..745
            Associated Faults..745
            Fault Facts..745
            Drive Cycle to Determine Fault Status..745
            Possible Causes..745
            Pin-Point Tests (SPN 100 FMI 3)..746
            Tools Required..746
            SPN 100 FMI 4 - EOP Signal Out of Range LOW..748
            Fault Overview..748
            Lamp Reaction..748
            Associated Faults..748
            Fault Facts..748
            Drive Cycle to Determine Fault Status..748
            Possible Causes..748
            Pin-Point Tests (SPN 100 FMI 4)..749
            Tools Required..749
          EOT Sensor (Engine Oil Temperature)..754
            Overview..755
            Tools..755
            Pin-point Diagnostics..756
            SPN 175 FMI 2 - EOT signal erratic, intermittent, or incorrect..758
            Fault Overview..758
            Lamp Reaction..758
            Associated Faults..759
            Fault Facts..759
            Drive Cycle to Determine Fault Status..759
            Possible Causes..759
            SPN 175 FMI 3 - EOT signal Out of Range HIGH..760
            Fault Overview..760
            Time Requirements..760
            Lamp Reaction..760
            Associated Faults..760
            Fault Facts..760
            Drive Cycles..760
            Possible Causes..760
            Pin-Point Tests (SPN 175 FMI 3)..762
            Engine Oil Temperature (EOT) Sensor Circuit..762
            Tools Required..762
            SPN 175 FMI 4 - EOT signal Out of Range LOW..766
            Fault Overview..766
            Lamp Reaction..766
            Associated Faults..766
            Fault Facts..766
            Drive Cycles..766
            Possible Causes..766
            Pin-Point Tests (SPN 175 FMI 4)..767
            Tools Required..767
            SPN 175..768
            Malfunction Indicator Lamp (MIL) Reaction..768
            Associated Faults..768
            Drive Cycle to Determine Fault Status..768
          ETV (Engine Throttle Valve)..771
            Overview..772
            Tools..773
            Pin-point Diagnostics with ServiceMaxx? Software..774
            ETV Actuator Pin-point Diagnostics..775
            SPN 51..777
            Fault Overview..777
            Malfunction Indicator Lamp (MIL) Reaction..777
            Associated Faults..777
            Drive Cycle to Determine Fault Status..777
            SPN 51 FMI 3 - ETP signal Out of Range HIGH..780
            Fault Overview..780
            Lamp Reaction..780
            Associated Faults..780
            Drive Cycles..780
            Possible Causes..780
            SPN 51 FMI 4 - ETP signal Out of Range LOW..782
            Fault Overview..782
            Lamp Reaction..782
            Associated Faults..782
            Fault Facts..782
            Drive Cycle to Determine Fault Status..782
            Possible Causes..782
            Pin-Point Tests (SPN 51 FMI 4)..783
            Tools Required..783
            SPN 51..787
            Malfunction Indicator Lamp (MIL) Reaction..787
            Associated Faults..787
            Drive Cycle to Determine Fault Status..787
            SPN 51 FMI 7 - ETP does not agree with commanded position..789
            Fault Overview..789
            Lamp Reaction..789
            Associated Faults..789
            Fault Facts..789
            Drive Cycle to Determine Fault Status..789
            Possible Causes..789
            Pin-Point Tests (SPN 51 FMI 7)..790
            Tools Required..790
            SPN 3464..792
            Fault Overview..792
            Malfunction Indicator Lamp (MIL) Reaction..792
            Associated Faults..792
            Drive Cycle to Determine Fault Status..792
          EWPS (Engine Warning and Protection System)..795
          Function..797
            EWPS Programmable Parameters..798
            SPN 100 FMI 1 - Engine Oil System below Critical Pressure..801
            Associated Faults..801
            Fault Facts..801
            Drive Cycle to Determine Fault Status..801
            Possible Causes..801
            SPN 100 FMI 18 - Engine Oil System below Warning Pressure..802
            Associated Faults..802
            Fault Facts..802
            Drive Cycle to Determine Fault Status..802
            Possible Causes..802
            SPN 110 FMI 15 - Engine Coolant System above Warning Temperature..803
            Fault Overview..803
            Lamp Reaction..803
            Associated Faults..803
            Fault Facts..803
            Drive Cycle to Determine Fault Status..803
            Possible Causes..803
            SPN 110 FMI 16 - Engine Coolant System Above OBD Maximum Temperature..804
            Fault Overview..805
            Lamp Reaction..805
            Associated Faults..805
            Fault Facts..805
            Drive Cycle to Determine Fault Status..805
            Possible Causes..805
            SPN 111 FMI 1 - ECL below Warning/Critical Level..806
            Fault Overview..806
            Lamp Reaction..806
            Associated Faults..806
            Fault Facts..806
            Drive Cycle to Determine Fault Status..806
            Possible Causes..806
            SPN 190 FMI 0 - Engine overspeed - Most Severe Level..807
            Fault Overview..807
            Lamp Reaction..807
            Associated Faults..807
            Fault Facts..807
            Drive Cycle to Determine Fault Status..807
            Possible Causes..807
          FDP Sensor (Fuel Delivery Pressure) ..810
            Overview..811
            Tools..812
            Pin-point Diagnostics..812
            SPN 94..814
            Fault Overview..814
            Malfunction Indicator Lamp (MIL) Reaction..814
            Associated Faults..814
            Drive Cycle to Determine Fault Status..814
            SPN 94 FMI 3 - FDP signal Out of Range HIGH..817
            Fault Overview..817
            Lamp Reaction..817
            Associated Faults..817
            Fault Facts..817
            Drive Cycle..817
            Possible Causes..817
            Pin-Point Tests (SPN 94 FMI 3)..818
            Tools Required..818
            SPN 94 FMI 4 - FDP signal Out of Range LOW..820
            Fault Overview..820
            Lamp Reaction..820
            Associated Faults..820
            Fault Facts..820
            Drive Cycle ..820
            Possible Causes..820
            Pin-Point Tests (SPN 94 FMI 4)..821
            Tools Required..822
            SPN 94 FMI 17 - Fuel Delivery Pressure below minimum..826
            Fault Overview..826
            Lamp Reaction..826
            Associated Faults..826
            Fault Facts..826
            Drive Cycles..826
            Possible Causes..826
            SPN 94 FMI 18 - Fuel Delivery Pressure below minimum..827
            Fault Overview..827
            Lamp Reaction..827
            Associated Faults..827
            Fault Facts..827
            Drive Cycles..827
            Possible Causes..827
          IAH System (Intake Air Heater)..829
          Function..829
          Component Location..830
          Tools..830
            IAH Pin-point Diagnostics..831
            IAH Circuit Operation..833
            SPN / FMIs..833
            SPN 729 FMI 5 - IAHC open load / circuit..834
            Fault Overview..834
            Lamp Reaction..834
            Associated Faults..834
            Fault Facts..834
            Drive Cycle to Determine Fault Status..834
            Possible Causes..834
            Pin-Point Tests (SPN 729 FMI 5)..835
            Tools Required..835
          ICP Sensor (Injection Control Pressure)..839
            Overview of ICP Sensor Group..840
            Overview..840
            SPN 164 FMI 0 - ICP above KOEO Specification..840
            Fault Overview..840
            Lamp Reaction..840
            Associated Faults..841
            Fault Facts..841
            Drive Cycle to Determine Fault Status..841
            Possible Causes..841
            SPN 164 FMI 3 - ICP signal Out of Range HIGH..841
            Fault Overview..841
            Lamp Reaction..842
            Associated Faults..842
            Fault Facts..842
            Drive Cycle to Determine Fault Status..842
            Possible Causes..842
            Pin-Point Tests (SPN 164 FMI 3)..843
            Tools Required..843
            SPN 164 FMI 4 - ICP signal Out of Range LOW..851
            Fault Overview..851
            Lamp Reaction..851
            Associated Faults..851
            Fault Facts..851
            Drive Cycle to Determine Fault Status..851
            Possible Causes..851
            Pin-Point Tests (SPN 164 FMI 4)..852
            Tools Required..852
          ICP (Injection Control Pressure) System..856
            Overview..858
            Tools..858
            ICP System Pin-point Diagnostics..859
            SPN 164 FMI 1 - ICP Unable to Build During Engine Cranking..861
            Fault Overview..861
            Lamp Reaction..861
            Associated Faults..861
            Fault Facts..861
            Drive Cycle to Determine Fault Status..861
            Possible Causes..861
            SPN 164..863
            Malfunction Indicator Lamp (MIL) Reaction..863
            Associated Faults..863
            Drive Cycle to Determine Fault Status..863
            SPN 164 FMI 15 - ICP too high during test..865
            Fault Overview..865
            Lamp Reaction..865
            Associated Faults..865
            Fault Facts..865
            Drive Cycle to Determine Fault Status..865
            Possible Causes..865
            SPN 164 FMI 16 - ICP above desired level..866
            Fault Overview..867
            Lamp Reaction..867
            Associated Faults..868
            Fault Facts..868
            Drive Cycle to Determine Fault Status..868
            Possible Causes..868
            SPN 164 FMI 17 - ICP unable to build during test..871
            Fault Overview..871
            Lamp Reaction..871
            Associated Faults..871
            Fault Facts..871
            Drive Cycle to Determine Fault Status..871
            Possible Causes..871
            SPN 164 FMI 18 - ICP below desired level..875
            Fault Overview..876
            Lamp Reaction..876
            Associated Faults..876
            Fault Facts..876
            Drive Cycle to Determine Fault Status..876
            Possible Causes..876
            SPN 164..877
            Malfunction Indicator Lamp (MIL) Reaction..877
            Associated Faults..877
            Drive Cycle to Determine Fault Status..878
            SPN 164..881
            Malfunction Indicator Lamp (MIL) Reaction..881
            Associated Faults..881
            Drive Cycle to Determine Fault Status..881
            SPN 3055 FMI 2 - ICP / IPR Adaptation In-Range Fault..883
            Fault Overview..883
            Lamp Reaction..883
            Associated Faults..883
            Fault Facts..883
            Drive Cycle to Determine Fault Status..883
            Possible Causes..883
          IMP Sensor (Intake Manifold Pressure)..887
            Overview..891
            Tools..891
            Pin-point Diagnostics..892
            SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect..894
            Fault Overview..894
            Time Requirements..894
            Lamp Reaction..894
            Associated Faults..894
            Fault Facts..895
            Drive Cycle to Determine Fault Status..895
            Possible Causes..895
            SPN 102 FMI 3 - IMP signal Out of Range HIGH..895
            Fault Overview..895
            Lamp Reaction..896
            Associated Faults..896
            Fault Facts..896
            Drive Cycle to Determine Fault Status..896
            Possible Causes..896
            Pin-Point Tests (SPN 102 FMI 3)..897
            Tools Required..897
            SPN 102 FMI 4 - IMP signal Out of Range LOW..898
            Fault Overview..898
            Lamp Reaction..898
            Associated Faults..898
            Fault Facts..898
            Drive Cycle to Determine Fault Status..899
            Possible Causes..899
            Pin-Point Tests (SPN 102 FMI 4)..899
            Tools Required..900
            SPN 102..904
            Fault Overview..906
            Fault Detection / Management..906
            Malfunction Indicator Lamp (MIL) Reaction..906
            Associated Faults..906
            Drive Cycle to Determine Fault Status..906
            SPN 102..910
            Fault Overview..911
            Fault Detection / Management..911
            Malfunction Indicator Lamp (MIL) Reaction..911
            Associated Faults..911
            Drive Cycle to Determine Fault Status..911
            SPN 102..915
            Fault Overview..917
            Fault Detection / Management..917
            Malfunction Indicator Lamp (MIL) Reaction..917
            Associated Faults..917
            Drive Cycle to Determine Fault Status..917
          IMT Sensor (Intake Manifold Temperature)..922
          Overview of IMT Sensor Group..922
          Overview..922
            SPN 105 FMI 2 - IMT signal Erratic, Intermittent, or Incorrect..923
            Fault Overview..923
            Lamp Reaction..923
            Associated Faults..924
            Fault Facts..924
            Drive Cycle to Determine Fault Status..924
            Possible Causes..924
            SPN 105 FMI 3 - IMT signal Out of Range HIGH..925
            Fault Overview..925
            Lamp Reaction..925
            Associated Faults..925
            Fault Facts..925
            Drive Cycle to Determine Fault Status..925
            Possible Causes..925
            Pin-Point Tests (SPN 105 FMI 3)..926
            Tools Required..926
            SPN 105 FMI 4 - IMT signal Out of Range LOW..930
            Fault Overview..930
            Lamp Reaction..930
            Associated Faults..930
            Fault Facts..930
            Drive Cycle to Determine Fault Status..930
            Possible Causes..930
            Pin-Point Tests (SPN 105 FMI 4)..931
            Tools Required..931
          Injector Circuits..933
          Overview..935
          Tools..936
            Pin-point Diagnostics With ServiceMaxx? Software..938
            Injector 1 Checks..938
            Injector 2 Checks..940
            Injector 3 Checks..942
            Injector 4 Checks..944
            Injector 5 Checks..946
            Injector 6 Checks..948
            Injector Circuit Operation..950
            High Side Drive Output..950
            Low Side Drive Return..950
            Fault Detection / Management..950
            KOEO Injector Test..950
            SPN 651 ? 656..951
            Fault Overview..951
            Malfunction Indicator Lamp (MIL) Reaction..951
            Associated Faults..952
            Drive Cycle to Determine Fault Status..952
            SPN 651 ? 656..954
            Fault Overview..957
            Malfunction Indicator Lamp (MIL) Reaction..957
            Associated Faults..957
            Drive Cycle to Determine Fault Status..957
            SPN 2797 FMI 6 - Injector Control Group 1 Open coil - Short Circuit (INJ 1, 2, 3)..961
            Fault Overview..961
            Lamp Reaction..961
            Associated Faults..961
            Fault Facts..961
            Drive Cycle to Determine Fault Status..961
            Possible Causes..961
            Pin-Point Tests (SPN 2797 FMI 6)..963
            Tools Required..963
            SPN 2798 FMI 6 - Injector Control Group 2 Open coil - Short Circuit (INJ 4, 5, 6)..1005
            Fault Overview..1005
            Lamp Reaction..1005
            Associated Faults..1005
            Fault Facts..1005
            Drive Cycle to Determine Fault Status..1005
            Possible Causes..1005
            Pin-Point Tests (SPN 2798 FMI 6)..1007
            Tools Required..1007
          Injector Performance..1049
            Tools..1050
            SPN 4257..1051
            Fault Overview..1051
            Malfunction Indicator Lamp (MIL) Reaction..1051
            Associated Faults..1051
            Drive Cycle to Determine Fault Status..1051
            SPN 4257..1052
            Fault Overview..1054
            Malfunction Indicator Lamp (MIL) Reaction..1054
            Associated Faults..1054
            Drive Cycle to Determine Fault Status..1054
            SPN 4257..1061
            Fault Overview..1063
            Malfunction Indicator Lamp (MIL) Reaction..1063
            Associated Faults..1063
            Drive Cycle to Determine Fault Status..1063
          IPR (Injection Pressure Regulator)..1066
            Overview..1066
            Tools..1067
            Pin-point Diagnostics..1068
            SPN 679 FMI 3 - IPR Short to PWR..1070
            Fault Overview..1070
            Lamp Reaction..1070
            Associated Faults..1070
            Fault Facts..1070
            Drive Cycle to Determine Fault Status..1070
            Possible Causes..1070
            Pin-Point Tests (SPN 679 FMI3)..1071
            Tools Required..1071
            SPN 679 FMI 4 - IPR Open or short to GND..1073
            Fault Overview..1073
            Lamp Reaction..1073
            Associated Faults..1073
            Fault Facts..1073
            Drive Cycle to Determine Fault Status..1073
            Possible Causes..1073
            Pin-Point Tests (SPN 679 FMI 4)..1074
            Tools Required..1074
            SPN 679..1078
            Fault Overview..1078
            Malfunction Indicator Lamp (MIL) Reaction..1078
            Associated Faults..1078
            Drive Cycle to Determine Fault Status..1078
          SPN 593 FMI 31 - Engine Stopped by IST..1080
          Function..1080
          Tools..1080
          Idle Shutdown Warning..1080
          Engine Idle Shutdown Timer (IST) for California ESS Compliant Engines..1080
          CARB Idle Shutdown Timer (IST) Conditions..1081
          Idle Shutdown Timer (IST) (Federal ? Optional)..1081
          Federal IST Conditions..1081
          Common Enable Conditions for All Federal IST Options..1081
          Federal IST Mode 1: PTO Operation Option Enable Conditions..1082
          Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions..1082
          Federal IST Mode 3: Tamper Proof Option Enable Conditions..1082
          Fault Detection / Management..1082
          IAHC (Intake Air Heater Control)..1083
            Overview..1083
            Tools..1084
            SPN 729..1085
            Fault Overview..1085
            Malfunction Indicator Lamp (MIL) Reaction..1085
            Associated Faults..1085
            Drive Cycle to Determine Fault Status..1085
            SPN 729..1087
            Fault Overview..1087
            Malfunction Indicator Lamp (MIL) Reaction..1087
            Associated Faults..1087
            Drive Cycle to Determine Fault Status..1087
            SPN 729..1089
            Fault Overview..1089
            Malfunction Indicator Lamp (MIL) Reaction..1089
            Associated Faults..1089
            Drive Cycle to Determine Fault Status..1089
            SPN 729..1092
            Fault Overview..1093
            Malfunction Indicator Lamp (MIL) Reaction..1093
            Associated Faults..1093
            Drive Cycle to Determine Fault Status..1093
          J1939 Data Link..1096
          Function..1096
          Location..1097
          Tools..1097
            J1939 Data Link Pin-point Diagnostics..1097
            J1939 Data Link Circuit Operation..1099
            J1939 Data Link versus Private CAN..1101
            Diagnostic Connector..1101
            EGC..1101
            BC or MSM Module..1101
            Repair Information..1102
          MAF Sensor (Mass Air Flow)..1103
            Overview..1105
            Tools..1106
            Pin-point Diagnostics With ServiceMaxx? Software..1109
            MAF Pin-point Diagnostics..1110
            Extended Diagnostic Information..1110
            SPN 132..1111
            Fault Overview..1112
            Fault Detection / Management..1112
            Malfunction Indicator Lamp (MIL) Reaction..1112
            Associated Faults..1112
            Drive Cycle to Determine Fault Status..1112
            SPN 132..1117
            Fault Overview..1118
            Fault Detection / Management..1118
            Malfunction Indicator Lamp (MIL) Reaction..1118
            Associated Faults..1118
            Drive Cycle to Determine Fault Status..1118
            SPN 132 FMI 11 - MAF Sensor Calibration ? Insufficient number of data points..1122
            Fault Overview..1122
            Lamp Reaction..1122
            Associated Faults..1122
            Fault Facts..1122
            Drive Cycle to Determine Fault Status..1122
            Possible Causes..1122
            SPN 132 FMI 13 - MAF Sensor Calibration Needed..1123
            Fault Overview..1123
            Lamp Reaction..1123
            Associated Faults..1123
            Fault Facts..1123
            Drive Cycle to Determine Fault Status..1123
            Possible Causes..1123
            SPN 132..1124
            Fault Overview..1124
            Fault Detection / Management..1124
            Malfunction Indicator Lamp (MIL) Reaction..1124
            Associated Faults..1124
            Drive Cycle to Determine Fault Status..1124
            SPN 172 FMI 2 - IAT signal erratic, intermittent, or incorrect..1127
            Fault Overview..1127
            Lamp Reaction..1127
            Associated Faults..1128
            Fault Facts..1128
            Drive Cycle to Determine Fault Status..1128
            Possible Causes..1128
            SPN 172 FMI 3 - IAT Signal Out of Range HIGH..1129
            Fault Overview..1129
            Lamp Reaction..1129
            Associated Faults..1130
            Fault Facts..1130
            Drive Cycle to Determine Fault Status..1130
            Possible Causes..1130
            Pin-Point Tests (SPN 172 FMI 3)..1131
            Tools Required..1131
            SPN 172 FMI 4 - IAT Signal Out of Range LOW..1135
            Pin-Point Tests (SPN 172 FMI 4)..1136
            Tools Required..1136
          Service Interval Messages..1138
          Service Interval Messages Operation..1138
          TC2WG (Turbocharger 2 Wastegate)..1139
            Tools..1139
            Pinpoint Diagnostics..1139
            SPN 1189 FMI 3 - TC2WG short to PWR..1141
            Fault Overview..1141
            Lamp Reaction..1141
            Associated Faults..1141
            Fault Facts..1141
            Drive Cycle to Determine Fault Status..1141
            Possible Causes..1141
            Pin-Point Tests SPN 1189 FMI 3..1142
            Tools Required..1142
            SPN 1189 FMI 4 - TC2WG Open or short to GND..1144
            Fault Overview..1144
            Lamp Reaction..1144
            Associated Faults..1144
            Fault Facts..1144
            Drive Cycle to Determine Fault Status..1144
            Possible Causes..1144
            Pin-Point Tests (SPN 1189 FMI 4)..1145
            Tools Required..1146
          TC2CIT (Turbocharger 2 Compressor Inlet Temperature)..1149
            Overview..1150
            Tools..1151
            Pin-point Diagnostics With ServiceMaxx? Software..1152
            SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect..1154
            Fault Overview..1154
            Lamp Reaction..1154
            Associated Faults..1154
            Fault Facts..1155
            Drive Cycle to Determine Fault Status..1155
            Possible Causes..1155
            SPN 1173 FMI 3 - TC2CIT Signal Out of Range HIGH..1157
            Fault Overview..1157
            Lamp Reaction..1157
            Associated Faults..1157
            Fault Facts..1157
            Drive Cycle to Determine Fault Status..1157
            Possible Causes..1157
            Pin-Point Tests (SPN 1173 FMI 3)..1158
            Tools Required..1158
            SPN 1173 FMI 4 - TC2CIT Signal Out of Range LOW..1162
            Fault Overview..1162
            Lamp Reaction..1162
            Associated Faults..1162
            Fault Facts..1162
            Drive Cycle to Determine Fault Status..1162
            Possible Causes..1162
            Pin-Point Tests (SPN 1173 FMI 4)..1163
            Tools Required..1163
            SPN 1173..1165
            Fault Overview..1166
            Malfunction Indicator Lamp (MIL) Reaction..1166
            Fault Fact..1166
            Associated Faults..1166
            Drive Cycle to Determine Fault Status..1166
          TC2WC Solenoid (Turbocharger 2 Wastegate Control)..1170
          Function..1170
          Location..1170
          Tools..1170
            TC2WC Pin-point Diagnostics..1172
            TC2WC Circuit Operation..1173
            Fault Detection/Management..1173
          Transfer Case Circuit..1174
            Tools..1174
            Pin-Point Diagnostics..1175
            SPN 2796 FMI 2 ? Transfer Case Switch or Circuit Fault..1176
            Malfunction Indicator Lamp (MIL) Reaction..1176
            Associated Faults..1176
            Drive Cycle to Determine Fault Status..1176
          VREF (Reference Voltage)..1179
          Function..1180
          Tools..1180
            VREF Pin-point Diagnostics..1181
            VREF Circuit Operation..1186
            Fault Detection / Management..1186
            SPN 3509 FMI 3 - VREF1 voltage above maximum..1186
            Fault Overview..1186
            Lamp Reaction..1186
            Associated Faults..1186
            Fault Facts..1186
            Drive Cycle to Determine Fault Status..1186
            Possible Causes..1186
            Pin-Point Tests (SPN 3509 FMI 3)..1187
            Tools Required..1187
            SPN 3509 FMI 4 - VREF1 voltage below minimum..1193
            Fault Overview..1193
            Lamp Reaction..1193
            Associated Faults..1193
            Fault Facts..1193
            Drive Cycle to Determine Fault Status..1193
            Possible Causes..1193
            Pin-Point Tests (SPN 3509 FMI 3)..1194
            Tools Required..1194
          WIF Sensor (Water In Fuel)..1206
          Function..1206
          Sensor Location..1206
          Tools..1206
            WIF Pin-point Diagnostics..1208
            WIF Circuit Operation..1209
            Fault Detection/Management..1209
      Table of Contents..1210
        Diagnostic Trouble Codes..1212
      Table of Contents..1224
        Electrical Tools..1226
          24-Pin IP Engine Cable..1226
          Radiator Pressure Test Kit..1226
          36-Pin Injector Driver Cable..1227
          42-Pin Engine to Chassis Interface Cable..1227
          76-Pin Engine and Chassis Cables..1228
          180-Pin Breakout Box..1229
          Amp Clamp ZTSE4575..1230
          Digital Multimeter (DMM)..1231
          EXP-1000 HD by Midtronics..1232
          EZ-Tech? Electronic Service Tool (EST)..1233
            ServiceMaxx?  Software..1233
          International? Electronic Engine Terminal Test Kit ZTSE4435C..1234
          Interface cable (RP1210B compliant supporting J1939 and J1708)..1235
          3-Banana Plug Harness..1235
          500-Ohm Resistor Harness..1236
          Breakout Harness ZTSE4484 (IPR)..1236
          Breakout Harness ZTSE4485A (APP)..1237
          Breakout Harness ZTSE4602 (EOT, ECT1, and AFTFSV)..1237
          Breakout Harness ZTSE4674 (ECM and ACT PWR Relays)..1238
          Breakout Harness ZTSE4735A (ETV)..1238
          Breakout Harness ZTSE4760A (DOCIT, DPFIT, and DPFOT)..1239
          Breakout Harness ZTSE4761A (DPFDP)..1239
          Breakout Harness 4793 (UVC)..1239
          Breakout Harness ZTSE4830 (AFTFIS)..1240
          Breakout Harness ZTSE4831 (TC2WG)..1240
          Breakout Harness ZTSE4834 (EBPV)..1241
          Breakout Harness ZTSE4850 (IMP, ICP, EOP, FDP, and EBP)..1241
          Breakout Harness ZTSE4908 (EFAN)..1242
          Breakout Harness ZTSE4946 (EGT)..1242
          Breakout Harness ZTSE4948 (EGR)..1243
          Breakout Harness ZTSE4950 (CKP)..1243
          Breakout Harness ZTSE4951 (CMP)..1244
          Breakout Harness ZTSE4952 (ICP, ECB, and ECBP)..1244
          Breakout Harness 4960 (MAF)..1245
          Breakout Harness ZTSE4993 (IMT)..1245
          Breakout Harness ZTSE6002 (WIF)..1245
          Breakout Harness ZTSE6020 (24-pin)..1246
          Breakout Harness ZTSE6021 (AFTFD)..1246
          Breakout Harness ZTSE6023 (EFP)..1247
          Breakout Harness ZTSE6025 (IAH)..1247
          Breakout Harness ZTSE6027 (AFTFP)..1248
          Under Valve Cover (UVC) ZTSE4793..1249
          DEF Tank Heat Coolant Flow Valve ZTSE4827..1249
          Diesel Exhaust Fluid Dosing Unit (DEFDU) ZTSE4828..1249
          Mass Air Flow (MAF) Sensor ZTSE4960..1249
        Mechanical Tools..1250
          Charge Air Cooler Test Kit..1250
          Clean Fuel Tank Tool ..1250
          Combustion in Cooling System Tester..1251
          Crankcase Pressure Test Tool..1251
          Digital Manometer..1252
          EGR Cooler Leak Detection Kit..1253
          EGR Mixing Bowl Guide Pins..1254
          EGR Valve Puller..1254
          Fuel Inlet Restriction and Aeration Tool..1255
          Fuel/Oil Pressure Test Coupler..1255
          Fuel Pressure Gauge..1256
          Fuel Pressure Test Kit..1257
          Fuel Test Fitting..1257
          High Pressure Test Gauge..1258
          Pressure Test Kit..1259
          CAC Block Off Kit..1260
          Oil Cooler Test Plate..1261
          High Pressure Test Gauge..1262
          ICP Adapter Pressure Test Fitting..1262
          ICP Test Kit..1263
          Inline Shut-off Valve..1263
          IPR Plug Tester..1264
          Pressure Vacuum Module..1264
          Turbo Lifting Bracket..1265
          Slack Tube? Manometer..1266
          UV Leak Detection Kit..1268
          Vacuum Analyzer and Fuel Pump Tester..1269
      Table of Contents..1270
        Abbreviations and Acronyms..1272
          Abbreviations and Acronyms..1272
      Table of Contents..1282
        Terminology..1284
          Terms..1284
      Table of Contents..1296
        All Ratings..1298
        MaxxForce? DT (7.6L)..1304
          215 hp @ 2200 rpm (12NUK)..1304
          230 hp @ 2200 rpm (12NUL)..1306
          230 hp @ 2200 rpm (12NUM)..1307
          245 hp @ 2200 rpm (12NUN)..1308
          260 hp @ 2200 rpm (12NUP)..1309
          270 hp @ 2200 rpm (12NUR)..1310
          285 hp @ 2200 rpm (12NUS)..1311
          300 hp @ 2200 rpm (12NUT)..1312
        MaxxForce? 9 (9.3L)..1313
          300 hp @ 2000 rpm (12NUU)..1313
          315 hp @ 2000 rpm (12NUV)..1315
          315 hp @ 2000 rpm (12NUW)..1316
        MaxxForce? 10 (9.3L)..1317
          310 hp @ 2000 rpm (12NUX)..1317
          330 hp @ 2000 rpm (12NUY)..1319
          350 hp @ 2000 rpm (12NUZ)..1320
      Table of Contents..1322
        Signal Values..1324
      Table of Contents..1328
        Description..1330
  tables..8
    Technical Service Literature..8
    MaxxForce? DT, 9, and 10 Diesel Engines..18
     Air Management Test Setup..211
    Minimum Fuel Pump Volume Specification..244
    Example..315
    Example..316
    Example..316
    Example..316
    Example..318
    Example..318
    Example..319
    Example..319
    Example..319
    Example..320
    Example..320
    Example..321
    Example..322
    Voltage Checks at 24-pin Connector..326
    Voltage Checks at Relay..326
    Main Power Relay Control Circuit Resistance Check..326
    ACT PWR circuit to 24-pin connector..326
    Connector Voltage Check..331
    Harness Resistance Check..331
    FMI 5 ? AFT Fuel Doser Valve Open Load / Circuit..331
    Connector Voltage Check..338
    Harness Resistance Check..338
    Connector Voltage Check..347
    Harness Resistance Check..348
    Connector Voltage Check..352
    Harness Resistance Check..352
    AFT System Event Map..359
    SPN 3556 FMI 0 ? AFT Fuel Pressure 2 Below Warning Pressure..359
    SPN 3556 FMI 1 ? AFT Fuel Pressure 2 Below Desired (Possible System Leak)..359
    SPN 3556 FMI 7 ? AFT Fuel Not Responding as Expected..360
    SPN 3246 FMI 20 ? DPFOT signal drifted HIGH..360
    SPN 3719 FMI 0 ? DPF Soot Load ? Highest (level 3/3)..360
    SPN 3719 FMI 15 ? DPF Soot Load ? Lowest (level 1/3)..360
    SPN 3719 FMI 16 ? DPF Soot Load ? Moderate (level 2/3)..360
    SPN 3936 FMI 0 ? DPF Soot Load ? Severe De-Rate..361
    AFT System Cold Soak Sensor Compare Check..361
    SPN 1209 FMI 0 ? EBP above desired level..402
    SPN 1209 FMI 1 ? EBP below desired level..402
    SPN 2659 FMI 14 ? Service Tool Test ? EBP was unable to detect EGR movement..402
    SPN 2659 FMI 20 ? EGR High Flow Rate detected..403
    SPN 2659 FMI 21 ? EGR Low Flow Rate detected..403
    Cold Soak Sensor Compare Check..403
    Sensor Circuit Check..421
    Harness Resistance Check..422
    Operational Voltage Check..422
    Connector Voltage Check ? EST..442
    Harness Resistance Check..442
    Connector Voltage Check..446
    Connector Resistance Check to GND..446
    Harness Resistance Check..446
    Programmable Parameters..466
    Switch Checks..466
    Sensor and Circuit Resistance Check..468
    Harness Resistance Check..468
    Operational Checks..469
    Sensor and Circuit Resistance Check..471
    Harness Resistance Check..472
    Operational Checks..472
    DCU Power circuit checks..477
    J1939 Voltage Checks..478
    J1939 Harness Resistance Check..478
    Connector Voltage Check..486
    Harness Resistance Check..487
    SPN 4765 FMI 2 ? DOCIT signal erratic, intermittent, or incorrect..490
    SPN 4765 FMI 7 ? DOCIT not increasing with engine temperature..491
    Sensor Circuit Check..491
    Connector Voltage Check..491
    Harness Resistance Check..491
    SPN 3251 FMI 10 ? DPFDP in range stuck fault..501
    Sensor Circuit Check..502
    Connector Voltage Check..502
    Harness Resistance Check..502
    SPN 3242 FMI 2 ? DPFIT signal erratic, intermittent, or incorrect..511
    Sensor Circuit Check..512
    Connector Voltage Check..512
    Harness Resistance Check..512
    SPN 3246 FMI 2 ? DPFOT signal erratic, intermittent, or incorrect..524
    SPN 3246 FMI 7 ? DPFOT not warming along with engine..524
    Sensor Circuit Check..525
    Connector Voltage Check..525
    Harness Resistance Check..525
    SPN 1209 FMI 2 ? EBP signal erratic, intermittent, or incorrect..528
    Sensor Circuit Check..529
    Connector Voltage Check..529
    Harness Resistance Check..530
    Voltage Check at EBPV Connector ? Output State Test..544
    Operational Voltage Check..544
    Harness Resistance Check..545
    FMI 4 ? TC1TOP signal Out of Range LOW..549
    FMI 3 ? EBPC Short to PWR..551
    FMI 4 ? EBPC Short to GND..553
    Connector Voltage Check..561
    Connector Resistance Checks to GND..561
    Actuator Resistance Check..561
    Harness Resistance Check..562
    Sensor Circuit Check..566
    Connector Voltage Check..566
    Under Valve Cover (UVC) Resistance Check..567
    Harness Resistance Check..567
    Voltage Check at Relay..580
    Voltage Check at ECM..580
    Harness Resistance Check ? ECM to Relay..581
    Operational Voltage Check..581
    Harness Resistance Check ? Relay to Battery..581
    Connector Voltage Check..585
    Connector Resistance Check to GND..585
    Harness Resistance Check..585
    Voltage Checks at Relay..590
    Voltage Checks at ECM..590
    Harness Resistance Check..591
    Harness Resistance Check on Relay Power Circuits..591
    Connector Voltage Check..601
    Harness Resistance Check..601
    FMI 3 ? TOSS / VSS Signal Out of Range High..602
    FMI 4 ? TOSS / VSS Signal Out of Range Low..605
    FMI 2 ? Torque Limitation ? Too High ECT..609
    Connector Voltage Check..614
    Harness Resistance Check..614
    Switch Checks..615
    FMI 2 ? Brake Switch Circuit Fault..616
    FMI 19 ? Brake Switch Not Detected On J1939..618
    SPN 108 FMI 2 ? BARO signal erratic, intermittent, or incorrect..622
    SPN 108 FMI 3 ? BARO signal out-of-range HIGH..622
    SPN 108 FMI 4 ? BARO signal out-of-range LOW..622
    SPN 628 FMI 12 ? ECM Error - Program memory error..622
    SPN 629 FMI 12 ? ECM Error -  Internal hardware failure..622
    SPN 1136 FMI 0 ? ECM Error ? over temperature..622
    FMI 31 ? Altitude Reference Adder Fault..632
    SPN 110 FMI 2 ? ECT1 signal erratic, intermittent, or incorrect..639
    SPN 110 FMI 7 ? ECT1 and EOT Temperature Conflict..639
    Sensor Circuit Check..640
    Connector Voltage Check..640
    Harness Resistance Check..640
    FMI 7 ? ECT1 and EOT Temperature Conflict..651
    Voltage Check at EFC Connector ? Output State Test..669
    Voltage Check at Relay ? Output State Test..670
    Harness Resistance Check..670
    SPN 94 FMI 0 ? Fuel Delivery Pressure above Critical..674
    SPN 94 FMI 1 ? Fuel Delivery Pressure below Critical..674
    Voltage Checks at Relay..675
    Fuel Pump Operational Check..675
    Harness Voltage Checks..675
    Harness Resistance Check..676
    Connector Voltage Check..686
    EGR Duty Cycle Operational Specifications ? Output State Tests..686
    Harness Resistance Check..687
    EGR Valve Operation Verification Test..687
    EGR Valve Voltage Verification with High Pressure Turbocharger Wastegate Connected to Power..687
    FMI 4 ? EGR Cooler Efficiency: EGR Outlet Temp Above Expected..711
    FMI 31 ? Engine Misfire ? Multiple Cylinders..737
    FMI 31 ? Engine Misfire ? Single Cylinders..738
    SPN 175 FMI 2 ? EOT signal erratic, intermittent, or incorrect..756
    Sensor Circuit Check..757
    Connector Voltage Check..757
    Harness Resistance Check..757
    FMI 7 ? EOT not Warming Along with Engine..768
    ETV Actuator Circuit Check..775
    Connector Voltage Check..775
    Harness Resistance Check..776
    FMI 0 ? ETP Signal Erratic, Intermittent, or Incorrect..777
    FMI 5 ? ETP Open Load / Circuit..787
    FMI 11 ? ETC Operation Fault..792
    Sensor Circuit Check..813
    Connector Voltage Check..813
    Harness Resistance Check..813
    FMI 2 ? FDP Signal Erratic, Intermittent, or Incorrect..814
    Amperage Draw Check..831
    Element Resistance Check..832
    Voltage Check on Relay Switch ? Output State Test..832
    Voltage Check on Relay Coil ? Output State Test..832
    Harness Resistance Check ? Relay Coil Circuits..833
    Harness Resistance Check ? Relay Switch Circuits..833
    FMI 2 ? ICP Signal Erratic, Intermittent, or Incorrect..863
    FMI 20 ? ICP Above Desired Level..877
    FMI 21 ? ICP Above Desired Level..881
    SPN 102 FMI 0 ? IMP signal erratic, intermittent, or incorrect..892
    Sensor Circuit Check..893
    Connector Voltage Check..893
    Harness Resistance Check..893
    FMI 10 ? Boost Slow Response Fault..904
    FMI 16 ? Over boost..910
    FMI 18 ? Under boost..915
    Injector 1 ? Resistance Through Valve Cover Check..938
    Injector 1 ? Coil Resistance Checks..939
    Injector 1 ? Harness Resistance Check..939
    Injector 2 ? Resistance Through Valve Cover Check..940
    Injector 2 ? Coil Resistance Check..940
    Injector 2 ? Harness Resistance Check..941
    Injector 3 ? Resistance Through Valve Cover Check..942
    Injector 3 ? Coil Resistance Check..943
    Injector 3 ? Harness Resistance Check..943
    Injector 4 ? Resistance Through Valve Cover Check..944
    Injector 4 ? Coil Resistance Check..944
    Injector 4 ? Harness Resistance Check..945
    Injector 5 ? Resistance Through Valve Cover Check..946
    Injector 5 ? Coil Resistance Check..947
    Injector 5 ? Harness Resistance Check..947
    Injector 6 ? Resistance Through Valve Cover Check..948
    Injector 6 ? Coil Resistance Check..948
    Injector 6 ? Harness Resistance Check..949
    FMI 7 ? Injector 1 through 6 Fuel Spool Motion Compensation Max Authority Reached..951
    FMI 14 ? Injector 1 through 6 Fuel Quantity / Timing Error..954
    FMI 14 ? Injector 1 through 6 Fuel Quantity / Timing Error (Table 2)..955
    FMI 7 ? Injector coking compensation factor maximum authority reached..1051
    FMI 16 ? Multiple Injector High Flow Fault...1052
    FMI 18 ? Multiple Injector Low Flow Fault...1061
    Connector Voltage Check..1068
    Operational Voltage Check ? Output State Test..1068
    Actuator Resistance Check..1069
    Harness Resistance Check..1069
    FMI 5 ? IPR Open Load / Circuit..1078
    FMI 3 ? IAHC Short to PWR..1085
    FMI 4 ? IAHC Short to GND..1087
    FMI 5 ? IAHC Open Load / Circuit..1089
    FMI 18 ? IAH Monitor  Fault: Lack of heat in the Intake Manifold..1092
    Connector Voltage Check..1098
    EST Communication Check..1099
    Harness Resistance Check..1099
    MAF Calibration Requirements..1107
    MAF Calibration Pre-Checks..1108
    MAF Calibration Procedure ? Using ServiceMaxx? Software..1108
    Connector Voltage Check..1110
    Harness Resistance Check..1110
    FMI 0 ? Engine Inlet Air Mass Flow Rate High..1111
    FMI 1 ? Engine Inlet Air Mass Flow Rate Low..1117
    FMI 31 ? MAF Operation Fault..1124
    Voltage Check at TC2WG Connector ? Output State Test..1140
    Harness Resistance Check..1140
    Condition / Description..1141
    Setting Criteria..1141
    Enable Conditions / Condition Values..1141
    Condition / Description..1144
    Setting Criteria..1144
    Enable Conditions / Condition Values..1144
    Connector Voltage Check..1153
    Connector Resistance Check to GND..1153
    Harness Resistance Check..1153
    Condition / Description..1154
    Setting Criteria..1154
    Enable Conditions / Condition Values..1154
    FMI 16 ? TC2CIT Signal Above Desired (Interstage CAC Under Cooling)..1165
    Voltage Check at TC2WC Connector ? Output State Test..1172
    Harness Resistance Check..1173
    Connector Voltage Check..1175
    Harness Resistance Check..1175
    FMI 5 ? IPR Open Load / Circuit..1176
    VREF Voltage Check..1183
    Connector Resistance Check to GND..1184
    Harness Resistance Check..1185
    Voltage Check..1208
    Harness Resistance Check..1209
    Key-On Engine-Off..1298
    Example TC1TOP (Actual) Calculations..1298
    Key-On Engine-Off..1299
    Engine Cranking..1299
    Low Idle, no load, stabilized engine operating temperature..1300
    Low Idle, no load, stabilized engine operating temperature..1300
    High Idle, Parasitic load, at stabilized operating temperature..1300
    Actuator Output State Test..1300
    Full load, ECM rated speed at highway, stabilized operating temperature..1301
    Component Specifications..1302
    Crankcase Pressure..1303
    TC2WC Rod Extension..1303
0000001624 - Electronic Control Systems Diagnostics & Diagnostic Trouble Code..1333
  toc..0
    Removal of Tools, Parts, and Equipment..0
      Table of Contents..1333
        Description..1337
          Section Information..1337
        Electronic Control System Diagnostics Form EGED-495..1338
          Diagnostic Form Example..1338
        Sensor and Actuator Locations..1339
          Engine Mounted Components..1339
          Vehicle Mounted Components..1344
         Diagnostic Procedure Process..1344
          Description..1344
          Pin-grip Inspection..1344
            Diagnostics with EST..1344
            Diagnostics without EST..1344
          Sensor End Diagnostics (with ServiceMaxx? software)..1345
            Sensor End Diagnostics (2-Wire)..1345
            Sensor End Diagnostics (3-Wire)..1347
          Pin-point Diagnostics (without ServiceMaxx? software)..1350
          Actuator Operational Voltage Check ? Output State Test..1350
          Harness Resistance Check..1351
          Operational Voltage Check..1352
        Circuit Diagnostics..1353
          ACT PWR Relay (Actuator Power)..1353
          Function..1353
          ACT PWR Relay Location..1353
          Tools..1353
            ACT PWR Relay Pin-point Diagnostics..1354
            ACT PWR Circuit Operation..1356
            Fault Detection / Management..1356
          ACM Power (Aftertreatment Control Module)..1357
          Function..1357
          Component Location..1358
          Tools..1358
            ACM PWR Pin-point Diagnostics..1358
          ACM VREF Circuits..1361
          Function..1361
          Component Location..1361
          Tools..1361
            ACM VREF Circuit..1362
          AFTFD (Aftertreatment Fuel Doser)..1364
            Overview..1365
            Tools..1365
            AFTFD Pin-Point Diagnostics..1366
            SPN 3479 FMI 5 - AFT Fuel Doser Valve Open Load / Circuit..1368
            Fault Overview..1368
            Malfunction Indicator Lamp (MIL) Reaction..1368
            Associated Faults..1368
            Drive Cycle to Determine Fault Status..1368
            SPN 3479 FMI 6 - AFT Fuel Doser Valve High Side Short Circuit..1370
            Fault Overview..1370
            Malfunction Indicator Lamp (MIL) Reaction..1370
            Associated Faults..1370
            Drive Cycle to Determine Fault Status..1370
          Aftertreatment Fuel Inlet Sensor (AFTIS)..1372
            Overview..1373
            Tools..1374
            AFTFIS Pin-Point Diagnostics..1374
            SPN 5456 FMI 2 - AFTFIT Signal Erratic , Intermittent, or Incorrect..1376
            Fault Overview..1377
            Malfunction Indicator Lamp (MIL) Reaction..1377
            Associated Faults..1377
            Drive Cycle to Determine Fault Status..1377
          Aftertreatment Fuel Pressure 2 Sensor (AFTFP2)..1380
          Function..1380
          Sensor Location..1381
          Tools..1381
            AFTFP2 Sensor End Diagnostics..1381
            AFTFP2 Pin-point Diagnostics..1382
            AFTFP2 Circuit Operation..1382
          Aftertreatment Fuel Shutoff Valve (AFTFSV)..1383
          Function..1383
          Component Location..1383
          Tools..1384
            AFTFSV Connector End Diagnostics..1384
          AFT System (Aftertreatment)..1386
            Overview..1390
            Tools..1390
            Pin-Point Diagnostics..1391
            SPN 3246 FMI 21 - DPFOT Signal Drifted LOW..1394
            Fault Overview..1394
            Malfunction Indicator Lamp (MIL) Reaction..1394
            Associated Faults..1394
            Drive Cycle to Determine Fault Status..1394
            SPN 3251 FMI 0 - DPFDP Excessively HIGH..1397
            Fault Overview..1397
            Malfunction Indicator Lamp (MIL) Reaction..1397
            Associated Faults..1397
            Drive Cycle to Determine Fault Status..1397
            SPN 3251 FMI 14 - DPFDP Excessively Low..1401
            Fault Overview..1401
            Malfunction Indicator Lamp (MIL) Reaction..1401
            Associated Faults..1401
            Drive Cycle to Determine Fault Status..1401
            SPN 3936 FMI 8 - DPF Regenerations Are Occurring Too Frequently..1404
            Fault Overview..1405
            Malfunction Indicator Lamp (MIL) Reaction..1405
            Associated Faults..1405
            Drive Cycle to Determine Fault Status..1405
            SPN 3936 FMI 20 - DPF feedback adaptive limits reached..1409
            Fault Overview..1409
            Malfunction Indicator Lamp (MIL) Reaction..1409
            Associated Faults..1409
            Drive Cycle to Determine Fault Status..1409
            SPN 4766 FMI 10 - DPF Catalyst System Efficiency Below Threshold..1413
            Fault Overview..1414
            Malfunction Indicator Lamp (MIL) Reaction..1414
            Associated Faults..1414
            Drive Cycle to Determine Fault Status..1414
            SPN 5319 FMI 31 - DPFDP Excessively Low..1419
            Fault Overview..1419
            Malfunction Indicator Lamp (MIL) Reaction..1419
            Associated Faults..1420
            Drive Cycle to Determine Fault Status..1420
            AFT System Indicators..1423
            Hot Exhaust Temperature (HET) Lamp..1424
            Diesel Particulate Filter (DPF) Lamp..1424
            SPN 3719 FMI 15 ? DPF Soot Load - Lowest (level 1/3)..1425
            SPN 3719 FMI 16 ? DPF Soot Load -Moderate (level 2/3)..1425
            SPN 3719 FMI 0 DPF Soot Load - Highest (level 3/3)..1425
            Regen Inhibitors..1425
            DPF Regen Inhibit Conditions..1425
            Entry Conditions for a Rolling Regen..1426
            DPF Filter Cleanliness Test..1428
            Regen Inhibitors..1430
            Parked Regen Checks..1431
            DPF Filter Inspection..1433
            Normal DPF Outlet..1434
            Plugged DPF Inlet..1435
            DPF Contaminated with Coolant..1436
            DPF Contaminated with Oil and Soot..1437
            DPF Outlet Leaking Soot..1438
            External Damage to DPF..1439
            DPF Brick Measurement From Outlet..1440
          AMS (Air Management System)..1441
            Overview..1443
            Tools..1443
            Pin-point Diagnostics..1443
            SPN 2659 FMI 10 - EGR Slow Response Fault..1446
            Fault Overview..1448
            Fault Detection / Management..1448
            Malfunction Indicator Lamp (MIL) Reaction..1448
            Associated Faults..1448
            Drive Cycle to Determine Fault Status..1448
            SPN 2659 FMI 21 - EGR Low Flow Rate Detected..1452
            Fault Overview..1453
            Fault Detection / Management..1453
            Malfunction Indicator Lamp (MIL) Reaction..1453
            Associated Faults..1453
            Drive Cycle to Determine Fault Status..1453
          APP Sensor (Accelerator Pedal Position)..1456
          Function..1456
          Sensor Location..1456
          Tools..1457
            APP Sensor End Diagnostics..1457
            APP Pin-point Diagnostics..1460
            APP Circuit Operation..1461
            APP..1461
            APP Auto-Calibration..1461
            Fault Detection / Management..1461
          ATA Datalink (American Trucking Association)..1462
          Function..1462
          Location..1462
          Tools..1462
            ATA Pin-point Diagnostics..1463
            ATA Operation..1464
            Diagnostic Connector..1464
            EGC..1464
            Fault Detection / Management..1464
            Repair Information..1464
          CACOT Sensor (Charge Air Cooler Outlet Temperature)..1465
            Overview..1466
            Tools..1466
            SPN 2630 FMI 2 - CACOT Signal Erratic, Intermittent, or Incorrect..1468
            Fault Overview..1469
            Malfunction Indicator Lamp (MIL) Reaction..1469
            Associated Faults..1469
            Drive Cycle to Determine Fault Status..1469
            SPN 2630 FMI 3 - CACOT signal out of range HIGH..1471
            Fault Overview..1471
            Malfunction Indicator Lamp (MIL) Reaction..1471
            Associated Faults..1471
            Drive Cycle to Determine Fault Status..1471
            SPN 2630 FMI 4 - CACOT signal out of range LOW..1474
            Fault Overview..1474
            Malfunction Indicator Lamp (MIL) Reaction..1474
            Associated Faults..1474
            Drive Cycle to Determine Fault Status..1474
            SPN 2630 FMI 16 - CACOT Undercooling..1477
            Fault Overview..1478
            Malfunction Indicator Lamp (MIL) Reaction..1478
            Associated Faults..1478
            Drive Cycle to Determine Fault Status..1478
          CCS (Cruise Control System)..1481
          Function..1481
          Location..1482
          Tools..1482
            CCS Pin-point Diagnostics ..1482
          CKP Sensor (Crankshaft Position)..1484
          Function..1484
          Sensor Location..1484
          Tools..1484
            CKP Pin-point Diagnostics..1485
            CKP Circuit Operation..1486
            Fault / Detection Management..1486
          CMP Sensor (Camshaft Position)..1487
          Function..1487
          Sensor Location..1487
          Tools..1487
            CMP Pin-point Diagnostics..1488
            CMP Circuit Operation..1489
            Fault / Detection Management..1489
          Cylinder Balance..1490
            Cylinder Balance Operation..1490
            Cylinder Balance Diagnostics..1491
          DOCIT Sensor (Diesel Oxidation Catalyst Inlet Temperature)..1493
            Overview..1495
            Tools..1496
            DOCIT Pin-point Diagnostics..1496
            SPN 4765 FMI 20 - DOCIT Signal Drifted HIGH..1499
            Fault Overview..1499
            Malfunction Indicator Lamp (MIL) Reaction..1499
            Associated Faults..1499
            Drive Cycle to Determine Fault Status..1499
            SPN 4765 FMI 21 - DOCIT Signal Drifted LOW..1502
            Fault Overview..1502
            Malfunction Indicator Lamp (MIL) Reaction..1502
            Associated Faults..1502
            Drive Cycle to Determine Fault Status..1502
          DPFDP Sensor (Diesel Particulate Filter Differential Pressure)..1505
          Function..1506
          Sensor Location..1506
          Tools..1506
            DPFDP Sensor End Diagnostics..1507
            DPFDP Pin-point Diagnostics..1510
            DPFDP Circuit Operation..1510
          DPFIT Sensor (Diesel Particulate Filter Inlet Temperature)..1511
            Overview..1512
            Tools..1512
            Pin-Point Diagnostics..1513
            SPN 3242 FMI 20 - DPFIT Signal Drifted High..1515
            Fault Overview..1516
            Malfunction Indicator Lamp (MIL) Reaction..1516
            Associated Faults..1516
            Drive Cycle to Determine Fault Status..1516
            SPN 3242 FMI 21- DPFIT Signal Drifted Low..1520
            Fault Overview..1520
            Malfunction Indicator Lamp (MIL) Reaction..1520
            Associated Faults..1520
            Drive Cycle to Determine Fault Status..1520
          DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)..1523
          Function..1524
          Sensor Location..1524
          Tools..1524
            DPFOT Sensor End Diagnostics..1525
            DPFOT Pin-point Diagnostics..1527
            DPFOT Circuit Operation..1527
          EBP Sensor (Exhaust Back Pressure)..1528
          Function..1528
          Sensor Location..1528
          Tools..1528
            EBP Sensor End Diagnostics..1529
            EBP Pin-point Diagnostics..1531
            EBP Circuit Operation..1531
            Fault Detection / Management..1531
          EBPV (Exhaust Back Pressure Valve)..1532
          Function..1532
          Location..1532
          Tools..1532
            EBPV Pin-point Diagnostics..1533
            EBPV Circuit Operation..1534
            Fault Detection/Management..1534
          ECB Valve (Engine Compression Brake)..1535
          Function..1535
          Valve Location..1535
          Tools..1536
            ECB Pin-point Diagnostics..1536
            ECB Circuit Operation..1538
            Fault Detection / Management..1538
          ECBP Sensor (Engine Compression Brake Pressure)..1539
          Function..1539
          Sensor Location..1539
          Tools..1540
            ECBP Sensor End Diagnostics..1540
            ECBP Pin-point Diagnostics..1542
            ECBP Circuit Operation..1543
            Fault Detection / Management..1543
          ECI Circuit (Engine Crank Inhibit)..1544
          Function..1544
          Location..1544
          Tools..1544
            ECI Circuit Diagnostics..1545
            ECI Circuit Operation..1548
            DDS Circuit..1548
            Ignition Switch..1548
            ECI Circuit..1548
            Engine Control Module (ECM)..1548
            Starter Relay..1548
            Clutch Switch..1548
            Neutral Switch..1548
            WTEC MD with Auto Neutral..1548
            Fault Detection / Management..1548
          ECL Switch (Engine Coolant Level)..1549
          Function..1549
          Location..1549
          Tools..1549
            ECL Switch Pin-point Diagnostics..1550
            ECL Circuit Operation..1551
            Fault Detection / Management..1551
          ECM PWR (Engine Control Module Power)..1552
          Function..1552
          ECM Location..1552
          Tools..1552
            ECM PWR Pin-point Diagnostics..1553
            ECM PWR Circuit Operation..1555
            Fault Detection / Management..1555
          Engine Idle Speed..1556
            Tools..1556
            SPN 188 FMI 0 - Engine Unable to Achieve Desired Idle Speed (Too High)..1557
            Fault Overview..1557
            Malfunction Indicator Lamp (MIL) Reaction..1557
            Associated Faults..1557
            Drive Cycle to Determine Fault Status..1557
            SPN 188 FMI 1 - EGT Signal Erratic, Intermittent, or Incorrect..1559
            Fault Overview..1559
            Malfunction Indicator Lamp (MIL) Reaction..1559
            Associated Faults..1559
            Drive Cycle to Determine Fault Status..1559
          Transmission Output Shaft Speed (TOSS)..1561
            Overview..1562
            Tools..1562
            Pinpoint Diagnostics..1563
            SPN 191 FMI 3 - TOSS / VSS Signal Out of Range High..1564
            Fault Overview..1564
            Malfunction Indicator Lamp (MIL) Reaction..1564
            Associated Faults..1564
            Drive Cycle to Determine Fault Status..1564
            SPN 191 FMI 4 - TOSS / VSS Signal Out of Range Low..1566
            Fault Overview..1566
            Malfunction Indicator Lamp (MIL) Reaction..1566
            Associated Faults..1566
            Drive Cycle to Determine Fault Status..1566
          Torque Limitation..1568
            Tools..1568
            SPN 518 FMI 2 - Torque Limitation - Too High ECT..1568
            Fault Overview..1568
            Malfunction Indicator Lamp (MIL) Reaction..1568
            Associated Faults..1568
            Drive Cycle to Determine Fault Status..1568
          Brake Switch..1571
            Overview..1572
            Tools..1573
            Pin-Point Diagnostics..1573
            SPN 597 FMI 2 - Brake Switch Circuit Fault..1575
            Fault Overview..1575
            Malfunction Indicator Lamp (MIL) Reaction..1575
            Associated Faults..1575
            Drive Cycle to Determine Fault Status..1575
            SPN 597 FMI 19 - Brake Switch Not Detected On J1939..1578
            Fault Overview..1578
            Malfunction Indicator Lamp (MIL) Reaction..1578
            Associated Faults..1578
            Drive Cycle to Determine Fault Status..1578
          ECM Self Diagnostics (Engine Control Module)..1582
            Overview..1582
            Tools..1582
            Pin-point ECM Self Diagnostic Fault..1583
            SPN 629 FMI 0 - ECM CPU Load..1584
            Fault Overview..1584
            Malfunction Indicator Lamp (MIL) Reaction..1584
            Associated Faults..1584
            Drive Cycle to Determine Fault Status..1584
            SPN 1387 FMI 31 - Altitude Reference Adder Fault..1586
            Fault Overview..1586
            Malfunction Indicator Lamp (MIL) Reaction..1586
            Associated Faults..1586
            Drive Cycle to Determine Fault Status..1586
          ECP Sensor (Engine Coolant Pressure)..1589
            Overview..1589
            Tools..1590
            Pinpoint Diagnostics..1590
            SPN 109 FMI 1 - Coolant System Temperatures Too High..1592
            Fault Overview..1592
            Malfunction Indicator Lamp (MIL) Reaction..1592
            Associated Faults..1592
            Drive Cycle to Determine Fault Status..1592
            SPN 109 FMI 3 - ECP Signal Out of Range High..1594
            Fault Overview..1594
            Malfunction Indicator Lamp (MIL) Reaction..1594
            Associated Faults..1594
            Drive Cycle to Determine Fault Status..1594
            SPN 109 FMI 4 - ECP Signal Out of Range Low..1596
            Fault Overview..1596
            Malfunction Indicator Lamp (MIL) Reaction..1596
            Associated Faults..1596
            Drive Cycle to Determine Fault Status..1596
          ECT1 Sensor (Engine Coolant Temperature 1)..1598
            Overview..1599
            Tools..1599
            Pin-Point Diagnostics..1600
            SPN 110 FMI 7 - ECT1 and EOT Temperature Conflict..1603
            Fault Overview..1603
            Malfunction Indicator Lamp (MIL) Reaction..1603
            Associated Faults..1603
            Drive Cycle to Determine Fault Status..1603
            SPN 110 FMI 17 - Engine Coolant System Below OBD Monitoring Temperature..1606
            Fault Overview..1606
            Malfunction Indicator Lamp (MIL) Reaction..1606
            Associated Faults..1606
            Drive Cycle to Determine Fault Status..1607
            SPN 110 FMI 18 - Engine Coolant System Below closed loop minimum temperature..1609
            Fault Overview..1609
            Malfunction Indicator Lamp (MIL) Reaction..1609
            Associated Faults..1610
            Drive Cycle to Determine Fault Status..1610
            SPN 1659 FMI 20 - ECT1 below expected: Check Thermostat..1613
            Fault Overview..1613
            Malfunction Indicator Lamp (MIL) Reaction..1614
            Associated Faults..1614
            Drive Cycle to Determine Fault Status..1614
          EFC (Engine Fan Control)..1617
          Function..1617
          Location..1617
          Tools..1617
            EFC Circuit Diagnostics..1618
            EFC Circuit Operation..1620
            EFC Programmable Parameters..1620
            Fault Detection / Management..1620
          EFP (Electric Fuel Pump)..1621
          Function..1622
          EFP Location..1622
          Tools..1622
            EFP Pin-Point Diagnostics..1623
            EFP Circuit Operation..1626
            Fault Detection / Management..1626
          EGR Actuator (Exhaust Gas Recirculation)..1627
            Overview..1628
            Tools..1629
            Pinpoint Diagnostics With ServiceMaxx? Software..1630
            SPN 2791 FMI 3 - EGRC Short to PWR..1631
            Fault Overview..1631
            Malfunction Indicator Lamp (MIL) Reaction..1631
            Associated Faults..1632
            Drive Cycle to Determine Fault Status..1632
            SPN 2791 FMI 4 - EGRC Short to GND..1635
            Fault Overview..1635
            Malfunction Indicator Lamp (MIL) Reaction..1635
            Associated Faults..1635
            Drive Cycle to Determine Fault Status..1635
            SPN 2791 FMI 7 - EGR Valve Unable to Achieve Commanded Position..1638
            Fault Overview..1638
            Malfunction Indicator Lamp (MIL) Reaction..1638
            Associated Faults..1638
            Drive Cycle to Determine Fault Status..1638
            SPN 2791 FMI 14 - EGR valve Initialization Fault..1640
            Fault Overview..1640
            Malfunction Indicator Lamp (MIL) Reaction..1640
            Associated Faults..1640
            Drive Cycle to Determine Fault Status..1640
          EGR Cooler (Exhaust Gas Recirculation)..1643
            Tools..1644
            SPN 4752 FMI 4 - EGR Cooler Efficiency: EGR Outlet Temp Above Expected..1644
            Fault Overview..1644
            Malfunction Indicator Lamp (MIL) Reaction..1644
            Associated Faults..1645
            Drive Cycle to Determine Fault Status..1645
          EGT Sensor (Exhaust Gas Temperature)..1648
            Overview..1649
            Tools..1650
            SPN 173 FMI 2 - EGT signal erratic, intermittent, or incorrect..1652
            Fault Overview..1652
            Malfunction Indicator Lamp (MIL) Reaction..1652
            Associated Faults..1652
            Drive Cycle to Determine Fault Status..1652
          Engine Idle Torque..1655
            Tools..1655
            SPN 5395 FMI 0 - Engine Unable to Achieve Desired Idle Torque (Too High)...1656
            Fault Overview..1656
            Malfunction Indicator Lamp (MIL) Reaction..1656
            Associated Faults..1656
            Drive Cycle to Determine Fault Status..1656
            SPN 5395 FMI 1 - Engine Unable to Achieve Desired Idle Torque (Too Low)...1659
            Fault Overview..1659
            Malfunction Indicator Lamp (MIL) Reaction..1659
            Associated Faults..1659
            Drive Cycle to Determine Fault Status..1659
          Engine Misfire..1662
            Tools..1664
            SPN 1322 - 1328 FMI 31- Engine Misfire - Single and Multiple Cylinders..1664
            Fault Overview..1665
            Malfunction Indicator Lamp (MIL) Reaction..1665
            Associated Faults..1665
            Drive Cycle to Determine Fault Status..1665
          EOP Sensor (Engine Oil Pressure)..1670
          Function..1670
          Sensor Location..1670
          Tools..1670
            EOP Sensor End Diagnostics..1671
            EOP Pin-point Diagnostics..1672
            EOP Circuit Operation..1673
            Fault Detection / Management..1673
          EOT Sensor (Engine Oil Temperature)..1674
            Overview..1675
            Tools..1676
            Pinpoint Diagnostics..1676
            SPN 175 FMI 7 - EOT not Warming Along with Engine..1679
            Fault Overview..1679
            Malfunction Indicator Lamp (MIL) Reaction..1679
            Associated Faults..1679
            Drive Cycle to Determine Fault Status..1679
          ETV (Engine Throttle Valve)..1682
            Overview..1684
            Tools..1684
            Pinpoint Diagnostics with ServiceMaxx? Software..1685
            ETV Actuator Pin-point Diagnostics..1686
            SPN 51 FMI 0 - ETP Signal Erratic, Intermittent, or Incorrect..1688
            Fault Overview..1688
            Malfunction Indicator Lamp (MIL) Reaction..1688
            Associated Faults..1688
            Drive Cycle to Determine Fault Status..1688
            SPN 51 FMI 3 - ETP Signal Out of Range High..1692
            Fault Overview..1692
            Malfunction Indicator Lamp (MIL) Reaction..1692
            Associated Faults..1692
            Drive Cycle to Determine Fault Status..1692
            SPN 51 FMI 4 - ETP Signal Out of Range Low..1695
            Fault Overview..1695
            Malfunction Indicator Lamp (MIL) Reaction..1695
            Associated Faults..1695
            Drive Cycle to Determine Fault Status..1695
            SPN 51 FMI 5 - ETP Open Load / Circuit..1698
            Fault Overview..1698
            Malfunction Indicator Lamp (MIL) Reaction..1698
            Associated Faults..1698
            Drive Cycle to Determine Fault Status..1698
            SPN 3464 FMI 11 - ETC Operation Fault..1701
            Fault Overview..1701
            Malfunction Indicator Lamp (MIL) Reaction..1701
            Associated Faults..1701
            Drive Cycle to Determine Fault Status..1701
          EWPS (Engine Warning and Protection System)..1704
          Function..1705
            EWPS Programmable Parameters..1706
          FDP Sensor (Fuel Delivery Pressure) ..1709
            Overview..1709
            Tools..1710
            Pinpoint Diagnostics..1710
            SPN 94 FMI 2 - FDP Signal Erratic, Intermittent, or Incorrect..1712
            Fault Overview..1712
            Malfunction Indicator Lamp (MIL) Reaction..1712
            Associated Faults..1712
            Drive Cycle to Determine Fault Status..1712
            SPN 94 FMI 17- FDP Below Minimum..1715
            Fault Overview..1715
            Malfunction Indicator Lamp (MIL) Reaction..1715
            Associated Faults..1715
            Drive Cycle to Determine Fault Status..1715
          IAH System (Intake Air Heater)..1717
          Function..1717
          Component Location..1717
          Tools..1717
            IAH Pin-point Diagnostics..1718
            IAH Circuit Operation..1720
            DTCs..1720
          ICP Sensor (Injection Control Pressure)..1721
          Function..1721
          Sensor Location..1721
          Tools..1721
            ICP Sensor End Diagnostics..1722
            ICP Pin-point Diagnostics..1724
            ICP Circuit Operation..1725
            Fault Detection / Management..1725
          ICP (Injection Control Pressure) System..1726
            Overview..1728
            Tools..1728
            ICP System Pin-Point Diagnostics..1728
            SPN 164 FMI 2 - ICP Signal Erratic, Intermittent, or Incorrect...1731
            Fault Overview..1731
            Malfunction Indicator Lamp (MIL) Reaction..1731
            Associated Faults..1731
            Drive Cycle to Determine Fault Status..1731
            SPN 164 FMI 20 - ICP Above Desired Level...1733
            Fault Overview..1733
            Malfunction Indicator Lamp (MIL) Reaction..1733
            Associated Faults..1733
            Drive Cycle to Determine Fault Status..1733
            SPN 164 FMI 21 - ICP Above Desired Level...1736
            Fault Overview..1736
            Malfunction Indicator Lamp (MIL) Reaction..1736
            Associated Faults..1736
            Drive Cycle to Determine Fault Status..1736
            SPN 3055 FMI 2 - ICP / IPR Adaptation In-range Fault..1737
            Fault Overview..1738
            Malfunction Indicator Lamp (MIL) Reaction..1738
            Associated Faults..1738
            Drive Cycle to Determine Fault Status..1738
          IMP Sensor (Intake Manifold Pressure)..1741
            Overview..1744
            Tools..1744
            Pinpoint Diagnostics..1745
            SPN 102 FMI 10 - Boost Slow Response Fault..1748
            Fault Overview..1749
            Fault Detection / Management..1749
            Malfunction Indicator Lamp (MIL) Reaction..1749
            Associated Faults..1749
            Drive Cycle to Determine Fault Status..1749
            SPN 102 FMI 16 - Overboost..1754
            Fault Overview..1755
            Fault Detection / Management..1755
            Malfunction Indicator Lamp (MIL) Reaction..1755
            Associated Faults..1755
            Drive Cycle to Determine Fault Status..1755
            SPN 102 FMI 18 - Underboost..1759
            Fault Overview..1760
            Fault Detection / Management..1760
            Malfunction Indicator Lamp (MIL) Reaction..1760
            Associated Faults..1760
            Drive Cycle to Determine Fault Status..1760
          IMT Sensor (Intake Manifold Temperature)..1765
          Function..1765
          Sensor Location..1765
          Tools..1765
            IMT Sensor End Diagnostics..1766
            IMT Pin-point Diagnostics..1768
            IMT Circuit Operation..1768
            Fault Detection / Management..1768
          Injector Circuits..1769
          Overview..1772
          Tools..1773
            Pinpoint Diagnostics With ServiceMaxx? Software..1773
            Injector 1 Checks..1773
            Injector 2 Checks..1775
            Injector 3 Checks..1777
            Injector 4 Checks..1779
            Injector 5 Checks..1781
            Injector 6 Checks..1783
            Injector Circuit Operation..1785
            High Side Drive Output..1785
            Low Side Drive Return..1785
            Fault Detection / Management..1785
            KOEO Injector Test..1785
            SPN 651?656 FMI 7 - Injector 1?6 Fuel Spool Motion Compensation Max Authority Reached..1786
            Fault Overview..1786
            Malfunction Indicator Lamp (MIL) Reaction..1786
            Associated Faults..1786
            Drive Cycle to Determine Fault Status..1786
            SPN 651?656 FMI 14 - Injector 1?6 Fuel Quantity / Timing Error..1788
            Fault Overview..1789
            Malfunction Indicator Lamp (MIL) Reaction..1789
            Associated Faults..1789
            Drive Cycle to Determine Fault Status..1789
            SPN 2797 FMI 6 - Injector Control Group 1 Open Coil - Short Circuit (INJ 1, 2, 3)..1793
            Fault Overview..1793
            Malfunction Indicator Lamp (MIL) Reaction..1793
            Associated Faults..1793
            Drive Cycle to Determine Fault Status..1793
            Injector Control Group 2 Pin-Point Diagnostics..1794
            SPN 2798 FMI 6 - Injector Control Group 2 Open Coil - Short Circuit (INJ 4, 5, 6)..1800
            Fault Overview..1800
            Malfunction Indicator Lamp (MIL) Reaction..1800
            Associated Faults..1800
            Drive Cycle to Determine Fault Status..1800
            Injector Control Group 2 Pin-Point Diagnostics..1801
          Injector Performance..1807
            Tools..1808
            SPN 4257 FMI 7- Injector coking compensation factor maximum authority reached..1809
            Fault Overview..1809
            Malfunction Indicator Lamp (MIL) Reaction..1809
            Associated Faults..1809
            Drive Cycle to Determine Fault Status..1809
            SPN 4257 FMI 16 - Multiple Injector High Flow Fault...1811
            Fault Overview..1812
            Malfunction Indicator Lamp (MIL) Reaction..1812
            Associated Faults..1812
            Drive Cycle to Determine Fault Status..1812
            SPN 4257 FMI 18 - Multiple Injector Low Flow Fault...1820
            Fault Overview..1821
            Malfunction Indicator Lamp (MIL) Reaction..1821
            Associated Faults..1821
            Drive Cycle to Determine Fault Status..1821
          IPR (Injection Pressure Regulator)..1824
            Overview..1824
            Tools..1825
            Pin-Point Diagnostics..1826
            SPN 679 FMI 5 - IPR Open Load/Circuit..1828
            Fault Overview..1828
            Malfunction Indicator Lamp (MIL) Reaction..1828
            Associated Faults..1828
            Drive Cycle to Determine Fault Status..1828
          IST System (Idle Shutdown Timer)..1830
            Function..1830
            Tools..1830
            Engine Idle Shutdown timer for California ESS Compliant Engines..1831
            Engine Idle Shutdown Timer (Federal - Optional)..1832
            Common Enable Conditions for All Federal IST Options..1832
            Federal IST Mode 1: PTO Operation Option Enable Conditions..1832
            Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions..1832
            Federal IST Mode 3: Tamper Proof Option Enable Conditions..1832
            Fault Detection / Management..1832
          IAHC (Intake Air Heater Control)..1833
            Overview..1834
            Tools..1835
            SPN 729 FMI 3 - IAHC Short to PWR..1836
            Fault Overview..1836
            Malfunction Indicator Lamp (MIL) Reaction..1836
            Associated Faults..1836
            Drive Cycle to Determine Fault Status..1836
            SPN 729 FMI 4 - IAHC Short to GND..1838
            Fault Overview..1838
            Malfunction Indicator Lamp (MIL) Reaction..1838
            Associated Faults..1838
            Drive Cycle to Determine Fault Status..1838
            SPN 729 FMI 5 - IAHC Open Load / Circuit..1840
            Fault Overview..1840
            Malfunction Indicator Lamp (MIL) Reaction..1840
            Associated Faults..1840
            Drive Cycle to Determine Fault Status..1840
            SPN 729 FMI 18 - IAH Monitor Fault: Lack of heat in the Intake Manifold..1842
            Fault Overview..1842
            Malfunction Indicator Lamp (MIL) Reaction..1842
            Associated Faults..1842
            Drive Cycle to Determine Fault Status..1842
          J1939 Data Link..1846
          Function..1846
          Location..1846
          Tools..1846
            J1939 Data Link Pin-point Diagnostics..1847
            J1939 Data Link Circuit Operation..1848
            J1939 Data Link versus Private CAN..1849
            Diagnostic Connector..1849
            EGC..1849
            BC or MSM Module..1849
            Repair Information..1849
          MAF Sensor (Mass Air Flow)..1850
            Overview..1852
            Tools..1853
            Pinpoint Diagnostics With ServiceMaxx? Software..1856
            MAF Pin-point Diagnostics..1856
            Extended Diagnostic Information..1857
            SPN 132 FMI 0 - Engine Inlet Air Mass Flow Rate High..1858
            Fault Overview..1859
            Fault Detection / Management..1859
            Malfunction Indicator Lamp (MIL) Reaction..1859
            Associated Faults..1859
            Drive Cycle to Determine Fault Status..1859
            SPN 132 FMI 1 - Engine Inlet Air Mass Flow Rate Low..1863
            Fault Overview..1864
            Fault Detection / Management..1864
            Malfunction Indicator Lamp (MIL) Reaction..1864
            Associated Faults..1864
            Drive Cycle to Determine Fault Status..1864
          Service Interval Messages..1868
          Service Interval Messages Operation..1868
          TC1WC (Turbocharger 1 Wastegate Control)..1869
            Tools..1869
            Pinpoint Diagnostics..1869
            SPN 1188 FMI 3 - TC1WC Short to PWR...1871
            Fault Overview..1871
            Malfunction Indicator Lamp (MIL) Reaction..1871
            Associated Faults..1871
            Drive Cycle to Determine Fault Status..1871
            SPN 1188 FMI 4 - TC1WC Short to GND...1873
            Fault Overview..1873
            Malfunction Indicator Lamp (MIL) Reaction..1873
            Associated Faults..1873
            Drive Cycle to Determine Fault Status..1873
          TC2CIT (Turbocharger 2 Charge Inlet Temperature)..1876
            Overview..1878
            Tools..1879
            Pinpoint Diagnostics With ServiceMaxx? Software..1879
            SPN 1173 FMI 2 - TC2CIT Signal Erratic, Intermittent or Incorrect...1882
            Fault Overview..1882
            Malfunction Indicator Lamp (MIL) Reaction..1882
            Associated Faults..1882
            Drive Cycle to Determine Fault Status..1882
            SPN 1173 FMI 3 - Turbocharger 2 Compressor Inlet Temperature Out of Range HIGH..1885
            Fault Overview..1885
            Malfunction Indicator Lamp (MIL) Reaction..1885
            Associated Faults..1885
            Drive Cycle to Determine Fault Status..1885
            SPN 1173 FMI 4 - Turbocharger 2 Compressor Inlet Temperature Out of Range Low...1888
            Fault Overview..1888
            Malfunction Indicator Lamp (MIL) Reaction..1888
            Associated Faults..1888
            Drive Cycle to Determine Fault Status..1888
            SPN 1173 FMI 16 - TC2CIT Signal Above Desired (Interstage CAC Under Cooling)..1891
            Fault Overview..1892
            Malfunction Indicator Lamp (MIL) Reaction..1892
            Fault Fact..1892
            Associated Faults..1892
            Drive Cycle to Determine Fault Status..1892
          TC2WC Solenoid (Turbocharger 2 Wastegate Control)..1896
          Function..1896
          Location..1896
          Tools..1896
            TC2WC Pin-point Diagnostics..1897
            TC2WC Circuit Operation..1898
            Fault Detection/Management..1898
          Transfer Case Circuit..1899
            Tools..1900
            Pin-Point Diagnostics..1900
            SPN 2796 FMI 2 - Transfer Case Switch or Circuit Fault...1901
            Fault Overview..1901
            Malfunction Indicator Lamp (MIL) Reaction..1901
            Associated Faults..1901
            Drive Cycle to Determine Fault Status..1901
          VREF (Reference Voltage)..1903
          Function..1904
          Tools..1904
            VREF Pin-point Diagnostics..1905
            VREF Circuit Operation..1910
            Fault Detection / Management..1910
          WIF Sensor (Water In Fuel)..1911
          Function..1911
          Sensor Location..1911
          Tools..1911
            WIF Pin-point Diagnostics..1912
            WIF Circuit Operation..1914
            Fault Detection/Management..1914
      Table of Contents..1915
        Diagnostic Trouble Codes..1917
  tables..0
    Example..1346
    Example..1346
    Example..1347
    Example..1347
    Example..1348
    Example..1348
    Example..1349
    Example..1349
    Example..1349
    Example..1350
    Example..1351
    Example..1351
    Example..1352
    Voltage Checks at 24-Pin Connector..1355
    Voltage Checks at Relay..1355
    Main Power Relay Control Circuit Resistance Check..1355
    ACT PWR circuit to 24-Pin connector..1355
    ACM Power circuit checks..1359
    J1939 Voltage Checks..1360
    J1939 Harness Resistance Check..1360
    Connector Voltage Check..1362
    Harness Resistance Check..1363
    Connector Voltage Check..1366
    Harness Resistance Check..1367
    Connector Voltage Check..1374
    Harness Resistance Check..1375
    Connector Voltage Check..1382
    Harness Resistance Check..1382
    Connector Voltage Check..1385
    Harness Resistance Check..1385
    AFT System Event Map..1391
    SPN 3246 FMI 20 ? DPF over temperature - possible filter damage..1392
    SPN 3719 FMI 0 ? DPF Soot Load - Highest (level 3/3)..1392
    SPN 3719 FMI 15 ? DPF Soot Load - Lowest (level 1/3)..1392
    SPN 3719 FMI 16 ? DPF Soot Load - Moderate (level 2/3)..1392
    SPN 3936 FMI 0 ? DPF Soot Load - Severe De-Rate..1393
    AFT System Cold Soak Sensor Compare Check..1393
    Entry Conditions for a Parked Regen..1427
    Sensor Compare Checks..1429
    Exhaust Restriction Test..1429
    Check Rolling Regen Inhibitors..1430
    Check Rolling Regen Inhibitors..1431
    Parked Regen Checks..1432
    SPN 1209 FMI 0 - EBP above desired level..1443
    SPN 1209 FMI 1 - EBP below desired level..1444
    SPN 2659 FMI 14 - AMS - KOER AMT - EGR test failure..1444
    SPN 2659 FMI 20 - EGR flow excessive - EGR High Flow Rate detected..1444
    SPN 2659 FMI 21 - AMS - EGR Low Flow Rate detected..1445
    Cold Soak Sensor Compare Check..1445
    Sensor Circuit Check..1459
    Harness Resistance Check..1460
    Operational Voltage Check..1460
    Connector Voltage Check - EST..1463
    Harness Resistance Check..1463
    Connector Voltage Check..1467
    Connector Resistance Check to GND..1467
    Harness Resistance Check..1467
    Programmable Parameters..1482
    Switch Checks..1483
    Sensor and Circuit Resistance Check..1485
    Harness Resistance Check..1485
    Operational Checks..1486
    Sensor and Circuit Resistance Check..1488
    Harness Resistance Check..1489
    Operational Checks..1489
    SPN 4765 FMI 2 - DOCIT signal does not agree with other exhaust sensors..1497
    SPN 4765 FMI 7 - DOCIT not increasing with engine temperature..1497
    Sensor Circuit Check..1497
    Connector Voltage Check..1498
    Harness Resistance Check..1498
    SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor/circuit fault or missing DPF)..1507
    SPN 3251 FMI 2 - DPFDP above or below desired level..1508
    SPN 3251 FMI 10 - DPFDP signal abnormal rate of change..1508
    SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor/circuit fault or missing DPF)..1508
    Sensor Circuit Check..1509
    Connector Voltage Check..1510
    Harness Resistance Check..1510
    SPN 3242 FMI 2 - DPFIT signal does not agree with other exhaust sensors..1513
    Sensor Circuit Check..1514
    Connector Voltage Check..1514
    Harness Resistance Check..1515
    SPN 3246 FMI 2 - DPFOT signal does not agree with other exhaust sensors..1525
    SPN 3246 FMI 7 - DPFOT not warming along with engine..1526
    Sensor Circuit Check..1527
    Connector Voltage Check..1527
    Harness Resistance Check..1527
    SPN 1209 FMI 2 - EBP signal does not agree with other sensors at KOEO..1529
    Sensor Circuit Check..1530
    Connector Voltage Check..1531
    Harness Resistance Check..1531
    Voltage Check at EBPV Connector ? Output State Test..1533
    Operational Voltage Check..1534
    Harness Resistance Check..1534
    Connector Voltage Check..1537
    Connector Resistance Checks to GND..1537
    Actuator Resistance Check..1537
    Harness Resistance Check..1537
    Sensor Circuit Check..1541
    Connector Voltage Check..1542
    Under Valve Cover Resistance Check..1542
    Harness Resistance Check..1542
    Voltage Check at Relay..1546
    Voltage Check at ECM..1546
    Harness Resistance Check ? ECM to Relay..1547
    Operational Voltage Check..1547
    Harness Resistance Check ? Relay to Battery..1547
    Connector Voltage Check..1550
    Connector Resistance Check to GND..1550
    Harness Resistance Check..1550
    Voltage Checks at Relay..1554
    Voltage Checks at ECM..1554
    Harness Resistance Check..1555
    Harness Resistance Check on Relay Power Circuits..1555
    Connector Voltage Check..1563
    Harness Resistance Check..1563
    Connector Voltage Check..1573
    Harness Resistance Check..1573
    Switch Checks..1574
    SPN 108 FMI 2 - BARO Low/High at KOEO..1583
    SPN 108 FMI 3 - BARO signal out-of-range HIGH..1583
    SPN 108 FMI 4 - BARO signal out-of-range LOW..1583
    SPN 628 FMI 12 - ECM Error - Program memory error..1583
    SPN 629 FMI 12 - ECM Error - Internal hardware failure..1583
    SPN 1136 FMI 0 - ECM Error - over temperature..1583
    Sensor Circuit Check..1591
    Connector Voltage Check..1591
    Harness Resistance Check..1591
    SPN 110 FMI 2 - ECT1 above/below sensor compare at KOEO Cold..1600
    SPN 110 FMI 7 - ECT1 and EOT Temperature Conflict..1600
    Sensor Circuit Check..1601
    Connector Voltage Check..1601
    Harness Resistance Check..1602
    Voltage Check at EFC Connector - Output State Test..1618
    Voltage Check at Relay - Output State Test..1619
    Harness Resistance Check..1619
    Voltage Checks at Relay..1625
    Fuel Pump Operational Check..1625
    Harness Voltage Checks..1626
    Harness Resistance Check..1626
    Connector Voltage Check..1630
    Operational Voltage Check ? Output State Test..1631
    Harness Resistance Check..1631
    Connector Voltage Check..1651
    Harness Resistance Check..1651
    Sensor Circuit Check..1672
    Connector Voltage Check..1672
    Harness Resistance Check..1672
    SPN 175 FMI 2 - EOT In Range Fault..1676
    Sensor Circuit Check..1677
    Connector Voltage Check..1678
    Harness Resistance Check..1678
    ETV Actuator Circuit Check..1686
    Connector Voltage Check..1686
    Harness Resistance Check..1687
    Sensor Circuit Check..1711
    Connector Voltage Check..1711
    Harness Resistance Check..1711
    Amperage Draw Check..1718
    Element Resistance Check..1719
    Voltage Check on Relay Switch ? Output State Test..1719
    Voltage Check on Relay Coil ? Output State Test..1719
    Harness Resistance Check ? Relay Coil Circuits..1720
    Harness Resistance Check ? Relay Switch Circuits..1720
    SPN 164 FMI 0 - signal above KOEO Spec..1722
    Sensor Circuit Check..1723
    Connector Voltage Check..1724
    Under Valve Cover Resistance Check to Engine GND..1724
    Harness Resistance Check..1724
    SPN 102 FMI 0 - IMP signal does not agree with BARO..1745
    Sensor Circuit Check..1746
    Connector Voltage Check..1747
    Harness Resistance Check..1747
    SPN 105 FMI 2 - IMT signal does not agree with other sensors..1766
    Sensor Circuit Check..1767
    Connector Voltage Check..1768
    Harness Resistance Check..1768
    Injector 1 ? Resistance Through Valve Cover Check..1774
    Injector 1 - Coil Resistance Checks..1774
    Injector 1 ? Harness Resistance Check..1774
    Injector 2 ? Resistance Through Valve Cover Check..1775
    Injector 2 ? Coil Resistance Check..1775
    Injector 2 ? Harness Resistance Check..1776
    Injector 3 ? Resistance Through Valve Cover Check..1777
    Injector 3 ? Coil Resistance Check..1778
    Injector 3 ? Harness Resistance Check..1778
    Injector 4 ? Resistance Through Valve Cover Check..1779
    Injector 4 ? Coil Resistance Check..1779
    Injector 4 ? Harness Resistance Check..1780
    Injector 5 ? Resistance Through Valve Cover Check..1781
    Injector 5 ? Coil Resistance Check..1782
    Injector 5 ? Harness Resistance Check..1782
    Injector 6 ? Resistance Through Valve Cover Check..1783
    Injector 6 ? Coil Resistance Check..1783
    Injector 6 ? Harness Resistance Check..1784
    Injector Control Group 1 ? Resistance Through Valve Cover Check..1795
    Injector Control Group 1 - Coil Resistance Checks..1796
    Injector Control Group 1 ? Harness Resistance Check..1796
    Injector Control Group 2 ? Resistance Through Valve Cover Check..1802
    Injector Control Group 2 - Coil Resistance Checks..1803
    Injector Control Group 2 ? Harness Resistance Check..1803
    Connector Voltage Check..1826
    Operational Voltage Check ? Output State Test..1826
    Actuator Resistance Check..1827
    Harness Resistance Check..1827
    Connector Voltage Check..1847
    EST Communication Check..1848
    Harness Resistance Check..1848
    MAF Calibration Requirements..1854
    MAF Calibration Pre-Checks..1854
    MAF Calibration Procedure ? Using ServiceMaxx? Software..1855
    Connector Voltage Check..1856
    Harness Resistance Check..1856
    Voltage Check at TC1WC Connector ? Output State Test..1870
    Harness Resistance Check..1870
    Connector Voltage Check..1880
    Connector Resistance Check to GND..1880
    Harness Resistance Check..1881
    Voltage Check at TC2WC Connector ? Output State Test..1897
    Harness Resistance Check..1898
    Connector Voltage Check..1900
    Harness Resistance Check..1900
    VREF Voltage Check..1907
    Connector Resistance Check to GND..1908
    Harness Resistance Check..1909
    Voltage Check..1913
    Harness Resistance Check..1913
0000001681 (Rev.2) - 2010 MaxxForce 7 Engine Diagnostic Manual..1925
  toc..1927
    Table of Contents..1927
    Safety Terminology..1931
    Safety Instructions..1931
    Work Area..1931
    Safety Equipment..1931
    Protective Measures..1931
    Vehicle..1931
    Engine..1932
    Fire Prevention..1932
    Batteries..1932
    Compressed Air..1932
    Tools..1932
    Fluids Under Pressure..1933
    Fuel..1933
    Removal of Tools, Parts, and Equipment..1933
      Table of Contents..1935
        Engine Identification..1937
          Engine Serial Number..1937
          Engine Serial Number Example..1937
          Emission Label..1937
          Engine Accessories..1938
          Engine Description..1938
            Standard Features..1939
            Optional Features..1940
            Chassis-mounted Features..1940
          Engine Components..1941
        Air Management System..1946
          Air Management Components and Air Flow..1946
            Air Flow..1947
          Charge Air Cooler (CAC)..1947
          Charge Air Cooler Outlet Temperature (CACOT) Sensor..1947
          Dual Turbocharger Assembly..1949
            High-pressure Turbocharger..1950
            Turbocharger 1 Compressor Outlet Temperature (TC1COT) Sensor..1950
            Low-pressure Turbocharger..1950
            Turbocharger 2 Wastegate (TC2WG) Solenoid..1950
          Exhaust Gas Recirculation (EGR) System..1951
            EGR Flow..1951
            EGR Control Valve and Position Sensor..1952
            Engine Throttle Valve (ETV) and Position Sensor..1954
          Aftertreatment (AFT) System..1956
            AFT Control System..1956
            Sensors..1956
            Diesel Oxidation Catalyst (DOC)..1957
            Diesel Particulate Filter (DPF)..1957
            AFT Conditions and Responses..1957
        Fuel System..1958
          Fuel System Components..1958
          High-pressure Fuel System..1959
            High-pressure Fuel Pump (HPFP) Assembly..1959
            Internal Transfer Pump (ITP)..1959
            Fuel Pressure Control Valve (FPCV)..1960
            Fuel Volume Control Valve (FVCV)..1960
            Fuel Rail Pressure (FRP) Sensor..1960
            High-pressure Piezo Common Rail (HPCR) System..1960
            Return Fuel System..1960
          Low-pressure Fuel System..1962
            Fuel Pump..1962
            Primary Fuel Filter..1962
            Secondary Fuel Filter..1962
            Fuel Cooler..1962
          Fault Detection / Management..1962
        Engine Lubrication System..1963
          Lubrication System Components and Oil Flow..1963
        Cooling System..1965
          Cooling System Components and Flow..1965
            Water Pump..1965
            Front Crankcase Cover Flow..1966
            Thermostats..1966
            Deaeration Tank..1966
            Radiator Shutters (220 Horsepower only)..1966
            Fuel Coolant Valve (FCV)..1967
        Engine Speed Position System..1968
        Electronic Control System..1969
          Electronic Control System Components..1969
            Operation and Function..1971
            Reference Voltage (VREF)..1971
            Signal Conditioner..1971
            Microprocessor..1971
            Microprocessor Memory..1971
            Flash Memory..1972
            RAM..1972
            Engine Fan Control (EFC)..1972
            Inlet Air Heater (IAH)..1972
            Actuator Control..1972
          Actuators..1973
            H-Bridge Circuit..1973
            Exhaust Gas Recirculating (EGR) Valve and Control..1973
            ETV and Engine Throttle Position Sensor..1974
          Engine and Vehicle Sensors..1974
            Thermistor Sensors..1974
            Variable Capacitance Sensors..1976
            Micro Strain Gauge (MSG) Sensor..1977
            MSG Sensors..1977
            Magnetic Pickup Sensors..1978
            Magnetic Pickup Sensors..1978
            Potentiometer..1979
            Potentiometer..1979
            Switches..1980
            Switches..1980
          Inlet Air Heater (IAH) System..1981
      Table of Contents..1983
        Standard Features..1985
          Electronic Governor Control..1985
          SAE J1939 Data Link - also known as CAN (public)..1985
          SAE J1587 Data Link - also known as the American Trucking Association (ATA) data link...1985
          Service Diagnostics..1985
          Event Logging System..1987
          Electronic Speedometer and Tachometer..1987
          Aftertreatment (AFT) System..1987
          Fuel Delivery Pressure (FDP) Monitor..1987
          Inlet Air Heater (IAH)..1987
          Fast Idle Advance..1987
          Cold Ambient Protection (CAP)..1987
          Coolant Temperature Compensation (CTC)..1989
          Engine Crank Inhibit (ECI)..1989
        Optional Features..1989
          Change Oil Service Interval..1989
          Road Speed Limiting (RSL)..1989
          Cruise Control..1989
          Traction Control..1990
          Exhaust Back Pressure Valve (EBPV)..1990
          Engine Warning Protection System (EWPS)..1990
          Idle Shutdown Timer (IST)..1990
          IST for California ESS Compliant Engines..1990
          Engine Idle Shutdown Timer (IST for Federal?Optional)..1991
          Electronic Fan (EFAN)..1991
          Radiator Shutter Enable (RSE)..1992
          In Cab Power Take-Off (PTO) Control..1992
          Remote Accelerator Pedal Position (RAPP)..1992
      Table of Contents..1993
        Connecting EST with ServiceMaxx? Software to Engine..1995
        Viewing Diagnostic Trouble Codes..1995
          Diagnostic Trouble Codes (DTCs)..1995
          Suspect Parameter Number (SPN) ..1995
          Failure Mode Indicator (FMI)..1995
          Active and Previously Active DTCs..1995
        Service Bay Tests..1996
          Key On, Engine Off (KOEO) Tests..1996
          Tools..1996
            KOEO Standard Test..1996
            KOEO Output State Low and High..1997
            KOEO Intake Air Heater..1998
            KOEO Continuous Monitor Test..1999
            Relative Compression Test..2000
          Key On, Engine Running (KOER) Tests..2001
            KOER Standard Test..2001
            KOER Air Management Test..2001
            KOER Cylinder Cutout Test..2001
          Key On, Engine Running (KOER) Aftertreatment Tests..2003
            Onboard Filter Cleanliness Test..2003
        ServiceMaxx? Procedures..2003
          Fuel Pressure Adaptation Reset..2003
          KOER MAF Sensor Calibration..2004
      Table of Contents..2005
        Coolant System..2007
          Air Compressor Leak Test..2007
          Tools..2007
          Combustion Leaks to Coolant..2009
          Symptom..2009
          Possible Causes..2009
          Tools..2009
            Combustion Leak Test..2009
          Coolant Leak to Exhaust / Intake..2010
          Symptoms..2010
          Possible Causes..2010
          Tools..2011
            EGR Cooler Inspection..2011
          Coolant in Lube Oil..2012
          Symptom..2012
          Possible Causes..2012
          Tools..2013
            Lube Oil Contamination..2014
            Front Cover Inspection..2016
            Cylinder Head Leak Test..2016
          Coolant Over-Temperature..2017
          Symptom..2017
          Possible Causes..2018
          Tools..2018
            Coolant Over-Temperature Diagnostics and Repair..2019
            Temperature Sensor Validation Test..2020
            Cooling System Operating Pressure Test..2020
        Engine Inspection..2021
        Symptom..2021
        Possible Causes..2021
        Low Power..2021
        Rough Idle..2022
        Tools..2022
          Low Power (Turbocharger Assembly and Actuator)..2022
          Rough Idle..2022
          Engine and Flexplate Balance Inspection..2023
          Manual Compression Test..2024
          Tools..2024
            Test Procedure..2024
        Electrical System..2025
          ECM Reset (Intermittent Engine Stumble)..2025
          Symptom..2025
          Possible Causes..2025
            Diagnostics for Engine Stumble..2025
        Fuel System..2026
          Excessive Fuel Consumption..2026
          Symptom..2026
          Possible Causes..2026
          Operator effects..2026
          Application effects..2026
          Chassis effects..2026
          Engine effects..2027
            Verifying Excessive Fuel Consumption Complaints..2028
          Fuel in Coolant..2028
          Symptom..2028
          Possible Causes..2028
          Tools..2028
            Fuel in Coolant Leakage Test (Low-pressure)..2029
            Fuel in Coolant Leakage Test (High-pressure)..2030
          Fuel In Lube Oil..2031
          Symptom..2031
          Possible Causes..2031
          Leaking fuel under the valve cover..2031
          Porous cylinder head..2031
          Tools..2031
            Verifying Fuel Dilution from Oil System..2031
            Symptoms..2031
            Fuel Dilution Diagnostics..2031
            Fuel to Exhaust..2033
            Symptom..2033
            Possible Causes..2033
          Air or Combustion Leaks to Fuel..2033
          Possible Causes..2033
            Air or Combustion Leak to Fuel Test..2034
            Low Fuel Pressure and Aeration..2034
            Symptom..2034
            Possible Causes..2035
          Water In Fuel (WIF) Check..2035
          Possible Causes..2035
          Tools..2035
            Drain Water from Primary Fuel Filter..2035
          Over-Temperature..2036
          Symptom..2036
          Possible Causes..2036
          Tools..2036
            Fuel Over-Temperature Diagnosis and Repair..2036
        Lubrication System..2038
          Turbocharger Oil Discharge..2038
          Symptoms..2038
          Possible Causes..2039
            Diagnosing Turbocharger Oil Discharge from Turbine Outlet..2041
            Diagnosing Turbocharger Oil Discharge from Compressor Outlet..2042
          Low Oil Pressure..2043
          Possible Causes..2043
          Tools..2043
             Low Oil Pressure Diagnostics..2044
          Over-Temperature..2045
          Symptom..2045
          Possible Causes..2045
          Tools..2046
            Oil Over-Temperature Diagnosis and Repair..2046
            Sensor Validation Test..2046
      Table of Contents..2047
        Diagnostics Form..2049
          Diagnostics Form Header Information..2052
          Enter Diagnostics Form Header Information..2052
        Test Procedures..2054
          1. Initial Key On Check..2054
          Purpose..2054
          Tools..2054
          Procedure..2054
          Possible Causes..2054
          WAIT TO START lamp does not illuminate..2054
          WARN ENGINE lamp stays illuminated..2055
          2. Visual Inspection..2056
          Purpose..2056
          Tools..2056
            Engine Oil..2056
            Engine Coolant Level..2056
            Electrical System..2056
            Exhaust System..2057
            Intake Air System and Charge Air Cooler (CAC)..2058
            2.1 Fuel Level Check..2058
            2.2 Fuel Quality Check..2059
            Purpose..2059
            Tools..2059
            Possible Causes..2059
            Procedure..2059
          3. EST Connection and Data Recording..2060
          Purpose..2061
            Monitoring Engine Systems using an EST..2061
            Tools..2061
            Procedure..2061
          4. Check for DTCs..2062
          Purpose..2062
          Tools..2063
          Procedure..2063
          5. Engine Cranking..2063
          Purpose..2063
            Monitoring Engine Systems using an EST..2063
            Tools..2063
            Procedure..2064
            Possible Causes..2064
            Low battery voltage..2064
            Low cranking rpm..2065
            Low Fuel Rail Pressure..2065
            Monitoring FRP using a Breakout Harness..2065
            Tools..2065
            Procedure..2065
            Possible Causes..2066
        Special Test Procedures..2067
          Inlet Air Heater (IAH) Test..2067
          Purpose..2067
          Tools..2067
          Possible Causes..2067
            Amperage Draw..2067
            Procedure..2067
          Low-pressure Fuel System ..2069
            LP.1 - Electrical Fuel Pump Check..2070
            Purpose..2070
            Tools..2070
            Procedure..2070
            LP.2 - Fuel Pressure Test..2070
            Purpose..2070
            Tools..2070
            Check Fuel Delivery Pressure Using the EST ..2070
            Check Fuel Delivery Pressure Manually..2071
            LP.3 - Fuel Aeration Check..2072
            Purpose..2072
            Tools..2072
            Possible Causes..2072
            Procedure..2072
            LP.4 - Fuel Thermal Valve Check..2073
            Purpose..2073
            Tools..2073
            LP.5 - Fuel Pump Dead Head Test..2074
            Purpose..2074
            Tools..2074
            Procedure..2074
            LP.6 - Alternative Fuel Supply Test..2075
            Purpose..2075
            Possible Causes (High and Low Restriction)..2075
            Tools..2075
            Procedure..2075
            LP.7 - Return Fuel Flow Test..2076
            Purpose..2076
            Tools..2076
            Procedure..2076
            LP.8 - Fuel Return Restriction Test..2076
            Purpose..2076
            Tools..2076
            Procedure..2077
          High-pressure Fuel System Tests..2078
            HP.1 - Fuel Pressure Control Valve (FPCV) and Fuel Volume Control Valve (FVCV) Check..2079
            Purpose..2079
            Possible Causes..2079
            Tools..2079
            Procedure..2079
            HP.2 - FPCV and FVCV Resistance Check..2080
            Purpose..2080
            Possible Causes..2080
            Tools..2080
            Procedure..2080
            HP.3 - Fuel Rail Leak Check..2081
            Purpose..2081
            Possible Causes..2081
            Tools..2081
            Procedure..2081
            HP.4 - High-pressure Fuel Pump (HPFP) Dead Head Test..2082
            Possible Causes..2082
            Tools..2083
            Procedure..2083
            HP.5 - Injector Leak Isolation Check (Left Bank)..2083
            Purpose..2083
            Possible Causes..2083
            Tools..2084
            Procedure..2084
            HP.6 - Injector Leak Isolation Check (Right Bank)..2084
            Purpose..2084
            Possible Causes..2084
            Tools..2084
            Procedure..2084
      Table of Contents..2085
        Diagnostic Form..2087
          Diagnostics Form Header Information..2090
          Enter Diagnostics Form Header Information..2090
        Test Procedures..2092
          1. Initial Key On Check..2092
          Purpose..2092
          Tools..2092
          Procedure..2092
          Possible Causes..2092
          WAIT TO START lamp does not illuminate..2092
          AMBER WARNING lamp stays illuminated..2092
          2. Visual Inspection..2092
          Purpose..2093
          Tools..2093
            Engine Oil..2093
            Fuel Level..2093
            Engine Coolant Level..2095
            Electrical System..2095
            Exhaust System..2095
            Intake Air System and Charge Air Cooler (CAC)..2095
          3. EST Connection and Data Recording..2096
          Purpose..2096
            Monitoring Engine Systems using an EST..2096
            Tools..2096
            Procedure..2096
          4. Check for DTCs..2097
          Purpose..2097
          Tools..2097
          Procedure..2097
          5. Fuel Quality Check..2098
          Purpose..2098
          Tools..2098
          Possible Causes..2098
          Procedure..2098
          6. Fuel Pressure and Aeration Check..2100
          Purpose..2100
          Tools..2100
          Check Fuel Delivery Pressure Using the EST ..2100
          Check Fuel Delivery Pressure Manually..2100
          7. Engine Low Idle to High Idle..2101
          Purpose..2101
          Tools..2101
          Procedure..2101
          8. Road Test (0?60 mph, Full Throttle)..2103
          Purpose..2103
          Tools..2103
          Procedure..2104
        Special Test Procedures..2105
          Turbocharger Checks (Under Boost)..2105
          Purpose..2105
          Possible Causes..2105
          Procedure..2105
          Wastegate Checks (Over Boost)..2105
          Purpose..2105
          Tools..2105
          Procedure..2105
          Charge Air Cooler (CAC) Checks..2107
          Purpose..2107
          Possible Causes..2107
          Procedure..2107
          Blow-by Test..2107
          Purpose..2107
          Tools..2107
          Possible Causes..2107
          Procedure..2108
          Crankcase Pressure Test..2109
          Purpose..2109
          Tools..2109
          Possible Causes..2109
          Procedure..2109
          Intake Air Restriction Test..2111
          Purpose..2111
          Tools..2111
          Possible Causes..2111
          Procedure..2111
          Relative Compression Test..2112
          Purpose..2112
          Tools..2112
          Possible Causes..2112
          Procedure..2112
          Cylinder Cutout Test..2112
          Purpose..2112
          Tools..2112
          Possible Causes..2112
          Procedure..2113
      Table of Contents..2115
        Description..2119
          Section Information..2119
        Electronic Control System Diagnostics Form..2120
          0000003201 Diagnostic Form ..2120
        Sensor and Actuator Locations..2121
          Engine Mounted Components..2121
         Diagnostic Procedure Process..2126
          Description..2126
            Pin-grip Inspection..2126
            Diagnostics with EST..2126
            Diagnostics without EST..2126
          Sensor End Diagnostics (with ServiceMaxx? software)..2127
            Sensor End Diagnostics (2-Wire)..2127
            Sensor End Diagnostics (3-Wire)..2128
          Pin-point Diagnostics (without ServiceMaxx? software)..2132
          Actuator Operational Voltage Check ? Output State Test..2132
          Harness Resistance Check..2133
          Operational Voltage Check..2134
        Circuit Diagnostics..2135
          AFT (Aftertreatment) System..2135
            AFT System Diagnostics..2135
            Overview..2139
            Tools..2139
            AFT System Operation..2139
            Diesel Oxidation Catalyst (DOC)..2141
            Diesel Particulate Filter (DPF)..2141
            Regeneration..2141
            Passive Rolling Regeneration..2141
            Parked Regeneration Switch..2141
            Inhibit Regeneration Switch (optional)..2142
            DPF Soot Loading Percentage..2142
            DPF Ash Loading Percentage..2142
            DPF Status Lamp..2142
            High Exhaust System Temperature (HEST) Indicator ..2142
            Pinpoint Diagnostics With ServiceMaxx? Software..2145
            SPN 3936 FMI 2 - DPF System Feedback Control Fault..2148
            Fault Overview..2148
            Malfunction Indicator Lamp (MIL) Reaction..2148
            Fault Fact..2148
            Associated Faults..2148
            Drive Cycle to Determine Fault Status..2148
            SPN 3936 FMI 8 - DPF Regenerations are Occurring too Frequently..2150
            Fault Overview..2150
            Malfunction Indicator Lamp (MIL) Reaction..2150
            Associated Faults..2150
            Drive Cycle to Determine Fault Status..2150
            SPN 3936 FMI 20 - DPF Feedback - Feedback Max Authority..2155
            Fault Overview..2155
            Malfunction Indicator Lamp (MIL) Reaction..2155
            Fault Fact..2155
            Associated Faults..2155
            Drive Cycle to Determine Fault Status..2155
            SPN 4766 FMI 10 - Catalyst System Efficiency Below Threshold..2157
            Fault Overview..2158
            Fault Fact..2158
            Associated Faults..2158
            Drive Cycle to Determine Fault Status..2158
            SPN 5319 FMI 17 - DPF Incomplete Regeneration ..2160
            Fault Overview..2161
            Amber Warning Lamp (AWL) Reaction..2161
            Fault Fact..2161
            Associated Faults..2161
            Drive Cycle to Determine Fault Status..2161
            SPN 5319 FMI 31 - DPF Incomplete Regeneration ..2163
            Fault Overview..2164
            Malfunction Indicator Lamp (MIL) Reaction..2164
            Fault Fact..2164
            Associated Faults..2164
            Drive Cycle to Determine Fault Status..2164
          AMS (Air Management System)..2167
            Overview..2171
            Tools..2171
            Pinpoint Diagnostics..2171
            SPN 2659 FMI 10 - EGR Slow Response Fault..2176
            Fault Overview..2176
            Malfunction Indicator Lamp (MIL) Reaction..2176
            Associated Faults..2176
            Drive Cycle to Determine Fault Status..2176
            SPN 2659 FMI 15 - EGR High Flow Rate Detected..2180
            Fault Overview..2180
            Amber Warning Lamp (AWL) Reaction..2180
            Associated Faults..2180
            Drive Cycle to Determine Fault Status..2181
            SPN 2659 FMI 17 - EGR Low Flow Rate Detected..2183
            Fault Overview..2183
            Amber Warning Lamp (AWL) Reaction..2183
            Associated Faults..2183
            Drive Cycle to Determine Fault Status..2183
            SPN 2659 FMI 20 - EGR High Flow Rate Detected..2185
            Fault Overview..2185
            Malfunction Indicator Lamp (MIL) Reaction..2185
            Associated Faults..2185
            Drive Cycle to Determine Fault Status..2186
            SPN 2659 FMI 21 - EGR Low Flow Rate Detected..2188
            Fault Overview..2188
            Malfunction Indicator Lamp (MIL) Reaction..2188
            Associated Faults..2188
            Drive Cycle to Determine Fault Status..2188
            SPN 5543 FMI 16 - EBP Valve Internal Temperature Fault..2190
            Fault Overview..2190
            Malfunction Indicator Lamp (MIL) Reaction..2190
            Associated Faults..2190
            Drive Cycle to Determine Fault Status..2190
            Thermal Management Valve (TMV) Programmable Parameters..2190
            SPN 5543 FMI 19 - EBPC valve not detected on J1939..2194
            Fault Overview..2194
            Malfunction Indicator Lamp (MIL) Reaction..2194
            Associated Faults..2194
            Drive Cycle to Determine Fault Status..2194
            Thermal Management Valve (TMV) Programmable Parameters..2194
            SPN 5543 FMI 20 - EBP valve electrical fault..2197
            Fault Overview..2197
            Malfunction Indicator Lamp (MIL) Reaction..2197
            Associated Faults..2197
            Drive Cycle to Determine Fault Status..2197
            Thermal Management Valve (TMV) Programmable Parameters..2197
          APP (Accelerator Pedal Position) Sensor ..2200
          Function..2200
          Sensor Location..2200
          Tools..2201
            APP Sensor End Diagnostics..2202
            APP Pin-point Diagnostics..2205
            APP Circuit Operation..2207
            Accelerator Pedal Position (APP) sensor..2207
            Fault Detection / Management..2207
          ATA (American Trucking Association) Data Link (SAE J1587)..2208
          Function..2208
          Location..2209
          Tools..2209
            ATA (SAE J1587) Pin-point Diagnostics..2210
            ATA (SAE J1587) Operation..2211
            Diagnostic Connector..2211
            Electronic Gauge Cluster (EGC)..2211
            Fault Detection / Management..2212
            Repair Information..2212
          Brake Switch Circuits..2213
          Function..2213
          Location..2214
          Tools..2214
            Brake Switch Circuits Pin-point Diagnostics..2215
            Brake Switch Circuit Operation..2216
            Fault Detection / Management..2216
          CACOT (Charge Air Cooler Outlet Temperature) Sensor..2217
            Overview..2218
            Tools..2219
            SPN 2630 FMI 2 - CACOT Signal erratic, intermittent, or incorrect..2221
            Fault Overview..2222
            Malfunction Indicator Lamp (MIL) Reaction..2222
            Associated Faults..2222
            Drive Cycle to Determine Fault Status..2222
            SPN 2630 FMI 3 - CACOT signal out of range HIGH..2225
            Fault Overview..2225
            Malfunction Indicator Lamp (MIL) Reaction..2225
            Associated Faults..2225
            Drive Cycle to Determine Fault Status..2225
            SPN 2630 FMI 4 - CACOT signal out of range LOW..2228
            Fault Overview..2228
            Malfunction Indicator Lamp (MIL) Reaction..2228
            Associated Faults..2228
            Drive Cycle to Determine Fault Status..2228
            SPN 2630 FMI 16 - CACOT Undercooling..2231
            Fault Overview..2232
            Malfunction Indicator Lamp (MIL) Reaction..2232
            Associated Faults..2232
            Drive Cycle to Determine Fault Status..2232
            SPN 2630 FMI 21 - CACOT signal Drifted LOW..2235
            Fault Overview..2235
            Malfunction Indicator Lamp (MIL) Reaction..2235
            Associated Faults..2235
            Drive Cycle to Determine Fault Status..2235
          CAN (Controller Area Network) Communications (J1939) ..2238
          Function..2238
          Location..2239
          Tools..2239
            CAN (J1939) Pin-point Diagnostics..2240
            CAN (J1939) Circuit Operation..2241
            CAN (J1939) versus ATA (SAE J1587)..2242
            Diagnostic Connector..2242
             Electronic Gauge Cluster (EGC)..2242
            Body Controller (BC) or Multiplex System Module (MSM)..2242
            Repair Information..2243
          CCS (Cruise Control Switches)..2244
          Function..2245
          Location..2245
          Tools..2245
            Cruise Control Switches Pin-point Diagnostics ..2245
          CKP (Crankshaft Position) Sensor..2247
          Function..2247
          Sensor Location..2247
          Tools..2247
            CKP Pin-point Diagnostics..2248
            CKP Circuit Operation..2249
            Fault / Detection Management..2249
          CMP (Camshaft Position) Sensor..2250
            CMP Diagnostics..2250
            Overview..2251
            Tools..2252
            Pinpoint Diagnostics With ServiceMaxx? Software..2252
            SPN 636 FMI 10 - CMP signal inactive..2254
            Fault Overview..2254
            Malfunction Indicator Lamp (MIL) Reaction..2254
            Fault Fact:..2254
            Associated Faults..2254
            Drive Cycle to Determine Fault Status..2254
          Cylinder Balance..2256
            Cylinder Balance Diagnostics..2256
            Overview..2258
            Pin-Point Diagnostics With ServiceMaxx? Software..2259
            SPN 1322 FMI 31 - Misfire ? Multiple Cylinder..2260
            Fault Overview..2260
            Malfunction Indicator Lamp (MIL) Reaction..2260
            Associated Faults..2261
            Drive Cycle to Determine Fault Status..2261
          DOCIT (Diesel Oxidation Catalyst Inlet Temperature) Sensor..2264
            DOCIT Sensor End Diagnostics..2264
            Overview..2265
            Tools..2266
            Pinpoint Diagnostics With ServiceMaxx? Software..2266
            SPN 4765 FMI 2 - DOCIT signal erratic, intermittent, or incorrect..2269
            Fault Overview..2269
            Malfunction Indicator Lamp (MIL) Reaction..2269
            Associated Faults..2269
            Drive Cycle to Determine Fault Status..2269
            SPN 4765 FMI 8 - DOCIT signal abnormal rate of change..2272
            Fault Overview..2272
            Malfunction Indicator Lamp (MIL) Reaction..2272
            Associated Faults..2272
            Drive Cycle to Determine Fault Status..2272
            SPN 4765 FMI 10 - DOCIT in range stuck fault..2275
            Fault Overview..2275
            Malfunction Indicator Lamp (MIL) Reaction..2275
            Fault Fact..2275
            Associated Faults..2275
            Drive Cycle to Determine Fault Status..2275
            SPN 4765 FMI 21 - DOCIT signal drifted LOW..2279
            Fault Overview..2279
            Malfunction Indicator Lamp (MIL) Reaction..2279
            Associated Faults..2279
            Drive Cycle to Determine Fault Status..2279
          DPFDP (Diesel Particulate Filter Differential Pressure) Sensor ..2282
            DPFDP Sensor End Diagnostics..2282
            Overview..2284
            Tools..2285
            Pinpoint Diagnostics With ServiceMaxx? Software..2285
            SPN 3251 FMI 1 - DPFDP Negative Delta Pressure..2288
            Fault Overview..2288
            Malfunction Indicator Lamp (MIL) Reaction..2288
            Associated Faults..2288
            Drive Cycle to Determine Fault Status..2288
            SPN 3251 FMI 10 - DPFDP in range stuck fault..2291
            Fault Overview..2292
            Malfunction Indicator Lamp (MIL) Reaction..2292
            Associated Faults..2292
            Drive Cycle to Determine Fault Status..2292
            SPN 3251 FMI 18 - DPFDP excessively LOW (Sensor / circuit fault or missing DPF)..2295
            Fault Overview..2296
            Amber Warning Lamp (AWL) Reaction..2296
            Associated Faults..2296
            Drive Cycle to Determine Fault Status..2296
            SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor / circuit fault or missing DPF)..2299
            Fault Overview..2300
            Malfunction Indicator Lamp (MIL) Reaction..2300
            Associated Faults..2300
            Drive Cycle to Determine Fault Status..2300
          DPFIT (Diesel Particulate Filter Inlet Temperature) Sensor..2303
            DPFIT Sensor End Diagnostics..2303
            Overview..2304
            Tools..2305
            Pinpoint Diagnostics With ServiceMaxx? Software..2305
            SPN 3242 FMI 2 - DFPIT signal erratic, intermittent, or incorrect..2307
            Fault Overview..2307
            Malfunction Indicator Lamp (MIL) Reaction..2307
            Associated Faults..2307
            Drive Cycle to Determine Fault Status..2307
            SPN 3242 FMI 10 - DPFIT stuck in range LOW fault..2310
            Fault Overview..2310
            Malfunction Indicator Lamp (MIL) Reaction..2310
            Fault Fact..2310
            Associated Faults..2310
            Drive Cycle to Determine Fault Status..2310
            SPN 3242 FMI 21 - DPFIT signal Drifted LOW..2315
            Fault Overview..2315
            Malfunction Indicator Lamp (MIL) Reaction..2315
            Associated Faults..2315
            Drive Cycle to Determine Fault Status..2315
          DPFOT (Diesel Particulate Filter Outlet Temperature) Sensor..2318
            Overview..2319
            Tools..2320
            Pinpoint Diagnostics With ServiceMaxx? Software..2320
            SPN 3246 FMI 2 - DPFOT Signal erratic, intermittent, or incorrect..2322
            Fault Overview..2322
            Malfunction Indicator Lamp (MIL) Reaction..2322
            Associated Faults..2322
            Drive Cycle to Determine Fault Status..2322
            SPN 3246 FMI 10 - DPFOT signal abnormal rate of change..2325
            Fault Overview..2325
            Malfunction Indicator Lamp (MIL) Reaction..2325
            Associated Faults..2325
            Drive Cycle to Determine Fault Status..2325
            SPN 3246 FMI 21 - DPFOT signal Drifted LOW..2329
            Fault Overview..2329
            Malfunction Indicator Lamp (MIL) Reaction..2329
            Associated Faults..2329
            Drive Cycle to Determine Fault Status..2329
          ECL (Engine Coolant Level) Sensor..2332
          Function..2332
          Location..2332
          Tools..2332
            ECL Pin-point Diagnostics..2334
            ECL Circuit Operation..2335
            Fault Detection / Management..2335
          ECM (Engine Control Module) PWR Relay..2336
          Function..2336
          ECM Location..2337
          Tools..2337
            ECM PWR Pin-point Diagnostics..2338
            ECM PWR Circuit Operation..2341
            Fault Detection / Management..2342
          ECM (Engine Control Module) Self-Diagnostics ..2343
          Fault Detection / Management..2345
            Pinpoint Diagnostics With ServiceMaxx? Software..2345
            SPN 629 FMI 9 - Engine Off Timer Error..2347
            Fault Overview..2347
            Malfunction Indicator Lamp (MIL) Reaction..2347
            Associated Faults..2347
            Drive Cycle to Determine Fault Status..2347
          ECT1 (Engine Coolant Temperature 1) Sensor..2349
            Overview..2351
            Tools..2352
            Pinpoint Diagnostics With ServiceMaxx? Software..2352
            Connector Voltage Check..2353
            SPN 110 FMI 2 - ECT1 signal erratic, intermittent, or incorrect..2354
            Fault Overview..2354
            Malfunction Indicator Lamp (MIL) Reaction..2354
            Associated Faults..2354
            Drive Cycle to Determine Fault Status..2354
            SPN 110 FMI 16 - Engine Coolant System above OBD maximum temperature..2357
            Fault Overview..2357
            Malfunction Indicator Lamp (MIL) Reaction..2358
            Associated Faults..2358
            Drive Cycle to Determine Fault Status..2358
            SPN 110 FMI 17- Engine Coolant System below OBD monitoring temperature..2360
            Fault Overview..2361
            Malfunction Indicator Lamp (MIL) Reaction..2361
            Fault Fact..2361
            Associated Faults..2361
            Drive Cycle to Determine Fault Status..2361
            SPN 110 FMI 18 - Engine Coolant System below closed loop minimum temperature..2364
            Fault Overview..2364
            Malfunction Indicator Lamp (MIL) Reaction..2365
            Fault Fact..2365
            Associated Faults..2365
            Drive Cycle to Determine Fault Status..2365
            SPN 1659 FMI 20 - ECT1 below expected: Check thermostat..2368
            Fault Overview..2368
            Malfunction Indicator Lamp (MIL) Reaction..2369
            Fault Fact..2369
            Associated Faults..2369
            Drive Cycle to Determine Fault Status..2369
          EFC (Engine Fan Control)..2372
          Function..2372
          Location..2373
          Tools..2373
            EFC Circuit Diagnostics..2373
            EFC Circuit Operation..2375
            EFC Programmable Parameters..2375
            Fault Detection / Management..2375
          EFT (Engine Fuel Temperature) Sensor..2376
            Overview..2377
            Tools..2378
            Pinpoint Diagnostics With ServiceMaxx? Software..2378
            EFT Pin-point Diagnostics..2379
            SPN 174 FMI 2 - EFT Signal erratic, intermittent, or incorrect..2380
            Fault Overview..2380
            Malfunction Indicator Lamp (MIL) Reaction..2380
            Associated Faults..2380
            Drive Cycle to Determine Fault Status..2380
            SPN 174 FMI 21 - EFT signal drifted LOW..2383
            Fault Overview..2383
            Malfunction Indicator Lamp (MIL) Reaction..2383
            Associated Faults..2383
            Drive Cycle to Determine Fault Status..2383
          EGR (Exhaust Gas Recirculation) Valve ..2386
            Overview..2389
            Tools..2390
            Pinpoint Diagnostics..2390
            SPN 27- FMI 7 - EGRP Does Not Agree with Commanded Position..2393
            Fault Overview..2393
            Malfunction Indicator Lamp (MIL) Reaction..2393
            Associated Faults..2393
            Drive Cycle..2393
            SPN 4752 - FMI 4 - EGR Cooler Efficiency: EGR outlet temp above expected..2396
            Fault Overview..2396
            Malfunction Indicator Lamp (MIL) Reaction..2396
            Associated Faults..2396
            Drive Cycle..2396
          EGRT (Exhaust Gas Recirculation Temperature) Sensor..2399
            EGRT Sensor End Diagnostics..2399
            Overview..2400
            Tools..2401
            Pinpoint Diagnostics With ServiceMaxx? Software..2401
            EGRT Pin-point Diagnostics..2402
            SPN 412 FMI 2 - EGRT Signal erratic, intermittent, or incorrect..2403
            Fault Overview..2404
            Malfunction Indicator Lamp (MIL) Reaction..2404
            Associated Faults..2404
            Drive Cycle to Determine Fault Status..2404
            SPN 412 FMI 21 - EGRT Signal drifted LOW..2407
            Fault Overview..2407
            Malfunction Indicator Lamp (MIL) Reaction..2407
            Associated Faults..2407
            Drive Cycle to Determine Fault Status..2407
          EGT (Exhaust Gas Temperature) Sensor..2410
            Overview..2411
            Tools..2412
            Pinpoint Diagnostics With ServiceMaxx? Software..2412
            Connector Voltage Check..2413
            SPN 173 FMI 2 - EGT Signal erratic, intermittent, or incorrect..2414
            Fault Overview..2414
            Malfunction Indicator Lamp (MIL) Reaction..2414
            Associated Faults..2414
            Drive Cycle to Determine Fault Status..2414
            SPN 173 FMI 21 - EGT Stuck in Range LOW..2417
            Fault Overview..2417
            Malfunction Indicator Lamp (MIL) Reaction..2417
            Associated Faults..2417
            Drive Cycle to Determine Fault Status..2417
          EOP (Engine Oil Pressure) Sensor..2420
          Function..2420
          Sensor Location..2420
          Tools..2420
            EOP Sensor End Diagnostics..2422
            EOP Pin-point Diagnostics..2424
            EOP Circuit Operation..2425
            Fault Detection / Management..2425
          EOT (Engine Oil Temperature) Sensor..2426
            Overview..2427
            Fast Idle Advance..2427
            Tools..2428
            Pinpoint Diagnostics With ServiceMaxx? Software..2428
            EOT Pin-point Diagnostics..2429
            SPN 175 FMI 2 - EOT Signal erratic, intermittent, or incorrect..2431
            Fault Overview..2431
            Malfunction Indicator Lamp (MIL) Reaction..2431
            Fault Fact..2431
            Associated Faults..2431
            Drive Cycle to Determine Fault Status..2431
            SPN 175 FMI 21 - EOT signal drifted LOW..2434
            Fault Overview..2434
            Malfunction Indicator Lamp (MIL) Reaction..2434
            Associated Faults..2434
            Drive Cycle to Determine Fault Status..2434
          ETV (Engine Throttle Valve)..2437
            Overview..2439
            ETP (Engine Throttle Position) sensor..2439
            ETV actuator..2439
            Fault Detection / Management..2439
            Tools..2440
            Pinpoint Diagnostics With ServiceMaxx? Software..2440
            SPN 51 FMI 7 ETP Does not agree with commanded position..2443
            Fault Overview..2443
            Malfunction Indicator Lamp (MIL) Reaction..2443
            Associated Faults..2443
            Drive Cycle to Determine Fault Status..2443
          EWPS (Engine Warning Protection System)..2446
            EWPS Diagnostics..2446
            Overview..2448
            Tools..2448
            Pinpoint Diagnostics With ServiceMaxx? Software..2449
            EWPS Programmable Parameters..2449
            SPN 188 FMI 0 - Engine unable to achieve desired idle speed (too high)..2453
            Fault Overview..2453
            Malfunction Indicator Lamp (MIL) Reaction..2453
            Associated Faults..2454
            Drive Cycle to Determine Fault Status..2454
            SPN 188 FMI 1 - Engine unable to achieve desired idle speed (too low)..2456
            Fault Overview..2456
            Malfunction Indicator Lamp (MIL) Reaction..2456
            Fault Fact..2456
            Associated Faults..2456
            Drive Cycle to Determine Fault Status..2456
            SPN 5395 FMI 0 - Engine unable to achieve desired idle torque (too high)..2458
            Fault Overview..2458
            Malfunction Indicator Lamp (MIL) Reaction..2458
            Associated Faults..2458
            Drive Cycle to Determine Fault Status..2458
            SPN 5395 FMI 1 - Engine unable to achieve desired idle torque (too low)..2460
            Fault Overview..2460
            Malfunction Indicator Lamp (MIL) Reaction..2460
            Fault Fact..2460
            Associated Faults..2460
            Drive Cycle to Determine Fault Status..2460
          FCC (Fuel Cooler Control) Valve..2462
          Function..2462
          Sensor Location..2462
          Tools..2462
            Fuel Cooler Control Valve Circuit Diagnostics..2463
            Fuel Cooler Control Valve Circuit Operation..2464
          FDP (Fuel Delivery Pressure) Sensor..2466
          Function..2466
          Sensor Location..2466
          Tools..2466
            FDP Sensor End Diagnostics..2467
            FDP Pin-point Diagnostics..2470
            FDP Circuit Operation..2471
            Fault Detection / Management..2471
          FPCV (Fuel Pressure Control Valve)..2471
          Function..2473
          FPCV Location..2473
          Tools..2474
            FPCV Pin-point Diagnostics..2474
            FPCV Circuit Operation..2475
            Fault Detection / Management..2475
          Fuel Pump..2476
          Function..2476
          FPC Location..2476
          Tools..2476
            Fuel Pump Pin-point Diagnostics..2478
            Fuel Pump Actuator..2479
            Fault Detection / Management..2479
          FRP (Fuel Rail Pressure) Sensor..2480
            Overview..2480
            Tools..2482
            Pinpoint Diagnostics With ServiceMaxx? Software..2482
            Connector Voltage Check..2484
            SPN 157 FMI 9 - Fuel Rail Pressure (FRP) Abnormal Rate of Change..2486
            Fault Overview..2486
            Amber Warning Lamp (AWL) Reaction..2486
            Associated Faults..2486
            Drive Cycle to Determine Fault Status..2486
            SPN 157 FMI 10 - Fuel Rail Pressure (FRP) Abnormal Rate of Change..2489
            Fault Overview..2489
            Malfunction Indicator Lamp (MIL) Reaction..2489
            Associated Faults..2489
            Drive Cycle to Determine Fault Status..2489
            SPN 157 FMI 13 - FRP Above KOEO Spec..2492
            Fault Overview..2492
            Malfunction Indicator Lamp (MIL) Reaction..2492
            Associated Faults..2492
            Drive Cycle to Determine Fault Status..2492
            FRP System Diagnostics..2496
            Overview..2499
            Tools..2500
            SPN 3055 FMI 2 - FPCV adaptation in-range fault..2501
            Fault Overview..2501
            Malfunction Indicator Lamp (MIL) Reaction..2501
            Associated Faults..2501
            Drive Cycle to Determine Fault Status..2501
            SPN 3055 FMI 15 - Fuel Rail Pressure (FRP) Below Minimum with Maxiumum Command..2502
            Fault Overview..2503
            Malfunction Indicator Lamp (MIL) Reaction..2503
            Associated Faults..2503
            Drive Cycle to Determine Fault Status..2503
            SPN 3055 FMI 16 - Fuel Rail Pressure (FRP) Below Minimum with Maxiumum Command..2505
            Fault Overview..2505
            Amber Warning Lamp (AWL) Reaction..2505
            Associated Faults..2505
            Drive Cycle to Determine Fault Status..2505
            SPN 3055 FMI 17 - Fuel Rail Pressure (FRP) Above Maximum with Minimum Command..2507
            Fault Overview..2507
            Malfunction Indicator Lamp (MIL) Reaction..2507
            Associated Faults..2507
            Drive Cycle to Determine Fault Status..2507
            SPN 3055 FMI 18 - Fuel Rail Pressure (FRP) Above Maximum with Minimum Command..2509
            Fault Overview..2510
            Amber Warning Lamp (AWL) Reaction..2510
            Associated Faults..2510
            Drive Cycle to Determine Fault Status..2510
            SPN 3055 FMI 31 - FPCV adaptation in-range fault..2512
            Fault Overview..2513
            Amber Warning Lamp (AWL) Reaction..2513
            Associated Faults..2513
            Drive Cycle to Determine Fault Status..2513
          FVCV (Fuel Volume Control Valve)..2515
          Function..2516
          FVCV Location..2516
          Tools..2517
            FVCV Pin-point Diagnostics..2517
            FVCV Circuit Operation..2518
            Fault Detection / Management..2518
          IAH (Inlet Air Heater)..2519
            Overview..2521
            Tools..2522
            Pinpoint Diagnostics With ServiceMaxx? Software..2522
            SPN 729 FMI 18 - IAH Monitor: lack of heat in the intake manifold..2525
            Fault Overview..2525
            Malfunction Indicator Lamp (MIL) Reaction..2525
            Associated Faults..2525
            Drive Cycle to Determine Fault Status..2526
          IMP (Intake Manifold Pressure) Sensor..2529
            Overview..2531
            Tools..2532
            Pinpoint Diagnostics With ServiceMaxx? Software..2532
            IMP Pin-point Diagnostics..2533
            SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect..2535
            Fault Overview..2535
            Amber Warning Lamp (AWL) Reaction..2535
            Associated Faults..2535
            Drive Cycle to Determine Fault Status..2535
            SPN 102 FMI 15 - Overboost..2538
            Fault Overview..2538
            Amber Warning Lamp (AWL) Reaction..2538
            Associated Faults..2538
            Drive Cycle to Determine Fault Status..2538
            SPN 102 FMI 16 - Overboost..2541
            Fault Overview..2541
            Malfunction Indicator Lamp (MIL) Reaction..2541
            Associated Faults..2541
            Drive Cycle to Determine Fault Status..2541
            SPN 102 FMI 18 - Underboost..2544
            Fault Overview..2544
            Malfunction Indicator Lamp (MIL) Reaction..2544
            Associated Faults..2544
            Drive Cycle to Determine Fault Status..2544
          IMT (Intake Manifold Temperature) Sensor..2547
            Overview..2548
            Tools..2549
            Pinpoint Diagnostics With ServiceMaxx? Software..2549
            IMT Pin-point Diagnostics..2550
            SPN 105 FMI 2 - IMT signal erratic, intermittent, or incorrect..2551
            Fault Overview..2552
            Malfunction Indicator Lamp (MIL) Reaction..2552
            Associated Faults..2552
            Drive Cycle to Determine Fault Status..2552
            SPN 105 FMI 21 - IMT signal drifted LOW..2555
            Fault Overview..2555
            Malfunction Indicator Lamp (MIL) Reaction..2555
            Associated Faults..2555
            Drive Cycle to Determine Fault Status..2555
          INJ (Injector Circuits)..2558
            INJ Diagnostics..2558
            Overview..2559
            Tools..2560
            Pinpoint Diagnostics With ServiceMaxx? Software..2560
            Injector 1 Check..2560
            Injector 2 Check..2562
            Injector 3 Check..2563
            Injector 4 Check..2564
            Injector 5 Check..2565
            Injector 6 Check..2566
            Injector 7 Check..2567
            Injector 8 Check..2568
            SPN 2797 FMI 2 - Injector Control Group 1 Open Circuit (INJ 1, 3, 5, 7)..2569
            Fault Overview..2569
            Amber Warning Lamp (AWL) Reaction..2569
            Associated Faults..2569
            Drive Cycle to Determine Fault Status..2569
            SPN 2797 FMI 3 - Injector Control Group 1 Open Circuit (INJ 1, 3, 5, 7)..2572
            Fault Overview..2572
            Malfunction Indicator Lamp (MIL) Reaction..2572
            Associated Faults..2572
            Drive Cycle to Determine Fault Status..2572
            SPN 2798 FMI 2 - Injector Control Group 2 Open Circuit (INJ 2, 4, 6, 8)..2575
            Fault Overview..2575
            Amber Warning Lamp (AWL) Reaction..2575
            Associated Faults..2575
            Drive Cycle to Determine Fault Status..2575
            SPN 2798 FMI 3 - Injector Control Group 2 Open Circuit (INJ 2, 4, 6, 8)..2578
            Fault Overview..2578
            Malfunction Indicator Lamp (MIL) Reaction..2578
            Associated Faults..2578
            Drive Cycle to Determine Fault Status..2578
          IST (Idle Shutdown Timer) System ..2581
          Function..2582
          Tools..2582
            IST Operation..2582
            Idle Shutdown Warning..2582
            Engine Idle Shutdown Timer for California ESS-Compliant Engines..2582
            CARB IST Conditions..2583
            Engine Idle Shutdown Timer (Federal-Optional)..2583
            Federal IST Conditions..2583
            Common Enable Conditions for All Federal IST Options..2583
            Federal IST Mode 1: PTO Operation Option Enable Conditions..2584
            Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions..2584
            Federal IST Mode 3: Tamper Proof Option Enable Conditions..2584
            Fault Detection / Management..2584
          MAF / AIT (Mass Air Flow / Air Inlet Temperature) Sensor..2585
            Overview..2587
            Sensor Location..2587
            Tools..2588
            Pinpoint Diagnostics With ServiceMaxx? Software..2591
            Extended Diagnostic Information..2592
            SPN 132 FMI 2 - MAF Signal Erratic, Intermittent, or Incorrect..2593
            Fault Overview..2593
            Malfunction Indicator Lamp (MIL) Reaction..2593
            Associated Faults..2593
            Drive Cycle to Determine Fault Status..2593
            SPN 172 FMI 2 - AIT Signal Erratic, Intermittent, or Incorrect..2596
            Fault Overview..2597
            Malfunction Indicator Lamp (MIL) Reaction..2597
            Associated Faults..2597
            Drive Cycle to Determine Fault Status..2597
          TOSS / VSS (Transmission Output Shaft Speed / Vehicle Speed Sensor) Sensor..2600
            Overview..2602
            Tools..2603
            Pinpoint Diagnostics With ServiceMaxx? Software..2604
            SPN 191 FMI 1- TOSS / VSS not detected with vehicle moving..2605
            Fault Overview..2605
            Malfunction Indicator Lamp (MIL) Reaction..2605
            Fault Fact..2605
            Associated Faults..2605
            Drive Cycle to Determine Fault Status..2605
          RSE (Radiator Shutter Enable)..2609
          Function..2609
          Component Location..2610
          Tools..2610
            RSE Circuit Diagnostics..2611
            RSE Circuit Operation..2612
            Fault Detection / Management..2612
          Service Interval Messages..2613
            Service Interval Messages Operation..2613
            SPN 1378 FMI 14 - Change engine oil service interval reset ahead of schedule..2614
            Fault Overview..2614
            Malfunction Indicator Lamp (MIL) Reaction..2614
            Associated Faults..2614
            Drive Cycle to Determine Fault Status..2614
          SMC (Starter Motor Control) Circuit ..2615
          Function..2616
          Location..2616
          Tools..2616
            SMC Circuit Diagnostics..2618
            SMC Circuit Operation..2622
            Driveline Disengagement Switch (DDS) Circuit..2622
            Ignition Switch..2622
            SMC Circuit..2622
            ECM..2622
            Start Relay..2622
            Clutch Switch (Manual Transmission)..2622
            Neutral Signal (Automatic Transmission)..2622
            Fault Detection / Management..2622
          TACH (Tachometer Output Circuit)..2623
            Tachometer Pin-point Diagnostics..2624
            Tachometer Circuit Operation..2625
            Diagnostic Trouble Codes (DTCs)..2625
          TC2WG (Turbocharger 2 Wastegate) Solenoid..2626
          Function..2626
          Sensor Location..2626
          Tools..2626
            TC2WG Circuit Diagnostics..2627
            TC2WG Circuit Operation..2628
            Fault Detection / Management..2628
          TC1COT (Turbocharger 1 Compressor Outlet Temperature) Sensor..2629
            TC1COT Sensor End Diagnostics..2629
            Overview..2630
            Tools..2631
            Pinpoint Diagnostics With ServiceMaxx? Software..2631
            TC1COT Pin-point Diagnostics..2632
            SPN 2629 FMI 2 - TC1COT signal erratic, intermittent, or incorrect..2633
            Fault Overview..2634
            Malfunction Indicator Lamp (MIL) Reaction..2634
            Associated Faults..2634
            Drive Cycle to Determine Fault Status..2634
            SPN 2629 FMI 16 - TC1COT Over temperature: Moderate De-Rate..2637
            Fault Overview..2637
            Malfunction Indicator Lamp (MIL) Reaction..2637
            Associated Faults..2637
            Drive Cycle to Determine Fault Status..2637
            SPN 2629 FMI 21 - TC1COT signal drifted LOW..2640
            Fault Overview..2640
            Malfunction Indicator Lamp (MIL) Reaction..2640
            Associated Faults..2640
            Drive Cycle to Determine Fault Status..2640
          VREF (Reference Voltage)..2643
          Function..2644
          Tools..2644
            VREF Pin-point Diagnostics..2644
            VREF Circuit Operation..2650
            Fault Detection / Management..2651
          VSO (Vehicle Speed Output)..2652
            Vehicle Speed Output Pin-point Diagnostics..2653
            Vehicle Speed Output Circuit Operation..2654
            Diagnostic Trouble Codes (DTCs) ..2654
          WIF (Water In Fuel) Sensor..2655
          Function..2655
          Sensor Location..2655
          Tools..2655
            WIF Pin-point Diagnostics..2656
            WIF Circuit Operation..2657
            Fault Detection / Management..2657
      Table of Contents..2659
        Diagnostic Trouble Codes..2661
      Table of Contents..2673
        Electrical Tools..2675
          42-Pin Engine to Chassis Interface Cable..2675
          98-Pin Engine and Chassis Cables..2675
          180-Pin Breakout Box..2676
          Digital IR Thermometer..2677
          Digital Multimeter (DMM)..2678
          EXP-1000 HD by Midtronics..2679
          EZ-Tech? Electronic Service Tool (EST)..2680
          International? Electronic Engine Terminal Test Kit..2681
          Interface cable (RP1210B compliant supporting J1939 and J1708)..2682
          3-Banana Plug Harness..2682
          16-Way Breakout Harness..2683
          500-Ohm Resistor Harness..2683
          Breakout Harness 4485A (APP)..2684
          Breakout Harness 4602 (ECT, EFT, EOT, and IMT)..2684
          Breakout Harness 4760A (DOCIT, DPFIT, DPFOT, and TC1COT)..2685
          Breakout Harness 4761A (DPFDP)..2685
          Breakout Harness 4762 (IPR, EGR, and VGT)..2686
          Breakout Harness 4831 (TC2WG)..2686
          Breakout Harness 4850 (IMP)..2687
          Breakout Harness 4908 (ECM Relay)..2687
          Breakout Harness 4946 (EGT)..2688
          Breakout Harness 4950 (CMP)..2688
          Breakout Harness 4951 (CKP)..2689
          Breakout Harness 4958 (FPCV and FVCV)..2689
          Breakout Harness 4960 (MAF)..2690
          Breakout Harness 4993 (IMT and CACOT)..2690
          Breakout Harness 6000 (UVC)..2691
          Breakout Harness 6001 (Fuel Pump)..2691
          Breakout Harness 6002 (WIF)..2691
          Breakout Harness 6005 (EBPV)..2692
          Breakout Harness 6025 (IAH)..2693
          Breakout Harness 6038 (FRP)..2693
        Mechanical Tools..2694
          Charge Air Cooler Test Kit..2694
          Clean Fuel Source Tool..2694
          Crankcase Pressure Test Adaptor..2695
          Crankcase Pressure Test Adaptor..2696
          Digital Manometer..2697
          EGR Cooler Leak Detection Kit..2698
          Fuel Inlet Restriction and Aeration Tool..2698
          Fuel / Oil Pressure Test Coupler..2699
          Fuel Pressure Test Kit..2700
          Fuel Rail Block Off Plugs..2700
          Fuel System Caps..2701
          High-pressure Pump Test Fitting..2701
          Fuel Injector Cups..2702
          Inline Shut-off Valve..2702
          Oil Cooler Block Off..2703
          Pressure Test Kit..2704
          Radiator Pressure Test Kit..2705
          Slack Tube? Manometer..2706
          Turbocharger Drain Block Off Plug..2707
          Turbocharger Oil Supply Block Off..2708
          Turbocharger Supply Block Off Plug..2709
          UV Leak Detection Kit..2710
          Vacuum Analyzer and Fuel Pump Tester..2711
      Table of Contents..2713
        Abbreviations and Acronyms..2715
          Abbreviations and Acronyms..2715
      Table of Contents..2723
        Terminology..2725
          Terminology..2725
            Terms..2725
      Table of Contents..2739
        MaxxForce? 7 (6.4L) All Ratings @ 2600 rpm (12NSH)..2741
      Table of Contents..2745
        Signal Values..2747
      Table of Contents..2751
        Description..2753
  tables..1929
    Technical Service Literature..1929
    MaxxForce? 7 Features and Specifications..1938
    Unacceptable Boost Possible Causes..2103
    Unacceptable Fuel Rail Pressure Possible Causes..2103
    Unacceptable Fuel Pressure Possible Causes..2103
    Example..2127
    Example..2128
    Example..2128
    Example..2128
    Example..2130
    Example..2130
    Example..2131
    Example..2131
    Example..2131
    Example..2132
    Example..2133
    Example..2133
    Example..2134
    Active Rolling Regeneration..2140
    Manual Parked Regeneration..2140
    Manual Parked Regeneration Procedure..2141
    Onboard Filter Cleanliness Test (ServiceMaxx? software)..2143
    Alert Levels of DPF Soot Loading..2143
    TMV - Standard and Output State Test..2172
    Connector Voltage Check..2172
    Connector Resistance Check to GND..2173
    Harness Resistance Check..2173
    SPN 1209 and FMI 0 - EBP above desired level..2173
    SPN 1692 and FMI 0 - Boost high / above desired level detected..2174
    SPN 1692 and FMI 17 - KOER STD - Boost unable to achieve desired set-point Pin-Point AMS Fault..2174
    SPN 1692 and FMI 18 - Boost unable to achieve desired set-point..2174
    SPN 2659 and FMI 17 -EGR Flow Rate unable to achieve desired set-point..2175
    SPN 2659 and FMI 20 - EGR high flow rate detected..2175
    SPN 2659 and FMI 21 - EGR low flow rate detected..2175
    Sensor Circuit Check..2204
    Connector Voltage Check..2205
    Connector Resistance Check to GND..2206
    Harness Resistance Check..2206
    Operational Voltage Check..2206
    Connector Voltage Check - EST..2210
    Harness Resistance Check..2211
    Brake Switch Circuits..2215
    Voltage Check..2216
    Harness Resistance Check..2216
    Connector Voltage Check..2220
    Connector Resistance Check to GND..2220
    Harness Resistance Check..2220
    Connector Voltage Check..2240
    EST Communication Check..2241
    Harness Resistance Check..2241
    Switch Checks..2245
    Circuit End Voltage Check..2246
    Sensor and Circuit Resistance Check..2248
    Harness Resistance Check..2248
    Operational Check..2249
    Sensor and Circuit Resistance Check..2252
    Harness Resistance Check..2252
    Operational Check..2253
    Sensor Circuit Check..2267
    Connector Voltage Check..2267
    Connector Resistance Check to GND..2267
    Harness Resistance Check..2268
    Sensor Circuit Check..2286
    Connector Voltage Check..2286
    Connector Resistance Checks to GND..2286
    Harness Resistance Check..2287
    Sensor Circuit Check..2306
    Connector Voltage Check..2306
    Connector Resistance Check to GND..2306
    Harness Resistance Check..2306
    Sensor Circuit Check..2321
    Connector Voltage Check..2321
    Connector Resistance Check to GND..2321
    Harness Resistance Check..2321
    Connector Voltage Check..2334
    Connector Resistance Check to GND..2334
    Sensor Resistance Check..2335
    Harness Resistance Check..2335
    Voltage Check at Relay..2339
    Voltage Check at ECM..2339
    Harness Resistance Check..2340
    Harness Resistance Check on Relay Power Circuits..2340
    SPN 108 / FMI 3- BARO signal Out of Range HIGH..2345
    SPN 108 / FMI 4 - BARO signal Out of Range LOW..2345
    SPN 628 / FMI 12 - ECM Memory Error..2345
    SPN 628 / FMI 14 - ECM Programming - EFRC Error..2345
    SPN 629 / FMI 2 - ECM Error - Level 2 Monitoring..2345
    SPN 629 / FMI 10 - ECM Error - Fuel Injector Circuit Performance Bank B..2346
    SPN 629 / FMI 12 - ECM Error - SPI..2346
    SPN 629 / FMI 31 - ECM Error - Level 3 Monitoring..2346
    SPN 1136 / FMI 0 - ECM Error - Over temperature..2346
    SPN 1136 / FMI 1 - ECM Error - Under temperature..2346
    Sensor Circuit Check..2353
    Connector Resistance Check to GND..2353
    Harness Resistance Check..2353
    Voltage Check at EFC Connector Output State Test..2374
    Voltage Check at Relay - Output State Test..2374
    Harness Resistance Check..2375
    Sensor Circuit Check..2379
    Connector Voltage Check..2379
    Connector Resistance Check to GND..2379
    Harness Resistance Check..2379
    EGR Valve Circuit Check..2391
    EGR Valve - Standard and Output State Test..2391
    Connector Voltage Check..2392
    Connector Resistance Check to GND..2392
    Harness Resistance Check..2392
    SPN 412 FMI 0 ? EGRT above Critical Temperature..2401
    Sensor Circuit Check..2402
    Connector Voltage Check..2402
    Connector Resistance Check to GND..2402
    Harness Resistance Check..2402
    Sensor Circuit Check..2413
    Connector Resistance Check to GND..2413
    Harness Resistance Check..2413
    Sensor Circuit Check..2423
    Connector Voltage Check..2424
    Connector Resistance Check to GND..2424
    Harness Resistance Check..2425
    Sensor Circuit Check..2429
    Connector Voltage Check..2429
    Connector Resistance Check to GND..2429
    Harness Resistance Check..2430
    ETV Circuit Check..2441
    ETV - Standard Test and Output State Test..2441
    Connector Voltage Check..2442
    Connector Resistance Check to GND..2442
    Harness Resistance Check..2442
    Voltage Check at Fuel Cooler Control Valve Connector ? Output State Test..2463
    Harness Resistance Check..2463
    SPN 94 FMI 0 ? Fuel Delivery Pressure Above Critical..2469
    Sensor Circuit Check..2469
    Connector Voltage Check..2470
    Connector Resistance Check to GND..2470
    Harness Resistance Check..2471
    Actuator / Harness Resistance Check..2475
    Operational Voltage Check - Output Circuit Check..2475
    Connector Voltage Check..2478
    Run Output State Test ? Low..2478
    Run Output State Test ? Low..2478
    Connector Resistance Check to GND..2479
    Harness Resistance Check..2479
    Sensor Circuit Check..2483
    Connector Resistance Check to GND..2484
    Under Valve Cover Resistance Check to Engine GND..2484
    Harness Resistance Check..2485
    Actuator / Harness Resistance Check..2518
    Operational Voltage Check - Output Circuit Check..2518
    Voltage Check on Relay Switch ? Output State Test IAH..2523
    Voltage Check on Relay Coil ? Output State Test..2523
    Amperage Draw Check..2523
    Element Resistance Check..2523
    Harness Resistance Check ? Relay Coil Circuits..2524
    Harness Resistance Check ? Relay Switch Circuits..2524
    Sensor Circuit Check..2533
    Connector Voltage Check..2533
    Connector Resistance Check to GND..2533
    Harness Resistance Check..2534
    Sensor Circuit Check..2550
    Connector Voltage Check..2550
    Connector Resistance Check to GND..2550
    Harness Resistance Check..2550
    Injector 1 - Resistance Checks Through Harness and Injector..2560
    Injector 1 - Resistance UVC Checks..2561
    Injector 1 - Harness Resistance Check..2561
    Injector 2 - Resistance Through Valve Cover to Engine GND Check..2562
    Injector 2 - Harness Resistance Check..2562
    Injector 3 - Resistance Through Valve Cover to Engine GND Check..2563
    Injector 3 - Harness Resistance Check..2563
    injector 4 - Resistance Through Valve Cover to Engine GND Check..2564
    Injector 4 - Harness Resistance Check..2564
    Injector 5 - Resistance Through Valve Cover to Engine GND Check..2565
    Injector 5 - Harness Resistance Check..2565
    Injector 6 - Resistance Through Valve Cover to Engine GND Check..2566
    Injector 6 - Harness Resistance Check..2566
    Injector 7 - Resistance Through Valve Cover to Engine GND Check..2567
    Injector 7 - Harness Resistance Check..2567
    Injector 8 - Resistance Through Valve Cover to Engine GND Check..2568
    Injector 8 - Harness Resistance Check..2568
    MAF Calibration Requirements..2588
    MAF Calibration Pre-Checks..2589
    MAF Calibration Procedure ? Using ServiceMaxx? Software..2590
    Connector Voltage Check..2592
    Harness Resistance Check..2592
    Connector Voltage Checks..2604
    Sensor Resistance Check..2604
    Harness Resistance Check..2604
    Voltage Check at RSE Connector - Output State Test..2611
    Harness Resistance Check..2612
    Voltage Check at Start Relay and Starter Solenoid..2620
    Voltage Check at ECM..2620
    Harness Resistance Check - ECM to Relay..2621
    Harness Resistance Check - Relay to Battery..2621
    Operational Voltage Check..2621
    Circuit End Voltage Check..2624
    Harness Resistance Check..2624
    Voltage Check at TC2WG Connector - Output State Test..2627
    Harness Resistance Check..2628
    Sensor Circuit Check..2632
    Connector Voltage Check..2632
    Connector Resistance Check to GND..2632
    Harness Resistance Check..2632
    VREF Voltage Check..2646
    Connector Resistance Check to GND..2647
    Harness Resistance Check..2648
    Harness Resistance Check (cont.)..2649
    Circuit End Voltage Check..2653
    Harness Resistance Check..2653
    Operational Check..2653
    Voltage Check..2657
    Connector Resistance Checks to GND..2657
    Harness Resistance Check..2657
    KOEO (Key ON, Engine OFF)..2741
    Engine cranking..2742
    Low Idle, no load, stabilized engine operating temperature..2742
    High Idle, no load, stabilized engine operating temperature..2742
    Full load, rated speed on highway, stabilized engine operating temperature..2743
    Stabilized engine operating temperature..2743
    Miscellaneous sensors and components..2743
0000001681 - 2010 MaxxForce 7 Engine Diagnostic Manual..2756
  toc..2758
    Table of Contents..2758
    Safety Terminology..2762
    Safety Instructions..2762
    Work Area..2762
    Safety Equipment..2762
    Protective Measures..2762
    Vehicle..2762
    Engine..2763
    Fire Prevention..2763
    Batteries..2763
    Compressed Air..2763
    Tools..2763
    Fluids Under Pressure..2764
    Fuel..2764
    Removal of Tools, Parts, and Equipment..2764
      Table of Contents..2766
        Engine Identification..2768
          Engine Serial Number..2768
          Engine Serial Number Example..2768
          Emission Label..2769
          Engine Accessories..2770
          Engine Description..2771
            Standard Features..2772
            Optional Features..2773
            Chassis-mounted Features..2773
          Engine Components..2774
        Air Management System..2779
          Air Management Components and Air Flow..2779
            Air Flow..2780
          Charge Air Cooler (CAC)..2781
          Charge Air Cooler Outlet Temperature (CACOT) Sensor..2782
          Dual Turbocharger Assembly..2783
            High-pressure Turbocharger..2784
            Turbocharger 1 Compressor Outlet Temperature (TC1COT) Sensor..2784
            Low-pressure Turbocharger..2784
            Turbocharger 2 Wastegate (TC2WG) Solenoid..2784
          Exhaust Gas Recirculation (EGR) System..2785
            EGR Flow..2785
            EGR Control Valve and Position Sensor..2786
            Engine Throttle Valve (ETV) and Position Sensor..2788
          Aftertreatment (AFT) System..2791
            AFT Control System..2791
            Sensors..2791
            Diesel Oxidation Catalyst (DOC)..2791
            Diesel Particulate Filter (DPF)..2791
            AFT Conditions and Responses..2791
        Fuel System..2792
          Fuel System Components..2792
          High-pressure Fuel System..2794
            High-pressure Fuel Pump (HPFP) Assembly..2794
            Internal Transfer Pump (ITP)..2794
            Fuel Pressure Control Valve (FPCV)..2794
            Fuel Volume Control Valve (FVCV)..2794
            Fuel Rail Pressure (FRP) Sensor..2794
            High-pressure Piezo Common Rail (HPCR) System..2794
            Return Fuel System..2794
          Low-pressure Fuel System..2796
            Fuel Pump..2796
            Primary Fuel Filter..2796
            Secondary Fuel Filter..2796
            Fuel Cooler..2796
          Fault Detection / Management..2797
        Engine Lubrication System..2798
          Lubrication System Components and Oil Flow..2798
        Cooling System..2800
          Cooling System Components and Flow..2800
            Water Pump..2800
            Front Crankcase Cover Flow..2801
            Thermostats..2801
            Deaeration Tank..2801
            Radiator Shutters (220 Horsepower only)..2801
            Fuel Coolant Valve (FCV)..2802
        Engine Speed Position System..2803
        Electronic Control System..2804
          Electronic Control System Components..2804
            Operation and Function..2806
            Reference Voltage (VREF)..2806
            Signal Conditioner..2806
            Microprocessor..2806
            Microprocessor Memory..2806
            Flash Memory..2807
            RAM..2807
            Engine Fan Control (EFC)..2807
            Inlet Air Heater (IAH)..2807
            Actuator Control..2807
          Actuators..2809
            H-Bridge Circuit..2809
            Exhaust Gas Recirculating (EGR) Valve and Control..2810
            ETV and Engine Throttle Position Sensor..2811
          Engine and Vehicle Sensors..2812
            Thermistor Sensors..2812
            Variable Capacitance Sensors..2814
            Micro Strain Gauge (MSG) Sensor..2815
            MSG Sensors..2815
            Magnetic Pickup Sensors..2816
            Magnetic Pickup Sensors..2816
            Potentiometer..2817
            Potentiometer..2817
            Switches..2818
            Switches..2818
          Inlet Air Heater (IAH) System..2819
      Table of Contents..2820
        Standard Features..2822
          Electronic Governor Control..2822
          SAE J1939 Data Link - also known as CAN (public)..2822
          SAE J1587 Data Link - also known as the American Trucking Association (ATA) data link...2822
          Service Diagnostics..2822
          Event Logging System..2824
          Electronic Speedometer and Tachometer..2824
          Aftertreatment (AFT) System..2824
          Fuel Delivery Pressure (FDP) Monitor..2824
          Inlet Air Heater (IAH)..2824
          Fast Idle Advance..2824
          Cold Ambient Protection (CAP)..2824
          Coolant Temperature Compensation (CTC)..2826
          Engine Crank Inhibit (ECI)..2826
        Optional Features..2827
          Change Oil Service Interval..2827
          Road Speed Limiting (RSL)..2827
          Cruise Control..2827
          Traction Control..2827
          Exhaust Back Pressure Valve (EBPV)..2827
          Engine Warning Protection System (EWPS)..2828
          Idle Shutdown Timer (IST)..2828
          IST for California ESS Compliant Engines..2828
          Engine Idle Shutdown Timer (IST for Federal?Optional)..2829
          Electronic Fan (EFAN)..2829
          Radiator Shutter Enable (RSE)..2830
          In Cab Power Take-Off (PTO) Control..2830
          Remote Accelerator Pedal Position (RAPP)..2830
      Table of Contents..2832
        Connecting EST with ServiceMaxx? Software to Engine..2834
          Interface Device Selection..2834
          Connecting ServiceMaxx? Software..2837
          Pinpoint Diagnostic Graphic Legend..2838
        Obtain Vehicle Health Report..2846
          Overview..2846
          Tools Required..2846
          Equipment Condition..2846
          Test Procedure..2846
          Expected Outcome..2846
          Follow-On Procedure..2846
        Viewing Diagnostic Trouble Codes..2847
          Diagnostic Trouble Codes (DTCs)..2847
          Suspect Parameter Number (SPN) ..2847
          Failure Mode Indicator (FMI)..2847
          Active and Previously Active DTCs..2847
        ServiceMaxx? Procedures..2848
          Fuel Pressure Adaptation Reset..2848
          KOER MAF Sensor Calibration..2849
      Table of Contents..2850
        How To Use Symptom Based Diagnostics..2854
        Operational Checkout Procedures..2855
          1.0 Preliminary Vehicle Operational Checkout Procedure..2855
        Hard Start and No Start Diagnostics..2857
          Diagnostics Form..2857
            Diagnostics Form Header Information..2859
            Enter Diagnostics Form Header Information..2859
          Test Procedures..2861
            1. Initial Key On Check..2861
            Purpose..2861
            Tools..2861
            Procedure..2861
            Possible Causes..2861
            WAIT TO START lamp does not illuminate..2861
            WARN ENGINE lamp stays illuminated..2862
            2. Visual Inspection..2862
            Purpose..2862
            Tools..2862
            Engine Oil..2862
            Engine Coolant Level..2862
            Electrical System..2863
            Exhaust System..2863
            Intake Air System and Charge Air Cooler (CAC)..2863
            2.1 Fuel Level Check..2864
            2.2 Fuel Quality Check..2864
            Purpose..2864
            Tools..2864
            Possible Causes..2864
            Procedure..2864
            3. EST Connection and Data Recording..2866
            Purpose..2866
            Monitoring Engine Systems using an EST..2866
            Tools..2866
            Procedure..2866
            4. Check for DTCs..2867
            Purpose..2867
            Tools..2868
            Procedure..2868
            5. Engine Cranking..2868
            Purpose..2868
            Monitoring Engine Systems using an EST..2868
            Tools..2868
            Procedure..2869
            Possible Causes..2869
            Low battery voltage..2869
            Low cranking rpm..2870
            Low Fuel Rail Pressure..2870
            Monitoring FRP using a Breakout Harness..2870
            Tools..2870
            Procedure..2870
            Possible Causes..2871
          Special Test Procedures..2872
            Inlet Air Heater (IAH) Test..2872
            Purpose..2872
            Tools..2872
            Possible Causes..2872
            Amperage Draw..2872
            Procedure..2872
            Low-pressure Fuel System ..2874
            LP.1 - Electrical Fuel Pump Check..2875
            Purpose..2875
            Tools..2875
            Procedure..2875
            LP.2 - Fuel Pressure Test..2875
            Purpose..2875
            Tools..2875
            Check Fuel Delivery Pressure Using the EST ..2875
            Check Fuel Delivery Pressure Manually..2876
            LP.3 - Fuel Aeration Check..2877
            Purpose..2877
            Tools..2877
            Possible Causes..2877
            Procedure..2877
            LP.4 - Fuel Thermal Valve Check..2878
            Purpose..2878
            Tools..2878
            LP.5 - Fuel Pump Dead Head Test..2879
            Purpose..2879
            Tools..2879
            Procedure..2879
            LP.6 - Alternative Fuel Supply Test..2880
            Purpose..2880
            Possible Causes (High and Low Restriction)..2880
            Tools..2880
            Procedure..2880
            LP.7 - Return Fuel Flow Test..2881
            Purpose..2881
            Tools..2881
            Procedure..2881
            LP.8 - Fuel Return Restriction Test..2881
            Purpose..2881
            Tools..2881
            Procedure..2882
            High-pressure Fuel System Tests..2883
            HP.1 - Fuel Pressure Control Valve (FPCV) and Fuel Volume Control Valve (FVCV) Check..2884
            Purpose..2884
            Possible Causes..2884
            Tools..2884
            Procedure..2884
            HP.2 - FPCV and FVCV Resistance Check..2885
            Purpose..2885
            Possible Causes..2885
            Tools..2885
            Procedure..2885
            HP.3 - Fuel Rail Leak Check..2886
            Purpose..2886
            Possible Causes..2886
            Tools..2886
            Procedure..2886
            HP.4 - High-pressure Fuel Pump (HPFP) Dead Head Test..2887
            Possible Causes..2887
            Tools..2888
            Procedure..2888
            HP.5 - Injector Leak Isolation Check (Left Bank)..2888
            Purpose..2888
            Possible Causes..2888
            Tools..2889
            Procedure..2889
            HP.6 - Injector Leak Isolation Check (Right Bank)..2889
            Purpose..2889
            Possible Causes..2889
            Tools..2889
            Procedure..2889
        Performance Diagnostics..2890
          Diagnostics Form..2890
            Diagnostics Form Header Information..2892
            Enter Diagnostics Form Header Information..2892
          Test Procedures..2894
            1. Initial Key On Check..2894
            Purpose..2894
            Tools..2894
            Procedure..2894
            Possible Causes..2894
            WAIT TO START lamp does not illuminate..2894
            WARN ENGINE lamp stays illuminated..2895
            2. Visual Inspection..2895
            Purpose..2895
            Tools..2895
            Engine Oil..2895
            Engine Coolant Level..2895
            Electrical System..2896
            Exhaust System..2896
            Intake Air System and Charge Air Cooler (CAC)..2896
            2.1 Fuel Level Check..2897
            2.2 Fuel Quality Check..2897
            Purpose..2897
            Tools..2897
            Possible Causes..2897
            Procedure..2897
            3. EST Connection and Data Recording..2899
            Purpose..2899
            Monitoring Engine Systems using an EST..2899
            Tools..2899
            Procedure..2899
            4. Check for DTCs..2900
            Purpose..2900
            Tools..2901
            Procedure..2901
            5. Fuel Quality Check..2901
            Purpose..2901
            Tools..2901
            Possible Causes..2901
            Procedure..2902
            6. Fuel Pressure and Aeration Check..2903
            Purpose..2903
            Tools..2903
            Check Fuel Delivery Pressure Using the EST ..2903
            Check Fuel Delivery Pressure Manually..2903
            7. Engine Low Idle to High Idle..2904
            Purpose..2904
            Tools..2904
            Procedure..2904
            8. Road Test (0?60 mph, Full Throttle)..2905
            Purpose..2905
            Tools..2905
            Procedure..2906
          Special Test Procedures..2908
            Turbocharger Checks (Under Boost)..2908
            Purpose..2908
            Possible Causes..2908
            Procedure..2908
            Wastegate Checks (Over Boost)..2909
            Purpose..2909
            Tools..2909
            Procedure..2909
            Charge Air Cooler (CAC) Checks..2911
            Purpose..2911
            Possible Causes..2911
            Procedure..2911
            Blow-by Test..2912
            Purpose..2912
            Tools..2912
            Possible Causes..2912
            Procedure..2912
            Crankcase Pressure Test..2914
            Purpose..2914
            Tools..2914
            Possible Causes..2914
            Procedure..2914
            Intake Air Restriction Test..2916
            Purpose..2916
            Tools..2916
            Possible Causes..2916
            Procedure..2916
            Relative Compression Test..2917
            Purpose..2917
            Tools..2917
            Possible Causes..2917
            Procedure..2917
            Cylinder Cutout Test..2918
            Purpose..2918
            Tools..2918
            Possible Causes..2918
            Procedure..2918
        Coolant System..2919
          Combustion Leaks to Coolant..2920
          Symptom..2920
          Possible Causes..2920
          Tools..2920
            Combustion Leak Test..2920
          Coolant Leak to Exhaust / Intake..2922
          Symptoms..2922
          Possible Causes..2922
          Tools..2922
            EGR Cooler Inspection..2922
          Coolant in Lube Oil..2925
          Symptom..2925
          Possible Causes..2925
          Tools..2925
            Lube Oil Contamination..2926
            Front Cover Inspection..2929
            Cylinder Head Leak Test..2930
          Coolant Over-Temperature..2932
          Symptom..2932
          Possible Causes..2933
          Tools..2933
            Coolant Over-Temperature Diagnostics and Repair..2934
            Temperature Sensor Validation Test..2935
            Cooling System Operating Pressure Test..2935
        Engine Inspection..2936
        Symptom..2936
        Possible Causes..2936
        Low Power..2936
        Rough Idle..2937
        Tools..2937
          Low Power (Turbocharger Assembly and Actuator)..2938
          Suspected Misfire..2939
          Rough Idle..2940
        Electrical System..2941
          ECM Reset (Intermittent Engine Stumble)..2941
          Symptom..2941
          Possible Causes..2941
            Diagnostics for Engine Stumble..2941
        Fuel System..2942
          Excessive Fuel Consumption..2943
          Symptom..2943
          Possible Causes..2943
          Operator effects..2943
          Application effects..2943
          Chassis effects..2943
          Engine effects..2943
            Verifying Excessive Fuel Consumption Complaints..2944
          Fuel in Coolant..2945
          Symptom..2945
          Possible Causes..2945
          Tools..2945
            Fuel in Coolant Leakage Test (Low-pressure)..2945
            Fuel in Coolant Leakage Test (High-pressure)..2946
          Fuel In Lube Oil..2948
          Symptom..2948
          Possible Causes..2948
          Leaking fuel under the valve cover..2948
          Porous cylinder head..2948
          Tools..2948
            Verifying Fuel Dilution from Oil System..2948
            Symptoms..2948
            Fuel Dilution Diagnostics..2948
            Fuel to Exhaust..2950
            Symptom..2950
            Possible Causes..2950
          Air or Combustion Leaks to Fuel..2951
          Possible Causes..2951
            Air or Combustion Leak to Fuel Test..2951
            Low Fuel Pressure and Aeration..2952
            Symptom..2952
            Possible Causes..2952
          Water In Fuel (WIF) Check..2953
          Possible Causes..2953
          Tools..2953
            Drain Water from Primary Fuel Filter..2953
          Over-Temperature..2955
          Symptom..2955
          Possible Causes..2955
          Tools..2955
            Fuel Over-Temperature Diagnosis and Repair..2955
        Lubrication System..2956
          Turbocharger Oil Discharge..2957
          Symptoms..2957
          Possible Causes..2958
            Diagnosing Turbocharger Oil Discharge from Turbine Outlet..2960
            Diagnosing Turbocharger Oil Discharge from Compressor Outlet..2961
          Low Oil Pressure..2963
          Possible Causes..2963
          Tools..2963
             Low Oil Pressure Diagnostics..2963
          Over-Temperature..2966
          Symptom..2966
          Possible Causes..2966
          Tools..2966
            Oil Over-Temperature Diagnosis and Repair..2966
            Sensor Validation Test..2966
      Table of Contents..2968
        Batteries and Electrical System Inspection..2972
        Overview..2972
        Tools Required..2972
          Equipment Condition..2972
          Inspection Procedure..2972
          Expected Outcome..2974
        Coolant Level and Quality Inspection..2975
        Overview..2975
          Tools Required..2975
          Equipment Condition..2975
          Inspection Procedure..2975
          Expected Outcome..2982
        DPF Inspection..2983
        Overview..2983
        Fuel Level and System Inspection..2984
        Overview..2984
        Tools Required..2984
          Equipment Condition..2984
          Preliminary Inspection Procedure..2984
          Inspection Procedure Canister Style Filter..2985
          Inspection Procedure Cartridge Style Filter..2986
          Expected Outcome..2987
        Intake Air Inspection..2988
        Overview..2988
          Tools Required..2988
          Equipment Condition..2988
          Inspection Procedure..2988
          Expected Outcome..2989
        Exhaust and Aftertreatment System Inspection..2990
        Overview..2990
        Tools Required..2990
          Equipment Condition..2990
          Inspection Procedure..2991
          Expected Outcome..2992
        Engine Oil Level and Quality Inspection..2993
        Overview..2993
          Tools Required..2993
          Equipment Condition..2993
          Inspection Procedure..2994
          Expected Outcome..2994
        Connecting Cylinder Performance Analyzer (CPA) Tool..2995
        Purpose..2995
        Tools..2995
        Procedure..2995
        Cylinder Performance Analyzer (CPA) Cold Idle Test..2999
        Purpose..2999
        Tools..2999
        Procedure..2999
        Cylinder Performance Analyzer (CPA) Signal Check..3003
        Purpose..3003
        Tools..3003
        Procedure..3003
        Cylinder Performance Analyzer (CPA) Hot Idle Test..3007
        Purpose..3007
        Tools..3007
        Procedure..3007
        Engine and Flexplate Balance Inspection..3010
        Manual Compression Test..3011
        Tools..3011
          Test Procedure..3011
        Air Compressor Leak Test..3012
        Tools..3012
        Key On, Engine Off (KOEO) Tests..3013
        Tools..3013
          KOEO Standard Test..3014
          KOEO Output State Low and High..3015
          KOEO Intake Air Heater..3016
          KOEO Continuous Monitor Test..3017
          Relative Compression Test..3018
        Key On, Engine Running (KOER) Tests..3019
          KOER Standard Test..3020
          KOER Air Management Test..3021
          KOER Cylinder Cutout Test..3022
        KOER Standard Test..3023
          Overview..3023
          Tools Required..3023
          Equipment Condition..3023
          Test Setup..3023
          Test Procedure..3023
          Expected Outcome..3023
          Follow-On Procedure..3024
        Onboard Filter Cleanliness Test..3025
          Overview..3025
          Tools Required..3025
          Equipment Condition..3025
          Test Setup..3025
          Test Procedure..3025
          Expected Outcome..3027
          Follow-On Procedure..3027
        Snap Acceleration Test..3028
          Overview..3028
          Tools Required..3028
          Equipment Condition..3028
          Test Setup..3028
          Test Procedure..3028
          Expected Outcome..3029
          Follow-On Procedure..3029
        Fuel Pressure Adaptation Reset Procedure..3030
          Overview..3030
          Tools Required..3030
          Equipment Condition..3030
          Test Setup..3030
          Test Procedure..3031
          Expected Outcome..3031
          Follow-On Procedure..3032
        Connecting Clean Fuel Source Tool..3033
          Overview..3033
          Tools Required..3033
          Equipment Condition..3033
          Test Setup..3033
          Test Procedure..3033
          Expected Outcome..3035
          Follow-On Procedure..3035
        Intermittent or Inactive Fault Diagnostic Procedure..3036
          Overview..3036
          Tools Required..3036
          Equipment Condition..3036
          Test Setup..3036
          Test Procedure..3036
          Expected Outcome..3037
          Follow-On Procedure..3037
        Fuel Dilution Test..3038
          Overview..3038
          Tools Required..3038
          Equipment Condition..3038
          Test Setup..3038
          Test Procedure..3038
          Expected Outcome..3041
          Follow-On Procedure..3041
        Smoke Test (Air Intake System)..3042
          Overview..3042
          Tools Required..3042
          Equipment Condition..3042
          Test Setup..3042
          Test Procedure..3043
          Expected Outcome..3044
          Follow-On Procedure..3044
        Smoke Test (Exhaust and Aftertreatment Systems)..3045
          Overview..3045
          Tools Required..3045
          Equipment Condition..3045
          Test Setup..3045
          Test Procedure..3046
          Test Setup 2..3047
          Expected Outcome..3047
          Follow-On Procedure..3047
        Oil Pressure Verification Test..3048
          Overview..3048
          Tools Required..3048
          Equipment Condition..3048
          Test Setup..3048
          Test Procedure..3048
          Expected Outcome..3051
          Follow-On Procedure..3051
        Key On, Engine Running (KOER) Aftertreatment Tests..3052
          Onboard Filter Cleanliness Test..3053
        Electrical System Test..3053
        Overview..3053
          DPF Inspection..3053
        Overview..3053
      Table of Contents..3054
        Diagnostic Trouble Code (DTC) List..3058
        Description..3068
          Section Information..3068
        Electronic Control System Diagnostics Form..3069
          0000003201 Diagnostic Form ..3069
        Sensor and Actuator Locations..3070
          Engine Mounted Components..3070
         Diagnostic Procedure Process..3075
          Description..3075
            Pin-grip Inspection..3075
            Diagnostics with EST..3075
            Diagnostics without EST..3075
          Sensor End Diagnostics (with ServiceMaxx? software)..3076
            Sensor End Diagnostics (2-Wire)..3076
            Sensor End Diagnostics (3-Wire)..3077
          Pin-point Diagnostics (without ServiceMaxx? software)..3081
          Actuator Operational Voltage Check ? Output State Test..3082
          Harness Resistance Check..3083
          Operational Voltage Check..3084
        Circuit Diagnostics..3085
          AFT (Aftertreatment) System..3085
            AFT System Diagnostics..3085
            Overview..3089
            Tools..3089
            AFT System Operation..3089
            Diesel Oxidation Catalyst (DOC)..3091
            Diesel Particulate Filter (DPF)..3091
            Regeneration..3091
            Passive Rolling Regeneration..3091
            Parked Regeneration Switch..3091
            Inhibit Regeneration Switch (optional)..3092
            DPF Soot Loading Percentage..3092
            DPF Ash Loading Percentage..3092
            DPF Status Lamp..3092
            High Exhaust System Temperature (HEST) Indicator ..3092
            SPN 3251 / FMI 0 ? DPF high flow resistance..3096
            SPN 3251 / FMI 21 ? DPF low flow resistance..3096
            SPN 3719 / FMI 0 ? DPF load: above critical level 1 - engine de-rate..3096
            SPN 3719 / FMI 15 ? DPF servicing required..3096
            SPN 3719 / FMI 16 ? DPF load: above warning level..3097
            SPN 3720 / FMI 0 ? DPF Ash load at maximum limit (Remove DPF for cleaning)..3097
            SPN 3936 / FMI 0 ? DPF load: above critical level 2 - further engine de-rate..3097
            SPN 5298 / FMI 2 ? Reduced DOC efficiency - engine de-rate..3097
            SPN 5319 / FMI 31 ? DPF Ash load at maximum limit (Remove DPF for cleaning)..3098
            SPN 3936 FMI 2 - DPF System Feedback Control Fault..3099
            Fault Overview..3099
            Malfunction Indicator Lamp (MIL) Reaction..3099
            Fault Fact..3099
            Associated Faults..3099
            Drive Cycle to Determine Fault Status..3099
            SPN 3936 FMI 8 - DPF Regenerations are Occurring too Frequently..3101
            Fault Overview..3101
            Malfunction Indicator Lamp (MIL) Reaction..3101
            Associated Faults..3101
            Drive Cycle to Determine Fault Status..3101
            SPN 3936 FMI 20 - DPF Feedback - Feedback Max Authority..3105
            Fault Overview..3105
            Malfunction Indicator Lamp (MIL) Reaction..3105
            Fault Fact..3105
            Associated Faults..3105
            Drive Cycle to Determine Fault Status..3105
            SPN 4766 FMI 10 - Catalyst System Efficiency Below Threshold..3107
            Fault Overview..3107
            Fault Fact..3107
            Associated Faults..3107
            Drive Cycle to Determine Fault Status..3107
            SPN 5319 FMI 17 - DPF Incomplete Regeneration ..3109
            Fault Overview..3109
            Amber Warning Lamp (AWL) Reaction..3109
            Fault Fact..3109
            Associated Faults..3109
            Drive Cycle to Determine Fault Status..3109
            SPN 5319 FMI 31 - DPF Incomplete Regeneration ..3112
            Fault Overview..3112
            Malfunction Indicator Lamp (MIL) Reaction..3112
            Fault Fact..3112
            Associated Faults..3112
            Drive Cycle to Determine Fault Status..3112
          AMS (Air Management System)..3115
            Overview..3119
            Tools..3119
            Pinpoint Diagnostics..3119
            SPN 2659 FMI 10 - EGR Slow Response Fault..3125
            Fault Overview..3125
            Malfunction Indicator Lamp (MIL) Reaction..3125
            Associated Faults..3125
            Drive Cycle to Determine Fault Status..3125
            SPN 2659 FMI 15 - EGR High Flow Rate Detected..3129
            Fault Overview..3129
            Amber Warning Lamp (AWL) Reaction..3129
            Associated Faults..3129
            Drive Cycle to Determine Fault Status..3129
            SPN 2659 FMI 17 - EGR Low Flow Rate Detected..3131
            Fault Overview..3131
            Amber Warning Lamp (AWL) Reaction..3131
            Associated Faults..3131
            Drive Cycle to Determine Fault Status..3131
            SPN 2659 FMI 20 - EGR High Flow Rate Detected..3133
            Fault Overview..3133
            Malfunction Indicator Lamp (MIL) Reaction..3133
            Associated Faults..3133
            Drive Cycle to Determine Fault Status..3133
            SPN 2659 FMI 21 - EGR Low Flow Rate Detected..3135
            Fault Overview..3135
            Malfunction Indicator Lamp (MIL) Reaction..3135
            Associated Faults..3135
            Drive Cycle to Determine Fault Status..3135
            SPN 5543 FMI 16 - EBP Valve Internal Temperature Fault..3137
            Fault Overview..3137
            Malfunction Indicator Lamp (MIL) Reaction..3137
            Associated Faults..3137
            Drive Cycle to Determine Fault Status..3137
            Thermal Management Valve (TMV) Programmable Parameters..3137
            SPN 5543 FMI 19 - EBPC valve not detected on J1939..3141
            Fault Overview..3141
            Malfunction Indicator Lamp (MIL) Reaction..3141
            Associated Faults..3141
            Drive Cycle to Determine Fault Status..3141
            Thermal Management Valve (TMV) Programmable Parameters..3141
            SPN 5543 FMI 20 - EBP valve electrical fault..3144
            Fault Overview..3144
            Malfunction Indicator Lamp (MIL) Reaction..3144
            Associated Faults..3144
            Drive Cycle to Determine Fault Status..3144
            Thermal Management Valve (TMV) Programmable Parameters..3144
          APP (Accelerator Pedal Position) Sensor ..3147
          Function..3147
          Sensor Location..3147
          Tools..3148
            APP Sensor End Diagnostics..3149
            APP Pin-point Diagnostics..3152
            APP Circuit Operation..3154
            Accelerator Pedal Position (APP) sensor..3154
            Fault Detection / Management..3154
          ATA (American Trucking Association) Data Link (SAE J1587)..3155
          Function..3155
          Location..3156
          Tools..3156
            ATA (SAE J1587) Pin-point Diagnostics..3157
            ATA (SAE J1587) Operation..3159
            Diagnostic Connector..3159
            Electronic Gauge Cluster (EGC)..3159
            Fault Detection / Management..3159
            Repair Information..3159
          Brake Switch Circuits..3160
          Function..3160
          Location..3161
          Tools..3161
            Brake Switch Circuits Pin-point Diagnostics..3162
            Brake Switch Circuit Operation..3164
            Fault Detection / Management..3164
          CACOT (Charge Air Cooler Outlet Temperature) Sensor..3165
            Overview..3166
            Tools..3167
            SPN 2630 FMI 2 - CACOT Signal erratic, intermittent, or incorrect..3169
            Fault Overview..3169
            Malfunction Indicator Lamp (MIL) Reaction..3169
            Associated Faults..3169
            Drive Cycle to Determine Fault Status..3169
            SPN 2630 FMI 3 - CACOT signal out of range HIGH..3172
            Fault Overview..3172
            Malfunction Indicator Lamp (MIL) Reaction..3172
            Associated Faults..3172
            Drive Cycle to Determine Fault Status..3172
            SPN 2630 FMI 4 - CACOT signal out of range LOW..3175
            Fault Overview..3175
            Malfunction Indicator Lamp (MIL) Reaction..3175
            Associated Faults..3175
            Drive Cycle to Determine Fault Status..3175
            SPN 2630 FMI 16 - CACOT Undercooling..3178
            Fault Overview..3179
            Malfunction Indicator Lamp (MIL) Reaction..3179
            Associated Faults..3179
            Drive Cycle to Determine Fault Status..3179
            SPN 2630 FMI 21 - CACOT signal Drifted LOW..3182
            Fault Overview..3182
            Malfunction Indicator Lamp (MIL) Reaction..3182
            Associated Faults..3182
            Drive Cycle to Determine Fault Status..3182
          CAN (Controller Area Network) Communications (J1939) ..3185
          Function..3185
          Location..3186
          Tools..3186
            CAN (J1939) Pin-point Diagnostics..3187
            CAN (J1939) Circuit Operation..3189
            CAN (J1939) versus ATA (SAE J1587)..3189
            Diagnostic Connector..3189
             Electronic Gauge Cluster (EGC)..3189
            Body Controller (BC) or Multiplex System Module (MSM)..3190
            Repair Information..3190
          CCS (Cruise Control Switches)..3191
          Function..3192
          Location..3192
          Tools..3192
            Cruise Control Switches Pin-point Diagnostics ..3193
          CKP (Crankshaft Position) Sensor..3194
          Function..3194
          Sensor Location..3194
          Tools..3194
            CKP Pin-point Diagnostics..3195
            CKP Circuit Operation..3197
            Fault / Detection Management..3197
          CMP (Camshaft Position) Sensor..3198
            CMP Diagnostics..3198
            Overview..3199
            Tools..3200
            Pinpoint Diagnostics With ServiceMaxx? Software..3200
            SPN 636 FMI 10 - CMP signal inactive..3202
            Fault Overview..3202
            Malfunction Indicator Lamp (MIL) Reaction..3202
            Fault Fact:..3202
            Associated Faults..3202
            Drive Cycle to Determine Fault Status..3202
          Cylinder Balance..3204
            Cylinder Balance Diagnostics..3204
            Overview..3206
            Pin-Point Diagnostics With ServiceMaxx? Software..3207
            SPN 1322 FMI 31 - Misfire ? Multiple Cylinder..3208
            Fault Overview..3208
            Malfunction Indicator Lamp (MIL) Reaction..3208
            Associated Faults..3208
            Drive Cycle to Determine Fault Status..3208
          DOCIT (Diesel Oxidation Catalyst Inlet Temperature) Sensor..3211
            DOCIT Sensor End Diagnostics..3211
            Overview..3212
            Tools..3213
            Pinpoint Diagnostics With ServiceMaxx? Software..3213
            SPN 4765 FMI 2 - DOCIT signal erratic, intermittent, or incorrect..3216
            Fault Overview..3216
            Malfunction Indicator Lamp (MIL) Reaction..3216
            Associated Faults..3216
            Drive Cycle to Determine Fault Status..3216
            SPN 4765 FMI 8 - DOCIT signal abnormal rate of change..3218
            Fault Overview..3218
            Malfunction Indicator Lamp (MIL) Reaction..3218
            Associated Faults..3218
            Drive Cycle to Determine Fault Status..3218
            SPN 4765 FMI 10 - DOCIT in range stuck fault..3221
            Fault Overview..3221
            Malfunction Indicator Lamp (MIL) Reaction..3221
            Fault Fact..3221
            Associated Faults..3221
            Drive Cycle to Determine Fault Status..3221
            SPN 4765 FMI 21 - DOCIT signal drifted LOW..3224
            Fault Overview..3224
            Malfunction Indicator Lamp (MIL) Reaction..3224
            Associated Faults..3224
            Drive Cycle to Determine Fault Status..3224
          DPFDP (Diesel Particulate Filter Differential Pressure) Sensor ..3227
            DPFDP Sensor End Diagnostics..3227
            Overview..3230
            Tools..3231
            Pinpoint Diagnostics With ServiceMaxx? Software..3231
            SPN 3251 FMI 1 - DPFDP Negative Delta Pressure..3234
            Fault Overview..3234
            Malfunction Indicator Lamp (MIL) Reaction..3234
            Associated Faults..3234
            Drive Cycle to Determine Fault Status..3234
            SPN 3251 FMI 10 - DPFDP in range stuck fault..3237
            Fault Overview..3237
            Malfunction Indicator Lamp (MIL) Reaction..3237
            Associated Faults..3237
            Drive Cycle to Determine Fault Status..3237
            SPN 3251 FMI 18 - DPFDP excessively LOW (Sensor / circuit fault or missing DPF)..3240
            Fault Overview..3240
            Amber Warning Lamp (AWL) Reaction..3240
            Associated Faults..3240
            Drive Cycle to Determine Fault Status..3240
            SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor / circuit fault or missing DPF)..3243
            Fault Overview..3243
            Lamp Reaction..3243
            Associated Faults..3243
            Fault Facts..3243
            Drive Cycle to Determine Fault Status..3243
            Possible Causes..3243
          DPFIT (Diesel Particulate Filter Inlet Temperature) Sensor..3248
            DPFIT Sensor End Diagnostics..3248
            Overview..3249
            Tools..3250
            Pinpoint Diagnostics With ServiceMaxx? Software..3250
            SPN 3242 FMI 2 - DFPIT signal erratic, intermittent, or incorrect..3252
            Fault Overview..3252
            Malfunction Indicator Lamp (MIL) Reaction..3252
            Associated Faults..3252
            Drive Cycle to Determine Fault Status..3252
            SPN 3242 FMI 10 - DPFIT stuck in range LOW fault..3254
            Fault Overview..3254
            Malfunction Indicator Lamp (MIL) Reaction..3254
            Fault Fact..3254
            Associated Faults..3254
            Drive Cycle to Determine Fault Status..3254
            SPN 3242 FMI 21 - DPFIT signal Drifted LOW..3257
            Fault Overview..3257
            Malfunction Indicator Lamp (MIL) Reaction..3257
            Associated Faults..3257
            Drive Cycle to Determine Fault Status..3257
          DPFOT (Diesel Particulate Filter Outlet Temperature) Sensor..3259
            Overview..3260
            Tools..3261
            Pinpoint Diagnostics With ServiceMaxx? Software..3261
            SPN 3246 FMI 2 - DPFOT Signal erratic, intermittent, or incorrect..3263
            Fault Overview..3263
            Malfunction Indicator Lamp (MIL) Reaction..3263
            Associated Faults..3263
            Drive Cycle to Determine Fault Status..3263
            SPN 3246 FMI 10 - DPFOT signal abnormal rate of change..3265
            Fault Overview..3265
            Malfunction Indicator Lamp (MIL) Reaction..3265
            Associated Faults..3265
            Drive Cycle to Determine Fault Status..3265
            SPN 3246 FMI 21 - DPFOT signal Drifted LOW..3269
            Fault Overview..3269
            Malfunction Indicator Lamp (MIL) Reaction..3269
            Associated Faults..3269
            Drive Cycle to Determine Fault Status..3269
          ECL (Engine Coolant Level) Sensor..3272
          Function..3272
          Location..3272
          Tools..3272
            ECL Pin-point Diagnostics..3274
            ECL Circuit Operation..3276
            Fault Detection / Management..3276
          ECM (Engine Control Module) PWR Relay..3277
          Overview..3278
          Tools..3278
            ECM PWR Pin-point Diagnostics..3279
            SPN 158 FMI 17 ? ECM Switched voltage too LOW..3282
            Overview..3282
            Lamp Reaction..3282
            Associated Faults..3282
            Fault Facts..3282
            Drive Cycle to Determine Fault Status..3282
            Possible Causes..3282
            Pin-Point Test SPN 158 FMI 17..3284
            Tools Required..3284
          ECM (Engine Control Module) Self-Diagnostics ..3287
          Fault Detection / Management..3289
            Pinpoint Diagnostics With ServiceMaxx? Software..3290
            SPN 629 FMI 9 - Engine Off Timer Error..3292
            Fault Overview..3292
            Malfunction Indicator Lamp (MIL) Reaction..3292
            Associated Faults..3292
            Drive Cycle to Determine Fault Status..3292
          ECT1 (Engine Coolant Temperature 1) Sensor..3294
            Overview..3296
            Tools..3297
            Pinpoint Diagnostics With ServiceMaxx? Software..3297
            Connector Voltage Check..3299
            SPN 110 FMI 2 - ECT1 signal erratic, intermittent, or incorrect..3300
            Fault Overview..3300
            Malfunction Indicator Lamp (MIL) Reaction..3300
            Associated Faults..3300
            Drive Cycle to Determine Fault Status..3300
            SPN 110 FMI 16 - Engine Coolant System above OBD maximum temperature..3303
            Fault Overview..3303
            Malfunction Indicator Lamp (MIL) Reaction..3303
            Associated Faults..3303
            Drive Cycle to Determine Fault Status..3303
            SPN 110 FMI 17- Engine Coolant System below OBD monitoring temperature..3305
            Fault Overview..3305
            Malfunction Indicator Lamp (MIL) Reaction..3305
            Fault Fact..3305
            Associated Faults..3305
            Drive Cycle to Determine Fault Status..3305
            SPN 110 FMI 18 - Engine Coolant System below closed loop minimum temperature..3308
            Fault Overview..3308
            Malfunction Indicator Lamp (MIL) Reaction..3308
            Fault Fact..3308
            Associated Faults..3308
            Drive Cycle to Determine Fault Status..3308
            SPN 1659 FMI 20 - ECT1 below expected: Check thermostat..3311
            Fault Overview..3311
            Malfunction Indicator Lamp (MIL) Reaction..3311
            Fault Fact..3311
            Associated Faults..3311
            Drive Cycle to Determine Fault Status..3311
          EFC (Engine Fan Control)..3314
          Function..3314
          Location..3315
          Tools..3315
            EFC Circuit Diagnostics..3316
            EFC Circuit Operation..3319
            EFC Programmable Parameters..3319
            Fault Detection / Management..3319
          EFT (Engine Fuel Temperature) Sensor..3320
            Overview..3321
            Tools..3322
            Pinpoint Diagnostics With ServiceMaxx? Software..3322
            EFT Pin-point Diagnostics..3324
            SPN 174 FMI 2 - EFT Signal erratic, intermittent, or incorrect..3325
            Fault Overview..3325
            Malfunction Indicator Lamp (MIL) Reaction..3325
            Associated Faults..3325
            Drive Cycle to Determine Fault Status..3325
            SPN 174 FMI 21 - EFT signal drifted LOW..3328
            Fault Overview..3328
            Malfunction Indicator Lamp (MIL) Reaction..3328
            Associated Faults..3328
            Drive Cycle to Determine Fault Status..3328
          EGR (Exhaust Gas Recirculation) Valve ..3331
            Overview..3334
            SPN 27 FMI 3 - EGRP signal Out of Range HIGH..3335
            Tools..3335
            Pinpoint Diagnostics..3335
            SPN 27 FMI 4 - EGRP signal Out of Range LOW..3338
            Tools..3338
            Pinpoint Diagnostics..3338
            SPN 27 FMI 10 - EGRP signal abnormal rate of change..3341
            Tools..3341
            Pinpoint Diagnostics..3341
            SPN 2791 FMI 3 - EGRC short to PWR..3344
            Tools..3344
            Pinpoint Diagnostics..3344
            SPN 2791 FMI 4 - EGRC short to GND..3347
            Tools..3347
            Pinpoint Diagnostics..3347
            SPN 2791 FMI 5 - EGRC open load / circuit..3350
            Tools..3350
            Pinpoint Diagnostics..3350
            SPN 2791 FMI 7 - EGR Valve unable to achieve commanded position..3353
            Tools..3353
            Pinpoint Diagnostics..3353
            SPN 2791 FMI 17 - EGR Valve unable to achieve commanded position..3356
            Tools..3356
            Pinpoint Diagnostics..3356
            SPN 27 FMI 7 - EGRP Does Not Agree with Commanded Position..3359
            Fault Overview..3359
            Malfunction Indicator Lamp (MIL) Reaction..3359
            Associated Faults..3359
            Drive Cycle..3359
            SPN 4752 - FMI 4 - EGR Cooler Efficiency: EGR outlet temp above expected..3363
            Fault Overview..3363
            Malfunction Indicator Lamp (MIL) Reaction..3363
            Associated Faults..3363
            Drive Cycle..3363
          EGRT (Exhaust Gas Recirculation Temperature) Sensor..3365
            EGRT Sensor End Diagnostics..3365
            Overview..3366
            Tools..3367
            Pinpoint Diagnostics With ServiceMaxx? Software..3367
            EGRT Pin-point Diagnostics..3369
            SPN 412 FMI 2 - EGRT Signal erratic, intermittent, or incorrect..3370
            Fault Overview..3370
            Malfunction Indicator Lamp (MIL) Reaction..3370
            Associated Faults..3370
            Drive Cycle to Determine Fault Status..3370
            SPN 412 FMI 21 - EGRT Signal drifted LOW..3373
            Fault Overview..3373
            Malfunction Indicator Lamp (MIL) Reaction..3373
            Associated Faults..3373
            Drive Cycle to Determine Fault Status..3373
          EGT (Exhaust Gas Temperature) Sensor..3376
            Overview..3377
            Tools..3378
            Pinpoint Diagnostics With ServiceMaxx? Software..3378
            Connector Voltage Check..3380
            SPN 173 FMI 0 ? Exhaust Gas System above Critical Temperature..3381
            Fault Overview..3381
            Lamp Reaction..3381
            Associated Faults..3381
            Fault Facts..3381
            Drive Cycle to Determine Fault Status..3381
            Possible Causes..3381
            SPN 173 FMI 2 - EGT Signal erratic, intermittent, or incorrect..3383
            Fault Overview..3383
            Malfunction Indicator Lamp (MIL) Reaction..3383
            Associated Faults..3383
            Drive Cycle to Determine Fault Status..3383
            SPN 173 FMI 21 - EGT Stuck in Range LOW..3386
            Fault Overview..3386
            Malfunction Indicator Lamp (MIL) Reaction..3386
            Associated Faults..3386
            Drive Cycle to Determine Fault Status..3386
          EOP (Engine Oil Pressure) Sensor..3389
          Function..3389
          Sensor Location..3389
          Tools..3389
            EOP Sensor End Diagnostics..3391
            EOP Pin-point Diagnostics..3393
            EOP Circuit Operation..3395
            Fault Detection / Management..3395
          EOT (Engine Oil Temperature) Sensor..3396
            Overview..3397
            Fast Idle Advance..3397
            Tools..3398
            Pinpoint Diagnostics With ServiceMaxx? Software..3398
            EOT Pin-point Diagnostics..3400
            SPN 175 FMI 2 - EOT Signal erratic, intermittent, or incorrect..3402
            Fault Overview..3402
            Malfunction Indicator Lamp (MIL) Reaction..3402
            Fault Fact..3402
            Associated Faults..3402
            Drive Cycle to Determine Fault Status..3402
            SPN 175 FMI 21 - EOT signal drifted LOW..3405
            Fault Overview..3405
            Malfunction Indicator Lamp (MIL) Reaction..3405
            Associated Faults..3405
            Drive Cycle to Determine Fault Status..3405
          ETV (Engine Throttle Valve)..3408
            Overview..3410
            ETP (Engine Throttle Position) sensor..3410
            ETV actuator..3410
            Fault Detection / Management..3410
            Tools..3411
            Pinpoint Diagnostics With ServiceMaxx? Software..3411
            SPN 51 FMI 7 ETP Does not agree with commanded position..3414
            Fault Overview..3414
            Malfunction Indicator Lamp (MIL) Reaction..3414
            Associated Faults..3414
            Drive Cycle to Determine Fault Status..3414
          EWPS (Engine Warning Protection System)..3417
            EWPS Diagnostics..3417
            Overview..3420
            Tools..3420
            Pinpoint Diagnostics With ServiceMaxx? Software..3421
            EWPS Programmable Parameters..3422
            SPN 100 FMI 18 ? Engine Oil System below Warning Pressure..3427
            Fault Overview..3427
            Lamp Reaction..3427
            Associated Faults..3427
            Fault Facts..3427
            Drive Cycle to Determine Fault Status..3427
            Possible Causes..3427
            SPN 188 FMI 0 - Engine unable to achieve desired idle speed (too high)..3432
            Fault Overview..3432
            Malfunction Indicator Lamp (MIL) Reaction..3432
            Associated Faults..3432
            Drive Cycle to Determine Fault Status..3432
            SPN 188 FMI 1 - Engine unable to achieve desired idle speed (too low)..3434
            Fault Overview..3434
            Malfunction Indicator Lamp (MIL) Reaction..3434
            Fault Fact..3434
            Associated Faults..3434
            Drive Cycle to Determine Fault Status..3434
            SPN 5395 FMI 0 - Engine unable to achieve desired idle torque (too high)..3436
            Fault Overview..3436
            Malfunction Indicator Lamp (MIL) Reaction..3436
            Associated Faults..3436
            Drive Cycle to Determine Fault Status..3436
            SPN 5395 FMI 1 - Engine unable to achieve desired idle torque (too low)..3438
            Fault Overview..3438
            Malfunction Indicator Lamp (MIL) Reaction..3438
            Fault Fact..3438
            Associated Faults..3438
            Drive Cycle to Determine Fault Status..3438
          FCC (Fuel Cooler Control) Valve..3440
          Function..3440
          Sensor Location..3440
          Tools..3440
            Fuel Cooler Control Valve Circuit Diagnostics..3441
            Fuel Cooler Control Valve Circuit Operation..3442
          FDP (Fuel Delivery Pressure) Sensor..3443
          Function..3443
          Sensor Location..3443
          Tools..3443
            FDP Sensor End Diagnostics..3445
            FDP Pin-point Diagnostics..3447
            FDP Circuit Operation..3449
            Fault Detection / Management..3449
          FPCV (Fuel Pressure Control Valve)..3450
          Function..3451
          FPCV Location..3451
          Tools..3452
            FPCV Pin-point Diagnostics..3453
            FPCV Circuit Operation..3455
            Fault Detection / Management..3455
          Fuel Pump..3456
          Function..3456
          FPC Location..3456
          Tools..3456
            Fuel Pump Pin-point Diagnostics..3458
            Fuel Pump Actuator..3460
            Fault Detection / Management..3460
          FRP (Fuel Rail Pressure) Sensor..3461
            Overview..3461
            Tools..3463
            Pinpoint Diagnostics With ServiceMaxx? Software..3463
            Connector Voltage Check..3465
            SPN 157 FMI 9 - Fuel Rail Pressure (FRP) Abnormal Rate of Change..3467
            Fault Overview..3467
            Amber Warning Lamp (AWL) Reaction..3467
            Associated Faults..3467
            Drive Cycle to Determine Fault Status..3467
            SPN 157 FMI 10 - Fuel Rail Pressure (FRP) Abnormal Rate of Change..3470
            Fault Overview..3470
            Malfunction Indicator Lamp (MIL) Reaction..3470
            Associated Faults..3470
            Drive Cycle to Determine Fault Status..3470
            SPN 157 FMI 13 - FRP Above KOEO Spec..3473
            Fault Overview..3473
            Malfunction Indicator Lamp (MIL) Reaction..3473
            Associated Faults..3473
            Drive Cycle to Determine Fault Status..3473
            FRP System Diagnostics..3477
            Overview..3480
            SPN 3055 FMI 0 - FRP exceeded maximum..3481
            Tools..3481
            SPN 3055 FMI 1 - Low fuel pressure at start..3481
            Tools..3481
            SPN 3055 FMI 13 - Fuel pressure offset check..3482
            Tools..3482
            SPN 3055 FMI 2 - FPCV adaptation in-range fault..3483
            Fault Overview..3483
            Malfunction Indicator Lamp (MIL) Reaction..3483
            Associated Faults..3483
            Drive Cycle to Determine Fault Status..3483
            SPN 3055 FMI 15 - Fuel Rail Pressure (FRP) Below Minimum with Maxiumum Command..3485
            Fault Overview..3485
            Malfunction Indicator Lamp (MIL) Reaction..3485
            Associated Faults..3485
            Drive Cycle to Determine Fault Status..3485
            SPN 3055 FMI 16 - Fuel Rail Pressure (FRP) Below Minimum with Maxiumum Command..3487
            Fault Overview..3487
            Amber Warning Lamp (AWL) Reaction..3487
            Associated Faults..3487
            Drive Cycle to Determine Fault Status..3487
            SPN 3055 FMI 17 - Fuel Rail Pressure (FRP) Above Maximum with Minimum Command..3489
            Fault Overview..3489
            Malfunction Indicator Lamp (MIL) Reaction..3489
            Associated Faults..3489
            Drive Cycle to Determine Fault Status..3489
            SPN 3055 FMI 18 - Fuel Rail Pressure (FRP) Above Maximum with Minimum Command..3492
            Fault Overview..3492
            Amber Warning Lamp (AWL) Reaction..3492
            Associated Faults..3492
            Drive Cycle to Determine Fault Status..3492
            SPN 3055 FMI 31 - FPCV adaptation in-range fault..3495
            Fault Overview..3495
            Amber Warning Lamp (AWL) Reaction..3495
            Associated Faults..3495
            Drive Cycle to Determine Fault Status..3495
          FVCV (Fuel Volume Control Valve)..3497
          Function..3498
          FVCV Location..3498
          Tools..3499
            FVCV Pin-point Diagnostics..3500
            FVCV Circuit Operation..3502
            Fault Detection / Management..3502
          IAH (Inlet Air Heater)..3503
            Overview..3505
            Tools..3506
            Pinpoint Diagnostics With ServiceMaxx? Software..3506
            SPN 729 FMI 18 - IAH Monitor: lack of heat in the intake manifold..3509
            Fault Overview..3509
            Malfunction Indicator Lamp (MIL) Reaction..3509
            Associated Faults..3509
            Drive Cycle to Determine Fault Status..3509
          IMP (Intake Manifold Pressure) Sensor..3512
            Overview..3514
            Tools..3515
            Pinpoint Diagnostics With ServiceMaxx? Software..3515
            IMP Pin-point Diagnostics..3517
            SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect..3518
            Fault Overview..3518
            Amber Warning Lamp (AWL) Reaction..3518
            Associated Faults..3518
            Drive Cycle to Determine Fault Status..3518
            SPN 102 FMI 15 - Overboost..3521
            Fault Overview..3521
            Amber Warning Lamp (AWL) Reaction..3521
            Associated Faults..3521
            Drive Cycle to Determine Fault Status..3521
            SPN 102 FMI 16 - Overboost..3524
            Fault Overview..3524
            Malfunction Indicator Lamp (MIL) Reaction..3524
            Associated Faults..3524
            Drive Cycle to Determine Fault Status..3524
            SPN 102 FMI 18 - Underboost..3527
            Fault Overview..3527
            Malfunction Indicator Lamp (MIL) Reaction..3527
            Associated Faults..3527
            Drive Cycle to Determine Fault Status..3527
          IMT (Intake Manifold Temperature) Sensor..3530
            Overview..3531
            Tools..3532
            Pinpoint Diagnostics With ServiceMaxx? Software..3532
            IMT Pin-point Diagnostics..3534
            SPN 105 FMI 2 - IMT signal erratic, intermittent, or incorrect..3535
            Fault Overview..3535
            Malfunction Indicator Lamp (MIL) Reaction..3535
            Associated Faults..3535
            Drive Cycle to Determine Fault Status..3535
            SPN 105 FMI 21 - IMT signal drifted LOW..3538
            Fault Overview..3538
            Malfunction Indicator Lamp (MIL) Reaction..3538
            Associated Faults..3538
            Drive Cycle to Determine Fault Status..3538
          INJ (Injector Circuits)..3541
            INJ Diagnostics..3541
            Overview..3542
            Tools..3543
            Pinpoint Diagnostics With ServiceMaxx? Software..3544
            Injector 1 Check..3544
            Injector 2 Check..3546
            Injector 3 Check..3547
            Injector 4 Check..3548
            Injector 5 Check..3549
            Injector 6 Check..3550
            Injector 7 Check..3551
            Injector 8 Check..3552
            SPN 2797 FMI 2 - Injector Control Group 1 Open Circuit (INJ 1, 3, 5, 7)..3553
            Fault Overview..3553
            Amber Warning Lamp (AWL) Reaction..3553
            Associated Faults..3553
            Drive Cycle to Determine Fault Status..3553
            SPN 2797 FMI 3 - Injector Control Group 1 Open Circuit (INJ 1, 3, 5, 7)..3556
            Fault Overview..3556
            Malfunction Indicator Lamp (MIL) Reaction..3556
            Associated Faults..3556
            Drive Cycle to Determine Fault Status..3556
            SPN 2798 FMI 2 - Injector Control Group 2 Open Circuit (INJ 2, 4, 6, 8)..3559
            Fault Overview..3559
            Amber Warning Lamp (AWL) Reaction..3559
            Associated Faults..3559
            Drive Cycle to Determine Fault Status..3559
            SPN 2798 FMI 3 - Injector Control Group 2 Open Circuit (INJ 2, 4, 6, 8)..3562
            Fault Overview..3562
            Malfunction Indicator Lamp (MIL) Reaction..3562
            Associated Faults..3562
            Drive Cycle to Determine Fault Status..3562
          IST (Idle Shutdown Timer) System ..3565
          Function..3566
          Tools..3566
            IST Operation..3567
            Idle Shutdown Warning..3567
            Engine Idle Shutdown Timer for California ESS-Compliant Engines..3567
            CARB IST Conditions..3567
            Engine Idle Shutdown Timer (Federal-Optional)..3568
            Federal IST Conditions..3568
            Common Enable Conditions for All Federal IST Options..3568
            Federal IST Mode 1: PTO Operation Option Enable Conditions..3568
            Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions..3569
            Federal IST Mode 3: Tamper Proof Option Enable Conditions..3569
            Fault Detection / Management..3569
          MAF / AIT (Mass Air Flow / Air Inlet Temperature) Sensor..3570
            Overview..3573
            Sensor Location..3573
            Tools..3574
            Pinpoint Diagnostics With ServiceMaxx? Software..3577
            SPN 132 FMI 2 - MAF Signal Erratic, Intermittent, or Incorrect..3580
            Fault Overview..3580
            Malfunction Indicator Lamp (MIL) Reaction..3580
            Associated Faults..3580
            Drive Cycle to Determine Fault Status..3580
            SPN 132 FMI 13 ? MAF Sensor Calibration Needed..3583
            Fault Overview..3583
            Lamp Reaction..3583
            Associated Faults..3583
            Fault Facts..3583
            Drive Cycle to Determine Fault Status..3583
            Possible Causes..3583
            SPN 172 FMI 2 - AIT Signal Erratic, Intermittent, or Incorrect..3585
            Fault Overview..3585
            Malfunction Indicator Lamp (MIL) Reaction..3585
            Associated Faults..3585
            Drive Cycle to Determine Fault Status..3585
          TOSS / VSS (Transmission Output Shaft Speed / Vehicle Speed Sensor) Sensor..3588
            Overview..3590
            Tools..3591
            Pinpoint Diagnostics With ServiceMaxx? Software..3592
            SPN 191 FMI 1 - TOSS / VSS not detected with vehicle moving..3593
            Fault Overview..3593
            Malfunction Indicator Lamp (MIL) Reaction..3593
            Fault Fact..3593
            Associated Faults..3593
            Drive Cycle to Determine Fault Status..3593
          RSE (Radiator Shutter Enable)..3597
          Function..3597
          Component Location..3598
          Tools..3598
            RSE Circuit Diagnostics..3599
            RSE Circuit Operation..3601
            Fault Detection / Management..3601
          Service Interval Messages..3602
            Service Interval Messages Operation..3602
            SPN 1378 FMI 14 - Change engine oil service interval reset ahead of schedule..3603
            Fault Overview..3603
            Malfunction Indicator Lamp (MIL) Reaction..3603
            Associated Faults..3603
            Drive Cycle to Determine Fault Status..3603
          SMC (Starter Motor Control) Circuit ..3605
          Function..3605
          Location..3606
          Tools..3606
            SMC Circuit Diagnostics..3607
            SMC Circuit Operation..3611
            Driveline Disengagement Switch (DDS) Circuit..3611
            Ignition Switch..3611
            SMC Circuit..3611
            ECM..3611
            Start Relay..3611
            Clutch Switch (Manual Transmission)..3611
            Neutral Signal (Automatic Transmission)..3611
            Fault Detection / Management..3611
          TACH (Tachometer Output Circuit)..3612
            Tachometer Pin-point Diagnostics..3613
            Tachometer Circuit Operation..3614
            Diagnostic Trouble Codes (DTCs)..3614
          TC2WG (Turbocharger 2 Wastegate) Solenoid..3615
          Function..3615
          Sensor Location..3615
          Tools..3615
            TC2WG Circuit Diagnostics..3617
            TC2WG Circuit Operation..3619
            Fault Detection / Management..3619
          TC1COT (Turbocharger 1 Compressor Outlet Temperature) Sensor..3620
            TC1COT Sensor End Diagnostics..3620
            Overview..3621
            Tools..3622
            Pinpoint Diagnostics With ServiceMaxx? Software..3622
            TC1COT Pin-point Diagnostics..3624
            SPN 2629 FMI 2 - TC1COT signal erratic, intermittent, or incorrect..3625
            Fault Overview..3625
            Malfunction Indicator Lamp (MIL) Reaction..3625
            Associated Faults..3625
            Drive Cycle to Determine Fault Status..3625
            SPN 2629 FMI 16 - TC1COT Over temperature: Moderate De-Rate..3628
            Fault Overview..3628
            Malfunction Indicator Lamp (MIL) Reaction..3628
            Associated Faults..3628
            Drive Cycle to Determine Fault Status..3628
            SPN 2629 FMI 21 - TC1COT signal drifted LOW..3631
            Fault Overview..3631
            Malfunction Indicator Lamp (MIL) Reaction..3631
            Associated Faults..3631
            Drive Cycle to Determine Fault Status..3631
          VREF (Reference Voltage)..3634
          Function..3635
          Tools..3635
            VREF Pin-point Diagnostics..3636
            VREF Circuit Operation..3642
            Fault Detection / Management..3643
          VSO (Vehicle Speed Output)..3644
            Vehicle Speed Output Pin-point Diagnostics..3645
            Vehicle Speed Output Circuit Operation..3646
            Diagnostic Trouble Codes (DTCs) ..3646
          WIF (Water In Fuel) Sensor..3647
          Function..3647
          Sensor Location..3647
          Tools..3647
            WIF Pin-point Diagnostics..3648
            WIF Circuit Operation..3650
            Fault Detection / Management..3650
      Table of Contents..3652
        Electrical Tools..3654
          42-Pin Engine to Chassis Interface Cable..3654
          98-Pin Engine and Chassis Cables..3654
          180-Pin Breakout Box..3655
          Digital IR Thermometer..3656
          Digital Multimeter (DMM)..3657
          EXP-1000 HD by Midtronics..3658
          EZ-Tech? Electronic Service Tool (EST)..3659
          International? Electronic Engine Terminal Test Kit..3660
          Interface cable (RP1210B compliant supporting J1939 and J1708)..3661
          3-Banana Plug Harness..3661
          16-Way Breakout Harness..3662
          500-Ohm Resistor Harness..3662
          Breakout Harness 4485A (APP)..3663
          Breakout Harness 4602 (ECT, EFT, EOT, and IMT)..3663
          Breakout Harness 4760A (DOCIT, DPFIT, DPFOT, and TC1COT)..3664
          Breakout Harness 4761A (DPFDP)..3664
          Breakout Harness 4762 (IPR, EGR, and VGT)..3665
          Breakout Harness 4831 (TC2WG)..3665
          Breakout Harness 4850 (IMP)..3666
          Breakout Harness 4908 (ECM Relay)..3666
          Breakout Harness 4946 (EGT)..3667
          Breakout Harness 4950 (CMP)..3667
          Breakout Harness 4951 (CKP)..3668
          Breakout Harness 4958 (FPCV and FVCV)..3668
          Breakout Harness 4960 (MAF)..3669
          Breakout Harness 4993 (IMT and CACOT)..3669
          Breakout Harness 6000 (UVC)..3670
          Breakout Harness 6001 (Fuel Pump)..3670
          Breakout Harness 6002 (WIF)..3670
          Breakout Harness 6005 (EBPV)..3671
          Breakout Harness 6025 (IAH)..3672
          Breakout Harness 6038 (FRP)..3672
        Mechanical Tools..3673
          Charge Air Cooler Test Kit..3673
          Clean Fuel Source Tool..3673
          Crankcase Pressure Test Adaptor..3674
          Crankcase Pressure Test Adaptor..3675
          Digital Manometer..3676
          EGR Cooler Leak Detection Kit..3677
          Fuel Inlet Restriction and Aeration Tool..3677
          Fuel / Oil Pressure Test Coupler..3678
          Fuel Pressure Test Kit..3679
          Fuel Rail Block Off Plugs..3679
          Fuel System Caps..3680
          High-pressure Pump Test Fitting..3680
          Fuel Injector Cups..3681
          Inline Shut-off Valve..3681
          Oil Cooler Block Off..3682
          Pressure Test Kit..3683
          Radiator Pressure Test Kit..3684
          Slack Tube? Manometer..3685
          Turbocharger Drain Block Off Plug..3686
          Turbocharger Oil Supply Block Off..3687
          Turbocharger Supply Block Off Plug..3688
          UV Leak Detection Kit..3689
          Vacuum Analyzer and Fuel Pump Tester..3690
      Table of Contents..3692
        Abbreviations and Acronyms..3694
          Abbreviations and Acronyms..3694
      Table of Contents..3702
        Terminology..3704
          Terminology..3704
            Terms..3704
      Table of Contents..3716
        MaxxForce? 7 (6.4L) All Ratings @ 2600 rpm (12NSH)..3718
      Table of Contents..3722
        Signal Values..3724
  tables..2760
    Technical Service Literature..2760
    MaxxForce? 7 Features and Specifications..2771
    Unacceptable Boost Possible Causes..2906
    Unacceptable Fuel Rail Pressure Possible Causes..2906
    Unacceptable Fuel Pressure Possible Causes..2906
    Primary Fuel Filter (Cartridge Style) Inspection..2986
    Mechanical Gauge Reading Specifications..3050
    Minimum..3050
    Typical..3050
    Low Idle..3050
    High Idle..3050
    ServiceMaxx EOP Sensor Value Specifications..3051
    Minimum..3051
    Typical..3051
    Low Idle..3051
    High Idle..3051
    Example..3076
    Example..3077
    Example..3077
    Example..3077
    Example..3079
    Example..3079
    Example..3080
    Example..3080
    Example..3080
    Example..3081
    Example..3082
    Example..3083
    Example..3084
    Active Rolling Regeneration..3090
    Manual Parked Regeneration..3090
    Manual Parked Regeneration Procedure..3091
    Onboard Filter Cleanliness Test (ServiceMaxx? software)..3093
    Alert Levels of DPF Soot Loading..3094
    TMV - Standard and Output State Test..3120
    Connector Voltage Check..3121
    Connector Resistance Check to GND..3121
    Harness Resistance Check..3121
    SPN 1209 and FMI 0 - EBP above desired level..3122
    SPN 1692 and FMI 0 - Boost high / above desired level detected..3122
    SPN 1692 and FMI 17 - KOER STD - Boost unable to achieve desired set-point Pin-Point AMS Fault..3122
    SPN 1692 and FMI 18 - Boost unable to achieve desired set-point..3123
    SPN 2659 and FMI 17 -EGR Flow Rate unable to achieve desired set-point..3123
    SPN 2659 and FMI 20 - EGR high flow rate detected..3123
    SPN 2659 and FMI 21 - EGR low flow rate detected..3124
    Sensor Circuit Check..3151
    Connector Voltage Check..3152
    Connector Resistance Check to GND..3153
    Harness Resistance Check..3153
    Operational Voltage Check..3153
    Connector Voltage Check - EST..3157
    Harness Resistance Check..3158
    Brake Switch Circuits..3162
    Voltage Check..3163
    Harness Resistance Check..3163
    Connector Voltage Check..3168
    Connector Resistance Check to GND..3168
    Harness Resistance Check..3168
    Connector Voltage Check..3187
    EST Communication Check..3188
    Harness Resistance Check..3188
    Switch Checks..3193
    Circuit End Voltage Check..3193
    Sensor and Circuit Resistance Check..3195
    Harness Resistance Check..3195
    Operational Check..3196
    Sensor and Circuit Resistance Check..3200
    Harness Resistance Check..3200
    Operational Check..3201
    Sensor Circuit Check..3214
    Connector Voltage Check..3214
    Connector Resistance Check to GND..3214
    Harness Resistance Check..3215
    Sensor Circuit Check..3232
    Connector Voltage Check..3232
    Connector Resistance Checks to GND..3232
    Harness Resistance Check..3233
    Sensor Circuit Check..3251
    Connector Voltage Check..3251
    Connector Resistance Check to GND..3251
    Harness Resistance Check..3251
    Sensor Circuit Check..3262
    Connector Voltage Check..3262
    Connector Resistance Check to GND..3262
    Harness Resistance Check..3262
    Connector Voltage Check..3274
    Connector Resistance Check to GND..3274
    Sensor Resistance Check..3275
    Harness Resistance Check..3275
    Voltage Check at Relay..3280
    Voltage Check at ECM..3280
    Harness Resistance Check..3281
    Harness Resistance Check on Relay Power Circuits..3281
    SPN 108 / FMI 3- BARO signal Out of Range HIGH..3290
    SPN 108 / FMI 4 - BARO signal Out of Range LOW..3290
    SPN 628 / FMI 12 - ECM Memory Error..3290
    SPN 628 / FMI 14 - ECM Programming - EFRC Error..3290
    SPN 629 / FMI 2 - ECM Error - Level 2 Monitoring..3290
    SPN 629 / FMI 10 - ECM Error - Fuel Injector Circuit Performance Bank B..3290
    SPN 629 / FMI 12 - ECM Error - SPI..3290
    SPN 629 / FMI 31 - ECM Error - Level 3 Monitoring..3291
    SPN 1136 / FMI 0 - ECM Error - Over temperature..3291
    SPN 1136 / FMI 1 - ECM Error - Under temperature..3291
    Sensor Circuit Check..3298
    Connector Resistance Check to GND..3299
    Harness Resistance Check..3299
    Voltage Check at EFC Connector Output State Test..3317
    Voltage Check at Relay - Output State Test..3317
    Harness Resistance Check..3318
    Sensor Circuit Check..3323
    Connector Voltage Check..3324
    Connector Resistance Check to GND..3324
    Harness Resistance Check..3324
    EGR Valve Circuit Check..3336
    EGR Valve - Standard and Output State Test..3336
    Connector Voltage Check..3337
    Connector Resistance Check to GND..3337
    Harness Resistance Check..3337
    EGR Valve Circuit Check..3339
    EGR Valve - Standard and Output State Test..3339
    Connector Voltage Check..3340
    Connector Resistance Check to GND..3340
    Harness Resistance Check..3340
    EGR Valve Circuit Check..3342
    EGR Valve - Standard and Output State Test..3342
    Connector Voltage Check..3343
    Connector Resistance Check to GND..3343
    Harness Resistance Check..3343
    EGR Valve Circuit Check..3345
    EGR Valve - Standard and Output State Test..3345
    Connector Voltage Check..3346
    Connector Resistance Check to GND..3346
    Harness Resistance Check..3346
    EGR Valve Circuit Check..3348
    EGR Valve - Standard and Output State Test..3348
    Connector Voltage Check..3349
    Connector Resistance Check to GND..3349
    Harness Resistance Check..3349
    EGR Valve Circuit Check..3351
    EGR Valve - Standard and Output State Test..3351
    Connector Voltage Check..3352
    Connector Resistance Check to GND..3352
    Harness Resistance Check..3352
    EGR Valve Circuit Check..3354
    EGR Valve - Standard and Output State Test..3354
    Connector Voltage Check..3355
    Connector Resistance Check to GND..3355
    Harness Resistance Check..3355
    EGR Valve Circuit Check..3357
    EGR Valve - Standard and Output State Test..3357
    Connector Voltage Check..3358
    Connector Resistance Check to GND..3358
    Harness Resistance Check..3358
    SPN 412 FMI 0 ? EGRT above Critical Temperature..3367
    Sensor Circuit Check..3368
    Connector Voltage Check..3369
    Connector Resistance Check to GND..3369
    Harness Resistance Check..3369
    Sensor Circuit Check..3379
    Connector Resistance Check to GND..3380
    Harness Resistance Check..3380
    Sensor Circuit Check..3392
    Connector Voltage Check..3393
    Connector Resistance Check to GND..3393
    Harness Resistance Check..3394
    Sensor Circuit Check..3399
    Connector Voltage Check..3400
    Connector Resistance Check to GND..3400
    Harness Resistance Check..3401
    ETV Circuit Check..3412
    ETV - Standard Test and Output State Test..3412
    Connector Voltage Check..3413
    Connector Resistance Check to GND..3413
    Harness Resistance Check..3413
    Voltage Check at Fuel Cooler Control Valve Connector ? Output State Test..3441
    Harness Resistance Check..3441
    SPN 94 FMI 0 ? Fuel Delivery Pressure Above Critical..3446
    Sensor Circuit Check..3446
    Connector Voltage Check..3447
    Connector Resistance Check to GND..3447
    Harness Resistance Check..3448
    Actuator / Harness Resistance Check..3453
    Operational Voltage Check - Output Circuit Check..3454
    Connector Voltage Check..3458
    Run Output State Test ? Low..3458
    Run Output State Test ? Low..3458
    Connector Resistance Check to GND..3459
    Harness Resistance Check..3459
    Sensor Circuit Check..3464
    Connector Resistance Check to GND..3465
    Under Valve Cover Resistance Check to Engine GND..3465
    Harness Resistance Check..3466
    Actuator / Harness Resistance Check..3500
    Operational Voltage Check - Output Circuit Check..3501
    Voltage Check on Relay Switch ? Output State Test IAH..3507
    Voltage Check on Relay Coil ? Output State Test..3507
    Amperage Draw Check..3507
    Element Resistance Check..3507
    Harness Resistance Check ? Relay Coil Circuits..3508
    Harness Resistance Check ? Relay Switch Circuits..3508
    Sensor Circuit Check..3516
    Connector Voltage Check..3517
    Connector Resistance Check to GND..3517
    Harness Resistance Check..3517
    Sensor Circuit Check..3533
    Connector Voltage Check..3534
    Connector Resistance Check to GND..3534
    Harness Resistance Check..3534
    Injector 1 - Resistance Checks Through Harness and Injector..3544
    Injector 1 - Resistance UVC Checks..3544
    Injector 1 - Harness Resistance Check..3545
    Injector 2 - Resistance Through Valve Cover to Engine GND Check..3546
    Injector 2 - Harness Resistance Check..3546
    Injector 3 - Resistance Through Valve Cover to Engine GND Check..3547
    Injector 3 - Harness Resistance Check..3547
    injector 4 - Resistance Through Valve Cover to Engine GND Check..3548
    Injector 4 - Harness Resistance Check..3548
    Injector 5 - Resistance Through Valve Cover to Engine GND Check..3549
    Injector 5 - Harness Resistance Check..3549
    Injector 6 - Resistance Through Valve Cover to Engine GND Check..3550
    Injector 6 - Harness Resistance Check..3550
    Injector 7 - Resistance Through Valve Cover to Engine GND Check..3551
    Injector 7 - Harness Resistance Check..3551
    Injector 8 - Resistance Through Valve Cover to Engine GND Check..3552
    Injector 8 - Harness Resistance Check..3552
    MAF Calibration Requirements..3574
    MAF Calibration Pre-Checks..3575
    MAF Calibration Procedure ? Using ServiceMaxx? Software..3576
    Connector Voltage Check..3578
    Harness Resistance Check..3578
    Connector Voltage Checks..3592
    Sensor Resistance Check..3592
    Harness Resistance Check..3592
    Voltage Check at RSE Connector - Output State Test..3599
    Harness Resistance Check..3600
    Voltage Check at Start Relay and Starter Solenoid..3609
    Voltage Check at ECM..3609
    Harness Resistance Check - ECM to Relay..3610
    Harness Resistance Check - Relay to Battery..3610
    Operational Voltage Check..3610
    Circuit End Voltage Check..3613
    Harness Resistance Check..3613
    Voltage Check at TC2WG Connector - Output State Test..3617
    Harness Resistance Check..3618
    Sensor Circuit Check..3623
    Connector Voltage Check..3624
    Connector Resistance Check to GND..3624
    Harness Resistance Check..3624
    VREF Voltage Check..3638
    Connector Resistance Check to GND..3639
    Harness Resistance Check..3640
    Harness Resistance Check (cont.)..3641
    Circuit End Voltage Check..3645
    Harness Resistance Check..3645
    Operational Check..3645
    Voltage Check..3649
    Connector Resistance Checks to GND..3649
    Harness Resistance Check..3649
    KOEO (Key ON, Engine OFF)..3718
    Engine cranking..3719
    Low Idle, no load, stabilized engine operating temperature..3719
    High Idle, no load, stabilized engine operating temperature..3719
    Full load, rated speed on highway, stabilized engine operating temperature..3720
    Stabilized engine operating temperature..3720
    Miscellaneous sensors and components..3720
0000001681 - Electronic Control Systems Diagnostics & Diagnostic Trouble Code..3729
  toc..0
    Removal of Tools, Parts, and Equipment..0
      Table of Contents..3729
        Description..3733
          Section Information..3733
        Electronic Control System Diagnostics Form..3734
          0000003201 Diagnostic Form ..3734
        Sensor and Actuator Locations..3735
          Engine Mounted Components..3735
         Diagnostic Procedure Process..3740
          Description..3740
            Pin-grip Inspection..3740
            Diagnostics with EST..3740
            Diagnostics without EST..3740
          Sensor End Diagnostics (with ServiceMaxx? software)..3741
            Sensor End Diagnostics (2-Wire)..3741
            Sensor End Diagnostics (3-Wire)..3743
          Pin-point Diagnostics (without ServiceMaxx? software)..3746
          Actuator Operational Voltage Check ? Output State Test..3746
          Harness Resistance Check..3747
          Operational Voltage Check..3748
        Circuit Diagnostics..3749
          AFT (Aftertreatment) System..3749
            AFT System Diagnostics..3749
            Overview..3753
            Tools..3753
            AFT System Operation..3753
            Diesel Oxidation Catalyst (DOC)..3755
            Diesel Particulate Filter (DPF)..3755
            Regeneration..3755
            Passive Rolling Regeneration..3755
            Parked Regeneration Switch..3755
            Inhibit Regeneration Switch (optional)..3755
            DPF Soot Loading Percentage..3755
            DPF Ash Loading Percentage..3755
            DPF Status Lamp..3755
            High Exhaust System Temperature (HEST) Indicator ..3756
            Pinpoint Diagnostics With ServiceMaxx? Software..3758
            SPN 3936 FMI 2 - DPF System Feedback Control Fault..3761
            Fault Overview..3761
            Malfunction Indicator Lamp (MIL) Reaction..3761
            Fault Fact..3761
            Associated Faults..3761
            Drive Cycle to Determine Fault Status..3761
            SPN 3936 FMI 8 - DPF Regenerations are Occurring too Frequently..3763
            Fault Overview..3763
            Malfunction Indicator Lamp (MIL) Reaction..3763
            Associated Faults..3763
            Drive Cycle to Determine Fault Status..3763
            SPN 3936 FMI 11- Feedback Control Range Fault..3767
            Fault Overview..3767
            Malfunction Indicator Lamp (MIL) Reaction..3767
            Fault Fact..3767
            Associated Faults..3767
            Drive Cycle to Determine Fault Status..3767
            SPN 3936 FMI 20 - DPF Feedback - Feedback Max Authority..3769
            Fault Overview..3769
            Malfunction Indicator Lamp (MIL) Reaction..3769
            Fault Fact..3769
            Associated Faults..3769
            Drive Cycle to Determine Fault Status..3769
            SPN 4766 FMI 10 - Catalyst System Efficiency Below Threshold..3771
            Fault Overview..3772
            Fault Fact..3772
            Associated Faults..3772
            Drive Cycle to Determine Fault Status..3772
          AMS (Air Management System)..3775
            Overview..3779
            Tools..3779
            Pinpoint Diagnostics..3779
            SPN 2659 FMI 10 - EGR Slow Response Fault..3784
            Fault Overview..3784
            Malfunction Indicator Lamp (MIL) Reaction..3784
            Associated Faults..3784
            Drive Cycle to Determine Fault Status..3784
            SPN 5543 FMI 16 - EBP Valve Internal Temperature Fault..3788
            Fault Overview..3788
            Malfunction Indicator Lamp (MIL) Reaction..3788
            Associated Faults..3788
            Drive Cycle to Determine Fault Status..3788
            SPN 5543 FMI 19 - EBPC valve not detected on J1939..3792
            Fault Overview..3792
            Malfunction Indicator Lamp (MIL) Reaction..3792
            Associated Faults..3792
            Drive Cycle to Determine Fault Status..3792
            SPN 5543 FMI 20 - EBP valve electrical fault..3795
            Fault Overview..3795
            Malfunction Indicator Lamp (MIL) Reaction..3795
            Associated Faults..3795
            Drive Cycle to Determine Fault Status..3795
          APP (Accelerator Pedal Position) Sensor ..3798
          Function..3798
          Sensor Location..3798
          Tools..3799
            APP Sensor End Diagnostics..3800
            APP Pin-point Diagnostics..3803
            APP Circuit Operation..3805
            Accelerator Pedal Position (APP) sensor..3805
            Fault Detection/Management..3805
          ATA (American Trucking Association) Data Link (SAE J1587)..3806
          Function..3806
          Location..3806
          Tools..3806
            ATA (SAE J1587) Pin-point Diagnostics..3807
            ATA (SAE J1587) Operation..3808
            Diagnostic Connector..3808
            Electronic Gauge Cluster (EGC)..3808
            Fault Detection/Management..3808
            Repair Information..3808
          Brake Switch Circuits..3809
          Function..3809
          Location..3809
          Tools..3809
            Brake Switch Circuits Pin-point Diagnostics..3810
            Brake Switch Circuit Operation..3811
            Fault Detection/Management..3811
          CACOT Sensor (Charge Air Cooler Outlet Temperature)..3812
            Overview..3813
            Tools..3814
            SPN 2630 FMI 2 - CACOT Signal erratic, intermittent, or incorrect..3816
            Fault Overview..3817
            Malfunction Indicator Lamp (MIL) Reaction..3817
            Associated Faults..3817
            Drive Cycle to Determine Fault Status..3817
            SPN 2630 FMI 3 - CACOT signal out of range HIGH..3820
            Fault Overview..3820
            Malfunction Indicator Lamp (MIL) Reaction..3820
            Associated Faults..3820
            Drive Cycle to Determine Fault Status..3820
            SPN 2630 FMI 4 - CACOT signal out of range LOW..3823
            Fault Overview..3823
            Malfunction Indicator Lamp (MIL) Reaction..3823
            Associated Faults..3823
            Drive Cycle to Determine Fault Status..3823
            SPN 2630 FMI 16 - CACOT Undercooling..3826
            Fault Overview..3827
            Malfunction Indicator Lamp (MIL) Reaction..3827
            Associated Faults..3827
            Drive Cycle to Determine Fault Status..3827
            SPN 2630 FMI 21 - CACOT signal Drifted LOW..3830
            Fault Overview..3830
            Malfunction Indicator Lamp (MIL) Reaction..3830
            Associated Faults..3830
            Drive Cycle to Determine Fault Status..3830
          CAN (Controller Area Network) Communications (J1939) ..3833
          Function..3833
          Location..3833
          Tools..3833
            CAN (J1939) Pin-point Diagnostics..3834
            CAN (J1939) Circuit Operation..3835
            CAN (J1939) versus ATA (SAE J1587)..3835
            Diagnostic Connector..3836
             Electronic Gauge Cluster (EGC)..3836
            Body Controller (BC) or Multiplex System Module (MSM)..3836
            Repair Information..3836
          CCS (Cruise Control Switches)..3837
          Function..3838
          Location..3838
          Tools..3838
            Cruise Control Switches Pin-point Diagnostics ..3838
          CKP (Crankshaft Position) Sensor..3840
          Function..3840
          Sensor Location..3840
          Tools..3840
            CKP Pin-point Diagnostics..3841
            CKP Circuit Operation..3842
            Fault/Detection Management..3842
          CMP Sensor (Camshaft Position)..3843
            CMP Diagnostics..3843
            Overview..3844
            Tools..3845
            Pinpoint Diagnostics With ServiceMaxx? Software..3845
            SPN 636 FMI 10 - CMP signal inactive..3847
            Fault Overview..3847
            Malfunction Indicator Lamp (MIL) Reaction..3847
            Fault Fact:..3847
            Associated Faults..3847
            Drive Cycle to Determine Fault Status..3847
          Cylinder Balance..3849
            Cylinder Balance Diagnostics..3849
            Overview..3851
            Pin-Point Diagnostics With ServiceMaxx? Software..3852
            SPN 1322 FMI 31 - Misfire ? Multiple Cylinder..3853
            Fault Overview..3853
            Malfunction Indicator Lamp (MIL) Reaction..3853
            Associated Faults..3853
            Drive Cycle to Determine Fault Status..3853
          DOCIT (Diesel Oxidation Catalyst Inlet Temperature) Sensor..3856
            DOCIT Sensor End Diagnostics..3856
            Overview..3858
            Tools..3859
            Pinpoint Diagnostics With ServiceMaxx? Software..3859
            SPN 4765 FMI 2 - DOCIT signal erratic, intermittent, or incorrect..3861
            Fault Overview..3861
            Malfunction Indicator Lamp (MIL) Reaction..3861
            Associated Faults..3861
            Drive Cycle to Determine Fault Status..3861
            SPN 4765 FMI 8 - DOCIT signal abnormal rate of change..3864
            Fault Overview..3864
            Malfunction Indicator Lamp (MIL) Reaction..3864
            Associated Faults..3864
            Drive Cycle to Determine Fault Status..3864
            SPN 4765 FMI 10 - DOCIT in range stuck fault..3867
            Fault Overview..3867
            Malfunction Indicator Lamp (MIL) Reaction..3867
            Fault Fact..3867
            Associated Faults..3867
            Drive Cycle to Determine Fault Status..3867
            SPN 4765 FMI 21 - DOCIT signal drifted LOW..3871
            Fault Overview..3871
            Malfunction Indicator Lamp (MIL) Reaction..3871
            Associated Faults..3871
            Drive Cycle to Determine Fault Status..3871
          DPFDP (Diesel Particulate Filter Differential Pressure) Sensor ..3874
            DPFDP Sensor End Diagnostics..3874
            Overview..3876
            Tools..3877
            Pinpoint Diagnostics With ServiceMaxx? Software..3877
            SPN 3251 FMI 1 - DPFDP Negative Delta Pressure..3880
            Fault Overview..3880
            Malfunction Indicator Lamp (MIL) Reaction..3880
            Associated Faults..3880
            Drive Cycle to Determine Fault Status..3880
            SPN 3251 FMI 10 - DPFDP in range stuck fault..3883
            Fault Overview..3884
            Malfunction Indicator Lamp (MIL) Reaction..3884
            Associated Faults..3884
            Drive Cycle to Determine Fault Status..3884
          DPFIT (Diesel Particulate Filter Inlet Temperature) Sensor..3888
            DPFIT Sensor End Diagnostics..3888
            Overview..3889
            Tools..3890
            Pinpoint Diagnostics With ServiceMaxx? Software..3890
            SPN 3242 FMI 2 - DFPIT signal erratic, intermittent, or incorrect..3892
            Fault Overview..3892
            Malfunction Indicator Lamp (MIL) Reaction..3892
            Associated Faults..3892
            Drive Cycle to Determine Fault Status..3892
            SPN 3242 FMI 10 - DPFIT stuck in range LOW fault..3895
            Fault Overview..3895
            Malfunction Indicator Lamp (MIL) Reaction..3895
            Fault Fact..3895
            Associated Faults..3895
            Drive Cycle to Determine Fault Status..3895
            SPN 3242 FMI 11 - DPFIT sensor rationality fault..3899
            Fault Overview..3899
            Malfunction Indicator Lamp (MIL) Reaction..3899
            Associated Faults..3899
            Drive Cycle to Determine Fault Status..3899
            SPN 3242 FMI 21 - DPFIT signal Drifted LOW..3902
            Fault Overview..3902
            Malfunction Indicator Lamp (MIL) Reaction..3902
            Associated Faults..3902
            Drive Cycle to Determine Fault Status..3902
          DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)..3905
            Overview..3906
            Tools..3907
            Pinpoint Diagnostics With ServiceMaxx? Software..3907
            SPN 3246 FMI 2 - DPFOT Signal erratic, intermittent, or incorrect..3909
            Fault Overview..3909
            Malfunction Indicator Lamp (MIL) Reaction..3909
            Associated Faults..3909
            Drive Cycle to Determine Fault Status..3909
            SPN 3246 FMI 10 - DPFOT signal abnormal rate of change..3912
            Fault Overview..3912
            Malfunction Indicator Lamp (MIL) Reaction..3912
            Associated Faults..3912
            Drive Cycle to Determine Fault Status..3912
            SPN 3246 FMI 21 - DPFOT signal Drifted LOW..3916
            Fault Overview..3916
            Malfunction Indicator Lamp (MIL) Reaction..3916
            Associated Faults..3916
            Drive Cycle to Determine Fault Status..3916
          ECL (Engine Coolant Level) Sensor..3919
          Function..3919
          Location..3919
          Tools..3919
            ECL Pin-point Diagnostics..3920
            ECL Circuit Operation..3921
            Fault Detection/Management..3921
          ECM (Engine Control Module) PWR Relay..3922
          Function..3922
          ECM Location..3922
          Tools..3922
            ECM PWR Pin-point Diagnostics..3923
            ECM PWR Circuit Operation..3926
            Fault Detection/Management..3926
          ECM (Engine Control Module) Self-Diagnostics ..3927
          Fault Detection/Management..3928
            Pinpoint Diagnostics With ServiceMaxx? Software..3928
            SPN 629 FMI 9 - Engine Off Timer Error..3930
            Fault Overview..3930
            Malfunction Indicator Lamp (MIL) Reaction..3930
            Associated Faults..3930
            Drive Cycle to Determine Fault Status..3930
          ECT1 (Engine Coolant Temperature 1) Sensor..3932
            Overview..3934
            Tools..3935
            Pinpoint Diagnostics With ServiceMaxx? Software..3935
            Connector Voltage Check..3936
            SPN 110 FMI 2 - ECT1 signal erratic, intermittent, or incorrect..3937
            Fault Overview..3937
            Malfunction Indicator Lamp (MIL) Reaction..3937
            Associated Faults..3937
            Drive Cycle to Determine Fault Status..3937
            SPN 110 FMI 16 - Engine Coolant System above OBD maximum temperature..3940
            Fault Overview..3940
            Malfunction Indicator Lamp (MIL) Reaction..3940
            Associated Faults..3941
            Drive Cycle to Determine Fault Status..3941
            SPN 110 FMI 17- Engine Coolant System below OBD monitoring temperature..3943
            Fault Overview..3944
            Malfunction Indicator Lamp (MIL) Reaction..3944
            Fault Fact..3944
            Associated Faults..3944
            Drive Cycle to Determine Fault Status..3944
            SPN 110 FMI 18 - Engine Coolant System below closed loop minimum temperature..3947
            Fault Overview..3947
            Malfunction Indicator Lamp (MIL) Reaction..3947
            Fault Fact..3948
            Associated Faults..3948
            Drive Cycle to Determine Fault Status..3948
            SPN 1659 FMI 20 - ECT1 below expected: Check thermostat..3951
            Fault Overview..3951
            Malfunction Indicator Lamp (MIL) Reaction..3951
            Fault Fact..3952
            Associated Faults..3952
            Drive Cycle to Determine Fault Status..3952
          EFC (Engine Fan Control)..3955
          Function..3955
          Location..3955
          Tools..3955
            EFC Circuit Diagnostics..3956
            EFC Circuit Operation..3958
            EFC Programmable Parameters..3958
            Fault Detection/Management..3958
          EFT Sensor (Engine Fuel Temperature)..3959
            Overview..3960
            Tools..3961
            Pinpoint Diagnostics With ServiceMaxx? Software..3961
            EFT Pin-point Diagnostics..3962
            SPN 174 FMI 2 - EFT Signal erratic, intermittent, or incorrect..3963
            Fault Overview..3963
            Malfunction Indicator Lamp (MIL) Reaction..3963
            Associated Faults..3963
            Drive Cycle to Determine Fault Status..3963
            SPN 174 FMI 21 - EFT signal drifted LOW..3966
            Fault Overview..3966
            Malfunction Indicator Lamp (MIL) Reaction..3966
            Associated Faults..3966
            Drive Cycle to Determine Fault Status..3966
          EGR (Exhaust Gas Recirculation) Valve ..3969
            Overview..3971
            Tools..3972
            Pinpoint Diagnostics..3972
            SPN 27- FMI 7 - EGRP Does Not Agree with Commanded Position..3975
            Fault Overview..3975
            Malfunction Indicator Lamp (MIL) Reaction..3975
            Associated Faults..3975
            Drive Cycle..3975
            SPN 4752 - FMI 4 - EGR Cooler Efficiency: EGR outlet temp above expected..3978
            Fault Overview..3978
            Malfunction Indicator Lamp (MIL) Reaction..3978
            Associated Faults..3978
            Drive Cycle..3978
          EGRT Sensor (Exhaust Gas Recirculation Temperature)..3981
            EGRT Sensor End Diagnostics..3981
            Overview..3982
            Tools..3983
            Pinpoint Diagnostics With ServiceMaxx? Software..3983
            EGRT Pin-point Diagnostics..3984
            SPN 412 FMI 2 - EGRT Signal erratic, intermittent, or incorrect..3986
            Fault Overview..3987
            Malfunction Indicator Lamp (MIL) Reaction..3987
            Associated Faults..3987
            Drive Cycle to Determine Fault Status..3987
            SPN 412 FMI 21 - EGRT Signal drifted LOW..3990
            Fault Overview..3990
            Malfunction Indicator Lamp (MIL) Reaction..3990
            Associated Faults..3990
            Drive Cycle to Determine Fault Status..3990
          EGT Sensor (Exhaust Gas Temperature)..3993
            Overview..3994
            Tools..3995
            Pinpoint Diagnostics With ServiceMaxx? Software..3995
            Connector Voltage Check..3996
            SPN 173 FMI 2 - EGT Signal erratic, intermittent, or incorrect..3997
            Fault Overview..3997
            Malfunction Indicator Lamp (MIL) Reaction..3997
            Associated Faults..3997
            Drive Cycle to Determine Fault Status..3997
            SPN 173 FMI 21 - EGT Stuck in Range LOW..4000
            Fault Overview..4000
            Malfunction Indicator Lamp (MIL) Reaction..4000
            Associated Faults..4000
            Drive Cycle to Determine Fault Status..4000
          EOP (Engine Oil Pressure) Sensor..4003
          Function..4003
          Sensor Location..4003
          Tools..4003
            EOP Sensor End Diagnostics..4004
            EOP Pin-point Diagnostics..4006
            EOP Circuit Operation..4007
            Fault Detection/Management..4007
          EOT Sensor (Engine Oil Temperature)..4008
            Overview..4009
            Fast Idle Advance..4009
            Tools..4010
            Pinpoint Diagnostics With ServiceMaxx? Software..4010
            EOT Pin-point Diagnostics..4011
            SPN 175 FMI 2 - EOT Signal erratic, intermittent, or incorrect..4013
            Fault Overview..4013
            Malfunction Indicator Lamp (MIL) Reaction..4013
            Fault Fact..4013
            Associated Faults..4013
            Drive Cycle to Determine Fault Status..4013
            SPN 175 FMI 21 - EOT signal drifted LOW..4016
            Fault Overview..4016
            Malfunction Indicator Lamp (MIL) Reaction..4016
            Associated Faults..4016
            Drive Cycle to Determine Fault Status..4016
          ETV (Engine Throttle Valve)..4019
            Overview..4020
            ETP (Engine Throttle Position) sensor..4020
            ETV actuator..4020
            Fault Detection/Management..4020
            Tools..4021
            Pinpoint Diagnostics With ServiceMaxx? Software..4021
            SPN 51 FMI 7 ETP Does not agree with commanded position..4024
            Fault Overview..4024
            Malfunction Indicator Lamp (MIL) Reaction..4024
            Associated Faults..4024
            Drive Cycle to Determine Fault Status..4024
          EWPS (Engine Warning Protection System)..4027
            EWPS Diagnostics..4027
            Overview..4029
            Tools..4029
            Pinpoint Diagnostics With ServiceMaxx? Software..4030
            EWPS Programmable Parameters..4030
            SPN 188 FMI 0 - Engine unable to achieve desired idle speed (too high)..4033
            Fault Overview..4033
            Malfunction Indicator Lamp (MIL) Reaction..4033
            Associated Faults..4033
            Drive Cycle to Determine Fault Status..4033
            SPN 188 FMI 1 - Engine unable to achieve desired idle speed (too low)..4035
            Fault Overview..4035
            Malfunction Indicator Lamp (MIL) Reaction..4035
            Fault Fact..4035
            Associated Faults..4035
            Drive Cycle to Determine Fault Status..4035
            SPN 5395 FMI 0 - Engine unable to achieve desired idle torque (too high)..4038
            Fault Overview..4038
            Malfunction Indicator Lamp (MIL) Reaction..4038
            Associated Faults..4038
            Drive Cycle to Determine Fault Status..4038
            SPN 5395 FMI 1 - Engine unable to achieve desired idle torque (too low)..4040
            Fault Overview..4040
            Malfunction Indicator Lamp (MIL) Reaction..4040
            Fault Fact..4040
            Associated Faults..4040
            Drive Cycle to Determine Fault Status..4040
          FCC (Fuel Cooler Control) Valve..4042
          Function..4042
          Sensor Location..4042
          Tools..4042
            Fuel Cooler Control Valve Circuit Diagnostics..4043
            Fuel Cooler Control Valve Circuit Operation..4044
          FDP (Fuel Delivery Pressure) Sensor..4045
          Function..4045
          Sensor Location..4045
          Tools..4045
            FDP Sensor End Diagnostics..4046
            FDP Pin-point Diagnostics..4048
            FDP Circuit Operation..4049
            Fault Detection / Management..4049
          FPCV (Fuel Pressure Control Valve)..4050
          Function..4050
          FPCV Location..4050
          Tools..4051
            FPCV Pin-point Diagnostics..4051
            FPCV Circuit Operation..4052
            Fault Detection / Management..4052
          Fuel Pump..4053
          Function..4053
          FPC Location..4053
          Tools..4053
            Fuel Pump Pin-point Diagnostics..4054
            Fuel Pump Actuator..4055
            Fault Detection / Management..4055
          FRP Sensor (Fuel Rail Pressure)..4056
            Overview..4057
            Tools..4058
            Pinpoint Diagnostics With ServiceMaxx? Software..4058
            Connector Voltage Check..4060
            SPN 157 FMI 13 - FRP Above KOEO Spec..4062
            Fault Overview..4062
            Malfunction Indicator Lamp (MIL) Reaction..4062
            Associated Faults..4062
            Drive Cycle to Determine Fault Status..4062
          FRP (Fuel Rail Pressure) System ..4065
            FRP System Diagnostics..4065
            Overview..4068
            Tools..4069
            SPN 3055 FMI 2 - FPCV adaptation in-range fault..4070
            Fault Overview..4070
            Malfunction Indicator Lamp (MIL) Reaction..4070
            Associated Faults..4070
            Drive Cycle to Determine Fault Status..4070
          FVCV (Fuel Volume Control Valve)..4072
          Function..4072
          FVCV Location..4072
          Tools..4073
            FVCV Pin-point Diagnostics..4073
            FVCV Circuit Operation..4074
            Fault Detection / Management..4074
          IAH (Inlet Air Heater)..4075
            Overview..4077
            Tools..4078
            Pinpoint Diagnostics With ServiceMaxx? Software..4078
            SPN 729 FMI 18 - IAH Monitor: lack of heat in the intake manifold..4081
            Fault Overview..4081
            Malfunction Indicator Lamp (MIL) Reaction..4081
            Associated Faults..4081
            Drive Cycle to Determine Fault Status..4081
          IMP (Intake Manifold Pressure) Sensor..4084
            Overview..4086
            Tools..4087
            Pinpoint Diagnostics With ServiceMaxx? Software..4087
            IMP Pin-point Diagnostics..4088
            SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect..4090
            Fault Overview..4090
            Malfunction Indicator Lamp (MIL) Reaction..4090
            Associated Faults..4090
            Drive Cycle to Determine Fault Status..4090
            SPN 102 FMI 16 - Overboost..4093
            Fault Overview..4093
            Malfunction Indicator Lamp (MIL) Reaction..4093
            Associated Faults..4093
            Drive Cycle to Determine Fault Status..4093
            SPN 102 FMI 18 - Underboost..4096
            Fault Overview..4096
            Malfunction Indicator Lamp (MIL) Reaction..4096
            Associated Faults..4096
            Drive Cycle to Determine Fault Status..4096
          IMT (Intake Manifold Temperature) Sensor..4099
            Overview..4100
            Tools..4101
            Pinpoint Diagnostics With ServiceMaxx? Software..4101
            IMT Pin-point Diagnostics..4102
            SPN 105 FMI 2 - IMT signal erratic, intermittent, or incorrect..4103
            Fault Overview..4104
            Malfunction Indicator Lamp (MIL) Reaction..4104
            Associated Faults..4104
            Drive Cycle to Determine Fault Status..4104
            SPN 105 FMI 21 - IMT signal drifted LOW..4107
            Fault Overview..4107
            Malfunction Indicator Lamp (MIL) Reaction..4107
            Associated Faults..4107
            Drive Cycle to Determine Fault Status..4107
          INJ (Injector Circuits)..4110
            INJ Diagnostics..4110
            Overview..4111
            Tools..4112
            Pinpoint Diagnostics With ServiceMaxx? Software..4112
            Injector 1 Check..4112
            Injector 2 Check..4114
            Injector 3 Check..4115
            Injector 4 Check..4116
            Injector 5 Check..4117
            Injector 6 Check..4118
            Injector 7 Check..4119
            Injector 8 Check..4120
            SPN 2797 FMI 3 - Injector Control Group 1 Open Circuit (INJ 1, 3, 5, 7)..4121
            Fault Overview..4121
            Malfunction Indicator Lamp (MIL) Reaction..4121
            Associated Faults..4121
            Drive Cycle to Determine Fault Status..4121
            SPN 2798 FMI 3 - Injector Control Group 2 Open Circuit (INJ 2, 4, 6, 8)..4125
            Fault Overview..4125
            Malfunction Indicator Lamp (MIL) Reaction..4125
            Associated Faults..4125
            Drive Cycle to Determine Fault Status..4125
          IST (Idle Shutdown Timer) System ..4129
          Function..4129
          Tools..4129
            IST Operation..4129
            Idle Shutdown Warning..4129
            Engine Idle Shutdown Timer for California ESS-Compliant Engines..4129
            CARB IST Conditions..4130
            Engine Idle Shutdown Timer (Federal-Optional)..4130
            Federal IST Conditions..4130
            Common Enable Conditions for All Federal IST Options..4130
            Federal IST Mode 1: PTO Operation Option Enable Conditions..4131
            Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions..4131
            Federal IST Mode 3: Tamper Proof Option Enable Conditions..4131
            Fault Detection/Management..4131
          MAF/AIT Sensor (Mass Air Flow/Air Inlet Temperature)..4132
            Overview..4134
            Sensor Location..4134
            Tools..4135
            Pinpoint Diagnostics With ServiceMaxx? Software..4138
            Extended Diagnostic Information..4139
            SPN 132 FMI 2 - MAF Signal Erratic, Intermittent, or Incorrect..4140
            Fault Overview..4140
            Malfunction Indicator Lamp (MIL) Reaction..4140
            Associated Faults..4140
            Drive Cycle to Determine Fault Status..4140
            SPN 172 FMI 2 - AIT Signal Erratic, Intermittent, or Incorrect..4143
            Fault Overview..4144
            Malfunction Indicator Lamp (MIL) Reaction..4144
            Associated Faults..4144
            Drive Cycle to Determine Fault Status..4144
          TOSS / VSS (Transmission Output Shaft Speed / Vehicle Speed Sensor) Sensor..4147
            Overview..4149
            Tools..4150
            Pinpoint Diagnostics With ServiceMaxx? Software..4151
            SPN 191 FMI 1- TOSS / VSS not detected with vehicle moving..4152
            Fault Overview..4152
            Malfunction Indicator Lamp (MIL) Reaction..4152
            Fault Fact..4152
            Associated Faults..4152
            Drive Cycle to Determine Fault Status..4152
          RSE (Radiator Shutter Enable)..4156
          Function..4156
          Component Location..4156
          Tools..4156
            RSE Circuit Diagnostics..4157
            RSE Circuit Operation..4158
            Fault Detection/Management..4158
          Service Interval Messages..4159
            Service Interval Messages Operation..4159
            SPN 1378 FMI 14 - Change engine oil service interval reset ahead of schedule..4160
            Fault Overview..4160
            Malfunction Indicator Lamp (MIL) Reaction..4160
            Associated Faults..4160
            Drive Cycle to Determine Fault Status..4160
          SMC (Starter Motor Control) Circuit ..4161
          Function..4162
          Location..4162
          Tools..4162
            SMC Circuit Diagnostics..4163
            SMC Circuit Operation..4167
            Driveline Disengagement Switch (DDS) Circuit..4167
            Ignition Switch..4167
            SMC Circuit..4167
            ECM..4167
            Start Relay..4167
            Clutch Switch (Manual Transmission)..4167
            Neutral Signal (Automatic Transmission)..4167
            Fault Detection/Management..4167
          TACH (Tachometer Output Circuit)..4168
            Tachometer Pin-point Diagnostics..4169
            Tachometer Circuit Operation..4170
            Diagnostic Trouble Codes (DTCs)..4170
          TC1WC (Turbocharger 1 Wastegate Control) Solenoid..4171
          Function..4171
          Sensor Location..4171
          Tools..4171
            TC1WC Circuit Diagnostics..4172
            TC1WC Circuit Operation..4173
            Fault Detection/Management..4173
          TC1COT (Turbocharger 1 Compressor Outlet Temperature) Sensor..4174
            TC1COT Sensor End Diagnostics..4174
            Overview..4175
            Tools..4176
            Pinpoint Diagnostics With ServiceMaxx? Software..4176
            TC1COT Pin-point Diagnostics..4177
            SPN 2629 FMI 2 - TC1COT signal erratic, intermittent, or incorrect..4178
            Fault Overview..4179
            Malfunction Indicator Lamp (MIL) Reaction..4179
            Associated Faults..4179
            Drive Cycle to Determine Fault Status..4179
            SPN 2629 FMI 16 - TC1COT over temperature: moderate de-rate..4182
            Fault Overview..4182
            Malfunction Indicator Lamp (MIL) Reaction..4182
            Associated Faults..4182
            Drive Cycle to Determine Fault Status..4182
            SPN 2629 FMI 21 - TC1COT signal drifted LOW..4186
            Fault Overview..4186
            Malfunction Indicator Lamp (MIL) Reaction..4186
            Associated Faults..4186
            Drive Cycle to Determine Fault Status..4186
          VREF (Reference Voltage)..4189
          Function..4190
          Tools..4190
            VREF Pin-point Diagnostics..4190
            VREF Circuit Operation..4196
            Fault Detection/Management..4196
          VSO (Vehicle Speed Output)..4197
            Vehicle Speed Output Pin-point Diagnostics..4198
            Vehicle Speed Output Circuit Operation..4199
            Diagnostic Trouble Codes (DTCs) ..4199
          WIF (Water In Fuel) Sensor..4200
          Function..4200
          Sensor Location..4200
          Tools..4200
            WIF Pin-point Diagnostics..4201
            WIF Circuit Operation..4202
            Fault Detection / Management..4202
          WTSL (Wait to Start Lamp)..4203
          Overview..4203
          Tools..4203
            SPN 1081 FMI 3 - WTSL short to PWR..4203
            Fault Overview..4203
            Malfunction Indicator Lamp (MIL) Reaction..4203
            Associated Faults..4204
            Drive Cycle to Determine Fault Status..4204
            SPN 1081 FMI 4 - WTSL short to GND..4206
            Fault Overview..4206
            Malfunction Indicator Lamp (MIL) Reaction..4206
            Associated Faults..4206
            Drive Cycle to Determine Fault Status..4206
            SPN 1081 FMI 5 - WTSL circuit open load/circuit..4208
            Fault Overview..4208
            Malfunction Indicator Lamp (MIL) Reaction..4208
            Associated Faults..4208
            Drive Cycle to Determine Fault Status..4208
      Table of Contents..4211
        Diagnostic Trouble Codes..4213
  tables..0
    Example..3742
    Example..3742
    Example..3743
    Example..3743
    Example..3744
    Example..3744
    Example..3745
    Example..3745
    Example..3745
    Example..3746
    Example..3747
    Example..3747
    Example..3748
    Active Rolling Regeneration..3754
    Manual Parked Regeneration..3754
    Manual Parked Regeneration Procedure..3755
    Onboard Filter Cleanliness Test (ServiceMaxx? software)..3756
    Alert Levels of DPF Soot Loading..3757
    TMV - Standard and Output State Test..3780
    Connector Voltage Check..3780
    Connector Resistance Check to GND..3781
    Harness Resistance Check..3781
    SPN 1209 and FMI 0 - EBP above desired level..3781
    SPN 1692 and FMI 17 - KOER STD - Boost unable to achieve desired set-point Pin-Point AMS Fault..3782
    SPN 1692 and FMI 18 - Boost unable to achieve desired set-point..3782
    SPN 2659 and FMI 17 -EGR Flow Rate unable to achieve desired set-point..3782
    SPN 2659 and FMI 20 - EGR high flow rate detected..3783
    SPN 2659 and FMI 21 - EGR low flow rate detected..3783
    Sensor Circuit Check..3802
    Connector Voltage Check..3803
    Connector Resistance Check to GND..3804
    Harness Resistance Check..3804
    Operational Voltage Check..3804
    Connector Voltage Check - EST..3807
    Harness Resistance Check..3808
    Brake Switch Circuits..3810
    Voltage Check..3811
    Harness Resistance Check..3811
    Connector Voltage Check..3815
    Connector Resistance Check to GND..3815
    Harness Resistance Check..3815
    Connector Voltage Check..3834
    EST Communication Check..3835
    Harness Resistance Check..3835
    Switch Checks..3839
    Circuit End Voltage Check..3839
    Sensor and Circuit Resistance Check..3841
    Harness Resistance Check..3841
    Operational Check..3842
    Sensor and Circuit Resistance Check..3845
    Harness Resistance Check..3846
    Operational Check..3846
    Sensor Circuit Check..3860
    Connector Voltage Check..3860
    Connector Resistance Check to GND..3860
    Harness Resistance Check..3860
    Sensor Circuit Check..3878
    Connector Voltage Check..3878
    Connector Resistance Checks to GND..3878
    Harness Resistance Check..3879
    Sensor Circuit Check..3891
    Connector Voltage Check..3891
    Connector Resistance Check to GND..3891
    Harness Resistance Check..3891
    Sensor Circuit Check..3908
    Connector Voltage Check..3908
    Connector Resistance Check to GND..3908
    Harness Resistance Check..3908
    Connector Voltage Check..3920
    Connector Resistance Check to GND..3920
    Sensor Resistance Check..3921
    Harness Resistance Check..3921
    Voltage Check at Relay..3924
    Voltage Check at ECM..3924
    Harness Resistance Check..3925
    Harness Resistance Check on Relay Power Circuits..3925
    SPN 108/FMI 3- BARO signal Out of Range HIGH..3928
    SPN 108/FMI 4 - BARO signal Out of Range LOW..3928
    SPN 628/FMI 14 - ECM Programming - EFRC Error..3928
    SPN 629/FMI 2 - ECM Error - Level 2 Monitoring..3928
    SPN 629/FMI 12 - ECM Error - SPI..3929
    SPN 629/FMI 31 - ECM Error - Level 3 Monitoring..3929
    SPN 1136/FMI 0 - ECM Error - Over temperature..3929
    SPN 1136/FMI 1 - ECM Error - Under temperature..3929
    Sensor Circuit Check..3936
    Connector Resistance Check to GND..3936
    Harness Resistance Check..3936
    Voltage Check at EFC Connector Output State Test..3957
    Voltage Check at Relay - Output State Test..3957
    Harness Resistance Check..3958
    Sensor Circuit Check..3962
    Connector Voltage Check..3962
    Connector Resistance Check to GND..3962
    Harness Resistance Check..3962
    EGR Valve Circuit Check..3973
    EGR Valve - Standard and Output State Test..3973
    Connector Voltage Check..3974
    Connector Resistance Check to GND..3974
    Harness Resistance Check..3974
    SPN 412 FMI 0 ? EGRT above Critical Temperature..3984
    Sensor Circuit Check..3984
    Connector Voltage Check..3984
    Connector Resistance Check to GND..3984
    Harness Resistance Check..3985
    Sensor Circuit Check..3996
    Connector Resistance Check to GND..3996
    Harness Resistance Check..3996
    Sensor Circuit Check..4005
    Connector Voltage Check..4006
    Connector Resistance Check to GND..4006
    Harness Resistance Check..4007
    Sensor Circuit Check..4011
    Connector Voltage Check..4011
    Connector Resistance Check to GND..4011
    Harness Resistance Check..4012
    ETV Circuit Check..4022
    ETV - Standard Test and Output State Test..4022
    Connector Voltage Check..4023
    Connector Resistance Check to GND..4023
    Harness Resistance Check..4023
    Voltage Check at Fuel Cooler Control Valve Connector ? Output State Test..4043
    Harness Resistance Check..4043
    SPN 94 FMI 0 ? Fuel Filter Minder Above Maximum Pressure ..4047
    Sensor Circuit Check..4047
    Connector Voltage Check..4048
    Connector Resistance Check to GND..4048
    Harness Resistance Check..4049
    Actuator / Harness Resistance Check..4052
    Operational Voltage Check - Output Circuit Check..4052
    Connector Voltage Check..4054
    Run Output State Test ? Low..4054
    Run Output State Test ? Low..4054
    Connector Resistance Check to GND..4055
    Harness Resistance Check..4055
    Sensor Circuit Check..4059
    Connector Resistance Check to GND..4060
    Under Valve Cover Resistance Check to Engine GND..4060
    Harness Resistance Check..4061
    Actuator / Harness Resistance Check..4074
    Operational Voltage Check - Output Circuit Check..4074
    Voltage Check on Relay Switch ? Output State Test IAH..4079
    Voltage Check on Relay Coil ? Output State Test..4079
    Amperage Draw Check..4079
    Element Resistance Check..4079
    Harness Resistance Check ? Relay Coil Circuits..4080
    Harness Resistance Check ? Relay Switch Circuits..4080
    Sensor Circuit Check..4088
    Connector Voltage Check..4088
    Connector Resistance Check to GND..4088
    Harness Resistance Check..4089
    Sensor Circuit Check..4102
    Connector Voltage Check..4102
    Connector Resistance Check to GND..4102
    Harness Resistance Check..4102
    Injector 1 - Resistance Checks Through Harness and Injector..4112
    Injector 1 - Resistance UVC Checks..4113
    Injector 1 - Harness Resistance Check..4113
    Injector 2 - Resistance Through Valve Cover to Engine GND Check..4114
    Injector 2 - Harness Resistance Check..4114
    Injector 3 - Resistance Through Valve Cover to Engine GND Check..4115
    Injector 3 - Harness Resistance Check..4115
    injector 4 - Resistance Through Valve Cover to Engine GND Check..4116
    Injector 4 - Harness Resistance Check..4116
    Injector 5 - Resistance Through Valve Cover to Engine GND Check..4117
    Injector 5 - Harness Resistance Check..4117
    Injector 6 - Resistance Through Valve Cover to Engine GND Check..4118
    Injector 6 - Harness Resistance Check..4118
    Injector 7 - Resistance Through Valve Cover to Engine GND Check..4119
    Injector 7 - Harness Resistance Check..4119
    Injector 8 - Resistance Through Valve Cover to Engine GND Check..4120
    Injector 8 - Harness Resistance Check..4120
    MAF Calibration Requirements..4135
    MAF Calibration Pre-Checks..4136
    MAF Calibration Procedure ? Using ServiceMaxx? Software..4137
    Connector Voltage Check..4139
    Harness Resistance Check..4139
    Connector Voltage Checks..4151
    Sensor Resistance Check..4151
    Harness Resistance Check..4151
    Voltage Check at RSE Connector - Output State Test..4157
    Harness Resistance Check..4158
    Voltage Check at Start Relay and Starter Solenoid..4165
    Voltage Check at ECM..4165
    Harness Resistance Check - ECM to Relay..4166
    Harness Resistance Check - Relay to Battery..4166
    Operational Voltage Check..4166
    Circuit End Voltage Check..4169
    Harness Resistance Check..4169
    Voltage Check at TC1WC Connector - Output State Test..4172
    Harness Resistance Check..4173
    Sensor Circuit Check..4177
    Connector Voltage Check..4177
    Connector Resistance Check to GND..4177
    Harness Resistance Check..4177
    VREF Voltage Check..4192
    Connector Resistance Check to GND..4193
    Harness Resistance Check..4194
    Harness Resistance Check (cont.)..4195
    Circuit End Voltage Check..4198
    Harness Resistance Check..4198
    Operational Check..4198
    Voltage Check..4202
    Connector Resistance Checks to GND..4202
    Harness Resistance Check..4202
0000001835 - MaxxForce DT, 9, and 10 Engine Service Manual..4223
  toc..4225
    Table of Contents..4225
    Safety Terminology..4229
    Safety Instructions..4229
    Work Area..4229
    Safety Equipment..4229
    Protective Measures..4229
    Vehicle..4229
    Engine..4230
    Fire Prevention..4230
    Batteries..4230
    Compressed Air..4230
    Tools..4230
    Fluids Under Pressure..4231
    Fuel..4231
    Removal of Tools, Parts, and Equipment..4231
      Table of Contents..4233
        Engine Identification..4235
          Engine Serial Number..4235
          Engine Serial Number Examples..4235
          Engine Serial Number Codes..4235
          Engine Emission Label..4236
          Engine Accessory Labels..4236
          Engine Description..4237
            Standard Features..4238
            Optional Features..4239
            Optional Cold Climate Features..4239
            Chassis Mounted Features..4239
          Engine Component Locations (245 hp and above)..4241
        Air Management System (AMS)..4246
          Air Flow ? Pre Combustion..4247
          Air Flow ? Post Combustion..4247
          Air Management Components..4247
            Turbochargers..4247
            Interstage Cooler (ISC)..4248
            High-pressure Charge Air Cooler (HPCAC)..4249
            Turbocharger 2 Wastegate Control (TC2WC) Valve..4249
            Exhaust Gas Recirculation (EGR) System..4250
            EGR Flow..4251
            EGR Valve..4251
            EGR Closed Loop System..4251
            Crankcase Ventilation System..4253
          Aftertreatment (AFT) System..4254
          AFT Control System..4254
          Sensors..4255
          Exhaust Back Pressure Valve..4255
          Pre-Diesel Oxidation Catalyst (PDOC)..4255
          Diesel Oxidation Catalyst (DOC)..4255
          Diesel Particulate Filter (DPF)..4255
          AFT Conditions and Responses..4255
          Downstream Injection System..4256
        Fuel Management System..4257
          ICP System..4258
            High-Pressure Oil Flow..4259
            ICP Closed Loop System..4259
            ICP Control System..4260
            Fuel Injector..4261
            Fuel Injector Features..4261
            Injector Coils and Spool Valve..4262
            Intensifier Piston and Plunger..4262
            Plunger and Barrel..4262
            Injector Needle..4262
            Fuel Injector Operation..4263
            Fill Stage..4263
            Injection..4264
            End of Injection..4264
        Fuel Supply System..4265
          Fuel Supply System Flow..4266
        Engine Lubrication System..4270
          Oil Flow..4271
        Engine Cooling System..4272
          Cooling System Description..4272
          Cooling System Components..4274
            Coolant Heater (optional)..4274
            Thermostat Operation..4274
            Low Temperature Radiator (LTR) Thermostat Operation..4277
        Electronic Control System..4278
          Electronic Control System Components..4278
            Operation and Function..4279
            Reference Voltage (VREF)..4279
            Microprocessor..4279
            Actuator Control..4279
          Actuators..4279
            Exhaust Gas Recirculation (EGR) Valve..4280
            Intake Air Heater (IAH) Relay..4280
            Engine Throttle Valve (ETV) and Position Sensor..4280
            Turbocharger 2 Wastegate Control (TC2WC) valve (turbocharger wastegate actuator)..4280
            Exhaust Back Pressure Valve (EBPV)..4280
            Engine Compression Brake (ECB) valve..4280
            Injection Pressure Regulator (IPR) valve..4280
          Engine and Vehicle Sensors..4281
            Temperature Sensors..4281
            Thermistor Sensors..4281
            ECT Sensor..4281
            EOT Sensor..4281
            AIT Sensor..4281
            IMT Sensor..4282
            Exhaust Gas Temperature (EGT) sensors..4282
            Variable Capacitance Sensors..4282
            FDP Sensor..4283
            EOP Sensor..4283
            EBP Sensor..4283
            MAF Sensor..4283
            IMP Sensor..4283
            Magnetic Pickup Sensors..4284
            CKP Sensor..4284
            CMP Sensor..4285
            VSS..4285
            High-Pressure Sensors..4286
            DPFDP Sensor..4286
            ECBP..4286
            ICP..4286
            Potentiometer..4287
            APP..4287
            Switches..4288
            DDS..4288
            ECL..4288
            WIF..4288
          Engine Throttle Valve Control System..4289
        Exhaust and Engine Brake System..4290
          Exhaust Brake..4290
          Engine Brake..4291
          ECBP..4291
          ECB..4291
          Brake Pressure Relief Valve..4291
          EBP..4292
          High-pressure Oil Manifold..4292
            Operation..4292
            Operation Modes..4294
            Coast Mode..4294
            Latched Mode..4294
            Cruise Mode..4294
      Table of Contents..4295
        Engine Preparation..4297
          Clean Engine..4297
          Drain Coolant..4298
          Drain Oil..4299
          Removing Engine from Vehicle..4299
        Removal..4300
          Electrical Connections..4300
          Aftertreatment / Turbocharger Disconnection Points..4301
          Turbocharger Oil Supply Tube Assembly and Heat Shield..4302
          ISC Inlet Elbow and Intercooler..4305
          Turbocharger Oil Drain Tubes and Turbocharger..4307
          Oil Filter..4308
          Oil System Module Assembly..4309
        Mounting Engine Stand Bracket and Engine..4310
          Mounting Engine Stand Bracket..4310
      Table of Contents..4313
        Engine Repair Procedures..4315
          Overview..4315
         Grid Heater Replacement ..4316
          Grid Heater Assembly Removal ..4316
          Grid Heater Assembly Removal..4318
          Grid Heater Element Housing Cleaning ..4320
          Grid Heater Assembly Installation ..4321
          Air and EGR Mixer Duct Assembly Installation..4324
      Table of Contents..4327
        Illustrations..4329
          Electronic Components ? Top..4329
          Electronic Components ? Front..4330
          Electronic Components ? Exhaust Side..4331
          Electronic Components ? Intake Side..4332
          Electronic Components ? Rear..4333
        Description of Engine Sensors, Valves, and Actuators..4333
          Turbocharger 2 Wastegate Control (TC2WC) Valve..4334
          Camshaft Position (CMP) Sensor..4335
          Crankshaft Position (CKP) Sensor..4336
          Engine Compression Brake (ECB) Valve ..4336
          Engine Compression Brake Pressure (ECBP) Sensor..4337
          Exhaust Back Pressure (EBP) Sensor..4337
          Engine Coolant Temperature 1 (ECT1) Sensor..4338
          Fuel Delivery Pressure (FDP) Sensor..4338
          Exhaust Gas Recirculation (EGR) Valve..4339
          Exhaust Gas Temperature (EGT) Sensor..4339
          Engine Oil Pressure (EOP) Sensor..4340
          Engine Oil Temperature (EOT) Sensor..4340
          Fuel Heater (250 watt)..4341
          Intake Air Heater (IAH) Relay Assembly..4341
          Injection Control Pressure (ICP) Sensor..4342
          Intake Manifold Temperature (IMT) Sensor..4342
          Intake Manifold Pressure (IMP) Sensor..4343
          Engine Throttle Valve (ETV) Assembly..4343
          Injection Pressure Regulator (IPR) Valve..4344
          Downstream Injection (DSI) Assembly..4344
          Water In Fuel (WIF) Sensor..4345
        Removal..4346
          Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve..4346
          Crankshaft Position (CKP) Sensor..4347
          Camshaft Position (CMP) Sensor..4348
          Exhaust Back Pressure (EBP) Sensor..4349
          Engine Control Module (ECM) and Mounting Bracket..4349
          Engine Coolant Temperature 1 (ECT1) Sensor..4351
          Electric Fuel Pump Connector..4351
          Fuel Delivery Pressure (FDP) Sensor..4352
          Exhaust Gas Recirculation (EGR) Valve Connector..4353
          Exhaust Gas Temperature (EGT) Sensor..4353
          Engine Oil Pressure (EOP) Sensor..4354
          Engine Oil Temperature (EOT) Sensor..4354
          Fuel Heater (250 watt)..4355
          Intake Air Heater (IAH) Relay Assembly..4356
          Injection Control Pressure (ICP) Sensor..4357
          Engine Throttle Valve (ETV) Assembly Connector..4357
          Injection Pressure Regulator (IPR) Valve Connector..4358
          Intake Manifold Pressure (IMP) Sensor..4359
          Intake Manifold Temperature (IMT) Sensor..4359
          Downstream Injection (DSI) Assembly Connectors..4360
          Water In Fuel (WIF) Sensor..4360
          Engine Harness Assembly..4362
          Valve Cover Gasket Assembly..4364
        Inspect..4365
          Inspect Wiring Harness, Connectors, and Electrical Components..4365
        Installation..4366
          Engine Harness Assembly and Camshaft Position (CMP) Sensor..4366
          Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve..4370
          Crankshaft Position (CKP) Sensor..4371
          Exhaust Back Pressure (EBP) Sensor..4371
          Electronic Control Module (ECM) and Mounting Bracket..4372
          Engine Coolant Temperature 1 (ECT1) Sensor..4373
          Fuel Delivery Pressure (FDP) Sensor..4373
          Exhaust Gas Recirculation (EGR) Control Valve Connector..4374
          Electric Fuel Pump Connector..4375
          Exhaust Gas Temperature (EGT) Sensor..4375
          Engine Oil Pressure (EOP) Sensor..4376
          Engine Oil Temperature (EOT) Sensor..4376
          Fuel Heater (250 watt) Connector..4377
          Intake Air Heater (IAH) Relay Assembly..4378
          Injector Control Pressure (ICP) Sensor..4379
          Engine Throttle Valve (ETV) Assembly Connector..4380
          Injection Pressure Regulator (IPR) Valve Connector..4380
          Intake Manifold Temperature (IMT) Sensor..4381
          Intake Manifold Pressure (IMP) Sensor..4381
          Downstream Injection (DSI) Assembly Connectors..4382
          Water In Fuel (WIF) Sensor..4383
          Valve Cover Gasket Assembly..4384
      Table of Contents..4387
        Exploded Views..4389
          Down Stream Injection (DSI) Assembly..4389
          Hydrocarbon Injector Assembly..4390
        Removal..4391
          Down Stream Injection (DSI) Assembly..4391
          Injection Unit Inlet Tube Assembly..4394
          Hydrocarbon Injector Assembly..4396
        Cleaning and Inspection..4399
          Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Cleaning..4399
          Exhaust Back Pressure Valve Housing Cleaning..4400
        Installation..4401
          Hydrocarbon Injector Assembly..4401
          Injection Unit Inlet Tube Assembly..4405
          Down Stream Injection (DSI) Assembly..4406
      Table of Contents..4411
        Exploded View..4413
        Removal..4417
          ISC..4418
            Interstage Inlet Duct Assembly..4418
            Interstage Cooler (ISC)..4421
          Turbo..4423
            Throttle Coupling..4423
            Turbocharger Oil Supply Tube Assembly..4424
            Exhaust Brake Valve and Turbocharger Outlet Elbow..4426
            Turbocharger Air Inlet Duct..4429
            Turbocharger Wastegate Actuator Assembly..4430
            Dual Stage Turbocharger Assembly..4431
            High-Pressure Turbocharger Center Section..4434
        Cleaning, Inspection, and Testing..4442
          Inspect and Clean Dual Stage Turbocharger Assembly and Related Parts..4442
          Dual Turbocharger Compressor Cleaning and Inspection..4442
          Inspection..4442
          Removal of Turbocharger Compressor Covers..4442
          Assembly..4445
          Inspect Turbine and Compressor..4446
          Inspect High-Pressure Turbine Housing..4447
          Crossover Tube Seal..4447
        Installation..4448
          High Pressure Turbocharger Center Section Assembly..4448
          Dual Stage Turbocharger Assembly..4456
          Turbocharger Wastegate Actuator Assembly (without precise regulated shop air pressure)..4459
          Turbocharger Wastegate Actuator Assembly (with precise regulated shop air pressure)..4459
          Turbocharger Air Inlet Duct..4461
          Exhaust Brake Valve and Turbocharger Outlet Elbow..4462
          Turbocharger Oil Supply Tube Assembly..4466
          Throttle Coupling..4469
          Interstage Cooler (ISC)..4470
          Interstage Inlet Duct Assembly..4474
      Table of Contents..4479
        Exploded View..4481
        Removal..4484
          Draining High Fin Density EGR Cooler..4485
          High Fin Density EGR Cooler and Components..4486
          EGR Valve Assembly..4489
          Engine Throttle Valve (ETV) Assembly..4490
          Air and EGR Mixer Duct Assembly..4490
        Cleaning, Inspecting, and Testing..4492
          Cleaning and Inspecting EGR System Components..4492
          Air and EGR Mixer Duct Assembly..4492
          EGR Valve Assembly..4492
          Engine Throttle Valve Assembly..4492
          High Fin Density EGR Cooler..4492
          Pressure Testing High Fin Density EGR Cooler..4492
          EGR Cooler Vent Tool..4493
          EGR Cooler Coolant Port Tool..4493
          EGR Cooler Exhaust Inlet Tool..4494
          EGR Cooler Exhaust Outlet Tool..4494
          SAE J512 Plugs..4494
          EGR Cooler Leak Test..4495
        Installation..4496
          Air and EGR Mixer Duct Assembly..4496
          Engine Throttle Valve (ETV) Assembly..4498
          EGR Valve Assembly..4498
          High Fin Density EGR Cooler and Components..4499
      Table of Contents..4505
        Exploded View..4507
        Removal..4509
          Exhaust Manifold..4510
          Intake Manifold, Fuel Valve, and Fuel Rail Plugs..4512
        Cleaning, Inspection, and Measurements..4514
          Exhaust Manifold..4514
          Exhaust Back Pressure (EBP) Sensor Tube Assembly..4514
          Intake Manifold..4514
        Installation..4515
          Exhaust Manifold..4515
          Intake Manifold, Fuel Valve, and Fuel Rail Plugs..4518
      Table of Contents..4523
        Exploded Views..4525
        Periodic Service..4529
          Fuel Strainer..4529
          Fuel Filter..4531
          Draining Water From Fuel Filter Assembly..4531
        Removal..4533
          Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater..4533
          Water Drain Valve Assembly..4534
          Brushless Electric Fuel Pump Assembly..4534
          Fuel Pressure Regulator Valve Assembly..4536
          Fuel Filter Assembly..4537
          High-pressure Oil Hose and Elbows..4538
          High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly..4539
          High-pressure Oil Manifold..4544
          Injector Oil Inlet Adapter (Puck) Assembly..4546
          Fuel Injector Assemblies..4547
        Cleaning and Inspection..4549
          Fuel Filter Assembly Service Recommendations..4549
          High-pressure Oil System Components..4549
        Installation..4551
          Fuel Injector Assemblies..4551
          Injector Oil Inlet Adapter (Puck) Assembly..4554
          High-pressure Oil Manifold..4554
          High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly..4557
          High-pressure Oil Hose and Elbows..4561
          Fuel Filter Assembly..4563
          Water Drain Valve Assembly..4564
          Brushless Electric Fuel Pump Assembly and Fuel Strainer..4565
          Fuel Pressure Regulator Valve Assembly..4566
          Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater..4567
      Table of Contents..4571
        Exploded View and Description..4573
          High-pressure Oil Manifold (Brake)..4573
        Periodic Service..4574
          Engine Brake Lash Adjustment..4574
        Removal..4578
          Engine Compression Brake (ECB) Valve..4578
          Engine Compression Brake Pressure (ECBP) Sensor..4579
          Valve Cover Gasket (Harness) Assembly (Brake)..4580
          High-pressure Oil Manifold (Brake)..4581
          Oil Pressure Relief Valve..4582
          Brake Actuator Piston Assembly..4582
        Cleaning and Inspection..4585
        Installation..4586
          Brake Actuator Piston Assembly..4586
          Oil Pressure Relief Valve..4587
          High-pressure Oil Manifold (Brake)..4588
          Valve Cover Gasket (Harness) Assembly (Brake)..4590
          Engine Compression Brake Pressure (ECBP) Sensor..4590
          Engine Compression Brake (ECB) valve assembly..4592
      Table of Contents..4595
        Illustrations..4597
          Air Compressor..4597
          Power Steering Pump..4598
        Description..4599
          Air Compressor..4599
          Power Steering Pump..4599
        Removal..4599
          Power Steering Pump..4600
          Air Compressor..4602
        Cleaning and Inspection..4604
        Installation..4605
          Air Compressor..4605
          Power Steering Pump Without Air Compressor..4607
          Power Steering Pump With Air Compressor..4608
      Table of Contents..4611
        Exploded View and Description..4613
        Removal..4614
          Drain Coolant..4614
          Oil Cooler Housing..4616
        Disassemble..4618
          Pressure Regulator Valve (Oil)..4618
          Thermal Valve (Oil)..4619
          Oil Cooler..4620
        Cleaning, Inspection, and Testing..4623
          Clean Oil Cooler Housing..4623
          Oil Cooler Pressure Test..4625
        Assemble..4627
          Oil Cooler..4627
          Thermal Valve (Oil)..4630
          Regulator Valve (Oil)..4631
        Installation..4632
          Oil Cooler Module..4632
          Oil Filter..4634
          Prime Lubrication System..4635
            Priming System..4635
            Cranking Method (Alternate)..4635
      Table of Contents..4639
        Exploded Views..4641
          Front Sump..4641
          Rear Sump..4642
        Removal..4643
          Drain Engine Oil..4643
          Oil Pan and Gasket..4644
          Suction Tube Assembly..4645
        Cleaning and Inspecting..4647
          Oil Pan and Suction Tube..4647
        Installation..4648
          Suction Tube Assembly..4648
          Oil Pan and Gasket..4649
          Fill Engine with Oil..4651
      Table of Contents..4653
        Exploded View..4655
        Removal..4657
          Dual Drive Belt..4658
          Single Drive Belt..4659
          Dual Idler Pulleys..4660
          Alternator Support..4661
          Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate..4662
          Coolant Supply Housing (Refrigerant Compressor Mount)..4663
          Water Outlet Tube and Thermostat..4664
          Water Pump Assembly..4665
          Water Inlet Elbow..4665
          Fan Drive..4666
            Spin-on Fan Drive..4666
            Horton DriveMaster? Fan Drive..4667
          Vibration Damper, Hub, and Wear Sleeve..4668
            Vibration Damper?Single Drive Belt Engines..4668
            Vibration Damper?Dual Drive Belt Engines..4669
            Damper Hub..4670
          Oil Pump Assembly..4671
          Front Engine Mount..4674
          Front Cover (Front Half)..4675
          Idler Gears..4676
          Front Cover (Rear Half)..4678
        Cleaning, Inspection, and Measurement..4679
          Cleaning and Inspection..4679
          Measuring Gear Backlash..4679
            Lower Idler Gear Backlash..4680
            Upper Idler Gear Backlash..4681
            Camshaft Gear Backlash..4682
          Measuring Oil Pump Side Clearance..4683
          Measuring Oil Pump End Clearance..4684
        Installation..4685
          Front Cover (Rear Half)..4685
          Idler Gears..4687
          Front Cover (Front Half)..4689
          Front Engine Mount..4691
          Oil Pump Assembly..4692
          Vibration Damper, Hub, and Wear Sleeve..4698
            Damper Hub..4698
            Vibration Damper?Dual Drive Belt Engines..4702
            Vibration Damper?Single Drive Belt Engines..4703
          Fan Drive..4704
            Spin-on Fan Drive..4704
            Horton DriveMaster? Fan Drive..4706
          Water Outlet Tube and Thermostat..4707
          Water Pump Assembly..4708
          Water Inlet Elbow..4709
          Coolant Housing (Refrigerant Compressor Mount)..4709
          Alternator Support..4711
          Dual Idler Pulleys..4712
          Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate..4713
          Single Drive Belt..4715
          Dual Drive Belt..4716
      Table of Contents..4721
        Illustrations and Description..4723
          Exploded View of Cylinder Head and Valve Train Components..4723
          Description..4724
        Periodic Service..4725
          Valve Lash Adjustment..4725
        Removal..4729
          Valve Cover..4729
          Rocker Arm Assembly..4732
          Rocker Arms..4734
          Cylinder Head..4735
          Roller Tappets and Guides..4738
        Cleaning, Inspection, Measurement, and Testing..4739
          Measuring Camshaft Lobe Lift..4739
          Cylinder Head Cleaning..4739
          Cleaning and Inspection of Roller Tappets and Guides..4740
          Cleaning and Inspection of Push Rods..4740
          Measuring Rocker Shaft..4741
          Inspection and Measurement of Rocker Arms..4742
          Measuring Cylinder Head Warpage..4743
          Measuring Cylinder Head Thickness..4744
          Measuring Valve Seat Leakage..4745
          Inspecting Cylinder Head for Cracks..4745
          Cylinder Head Pressure Test..4747
        Reconditioning..4749
          Removal of Valves from Cylinder Head..4749
          Inspection and Measurement of Valve Guides..4750
          Replacing Valve Guides..4752
          Inspecting and Measurement of Valve..4754
          Refacing Valves..4755
            Valve Face..4755
            Refacing Valve Stem Tip..4756
            Valve Face-to-Seat Contact Inspection..4757
          Resurfacing Valve Seats..4758
          Replacing Valve Seats..4760
            Removal..4760
            Installation..4762
          Valve Spring Inspection..4765
          Inspecting Valve Rotators and Retainers..4768
          Inspecting Valve Spring Retainer Keys..4769
          Replacing Fuel Injector Sleeves..4770
            Removal..4770
            Tool Removal..4773
            Cleaning..4773
            Installation..4774
          Installing Valves..4776
            Cleaning..4776
            Assembly..4776
        Installation..4778
          Roller Tappets and Guides..4778
          Cylinder Head..4778
          Torque Procedure for Torque-to-yield Head Bolts..4782
          Rocker Arms..4785
          Rocker Arm Assembly..4786
          Valve Cover..4788
      Table of Contents..4795
        Exploded View and Description..4797
        Flywheel housing SAE 1..4798
        Flywheel housing SAE 1A..4798
        Flywheel housing SAE 2..4798
        Flywheel housing (Bus) SAE 2..4798
        Flywheel and Flexplate Applications..4799
          Manual Transmissions..4799
          Automatic Transmissions..4802
        Removal..4804
          Flywheel Assembly..4804
          Flexplate (Automatic Transmissions)..4805
            Allison 2000 Series Transmissions..4806
            MD-3000 Series Transmissions..4807
          Crankshaft Timing Disk..4808
          Rear Oil Seal Assembly..4809
          Flywheel Housing..4811
        Cleaning, Inspection, and Measurement..4813
          Clean and Inspect..4813
          Measurement of Flywheel Housing Face Runout..4813
          Measurement of Flywheel Housing Bore Concentricity..4815
          Measurement of Crankshaft Pilot Concentricity..4816
          Measurement of Flywheel Surface Runout..4817
        Recondition..4818
          Resurface Flywheel..4818
          Replacement of Flywheel Ring Gear..4819
        Installation..4820
          Flywheel Housing and Rear Engine Mounting Brackets..4820
          Rear Oil Seal..4823
          Crankshaft Timing Disk..4825
          Flywheel Assembly..4827
          Flexplate (Automatic Transmissions)..4829
            Allison 2000 Series Transmissions..4829
            MD-3000 Series World Transmissions..4830
      Table of Contents..4833
        Exploded View and Description..4835
        Removal..4836
          Piston Cooling Tubes..4836
          Piston Protrusion Measurement ? Preliminary Check..4837
          Piston and Connecting Rod Assembly..4837
          Piston Pin and Rings..4841
          Cylinder Sleeve..4842
        Cleaning, Inspecting, and Measuring..4844
          Cleaning and Inspecting..4844
          Measuring Pistons..4845
            Top Compression Ring Grooves..4845
            Intermediate and Oil Control Ring Groove..4846
            Piston-to-Cylinder Sleeve Running Clearance..4847
          Measuring Piston Rings..4848
          Measuring Piston Pins..4848
          Measuring and Inspecting Connecting Rods..4850
            Piston Pin Bushing..4850
            Connecting Rod Bolt Holes Inspection..4850
            Connecting Rod Bearing Bore (Big End)..4851
            Connecting Rod Bend and Twist..4852
          Bearing Fitting Procedures..4853
            Measuring Bearing Running Clearance..4853
            Measuring Connecting Rod Side Clearance..4856
          Measuring Cylinder Sleeves..4857
            Telescoping Gauge Method..4857
            Dial Bore Gauge Method..4859
            Feeler Gauge Method..4859
          Measuring Counterbore Depth..4861
            Cylinder Liner Height Gauge Method..4861
            Depth Micrometer Method..4862
          Measuring Cylinder Sleeve Protrusion..4863
        Reconditioning..4867
          Resurfacing Counterbore..4867
            Preparation..4867
            Mounting the Counterbore Reconditioning Tool..4868
            Tool Settings..4870
            Cutting Counterbore Ledge..4871
            Tool Care and Maintenance..4873
        Installation..4874
          Cylinder Sleeve..4874
          Piston Rings..4876
          Piston Pin..4877
          Piston and Connecting Rod Assembly..4879
          Torque-to-yield Procedure for Connecting Rods..4882
          Piston Cooling Tubes..4884
        Engine Run-in Procedure..4886
      Table of Contents..4891
        Exploded Views and Description..4893
          Centrifuge Oil Filter..4893
          Crankcase Breather Assembly with Turbine..4894
          Crankcase, Crankshaft, and Camshaft..4896
        Removal..4898
          Centrifuge Oil Filter..4898
          Crankcase Ventilation System..4900
          Oil Level Gauge Assembly..4903
          Coolant Heater Assembly (optional)..4904
          Crankcase Ladder Assembly..4904
          Camshaft Gear..4906
          Camshaft Assembly..4907
          Camshaft Bearings..4908
          Main Bearing Caps, Crankshaft, and Main Bearings..4910
          Oil Pump Spline Drive and Crankshaft Gear..4912
        Cleaning, Inspection, and Measurement..4913
          Camshaft Assembly..4913
          Centrifuge Oil Filter Cleaning and Inspection..4914
          Crankcase Breather Assembly..4915
          Crankcase, Cup Plugs, and Piston Cooling Tubes..4915
          Crankshaft and Main Bearings..4917
          Camshaft End Play Measurement..4918
          Camshaft Lobes and Journals Measurement..4918
          Crankshaft End Play Measurement..4920
        Installation..4921
          Camshaft Bearings..4921
          Camshaft Assembly..4925
          Camshaft Gear..4926
          Crankshaft Gear and Oil Pump Spline Drive..4928
          Upper Main Bearings and Crankshaft Assembly..4929
          Main Bearing Fit Procedure..4932
          Main Bearings and Caps..4935
          Torque Procedure for Torque-to-yield Main Bearing Cap Bolts..4936
          Crankcase Ladder Assembly..4937
          Coolant Heater Assembly (optional)..4939
          Oil Level Gauge Assembly..4940
          Crankcase Ventilation System..4942
          Centrifuge Oil Filter..4945
      Table of Contents..4953
        Abbreviations and Acronyms..4955
          Abbreviations and Acronyms..4955
      Table of Contents..4965
        Terminology..4967
          Terms..4967
      Table of Contents..4979
        Specifications..4981
          Fuel and High-Pressure Oil Systems..4981
          Engine Brake..4981
          Air Compressor and Power Steering Pump..4981
          Oil System Module Assembly..4981
          Oil Pan and Oil Suction Tube..4981
          Front Cover, Cooling System, and Related Components..4982
          Cylinder Head and Valve Train..4984
          Flywheel and Flywheel Housing..4986
          Power Cylinders..4987
          Crankcase, Crankshaft, and Camshaft..4991
      Table of Contents..4995
        General Torque..4997
          Bolt Identification..4997
          General Torque Guidelines..4998
          Standard Torque Charts..4999
          Using a Torque Wrench Extension..5000
        Special Torque..5001
          Mounting Engine on Engine Stand..5001
          Engine Electrical..5001
          Down Stream Injection (DSI) & Related Components..5001
          Dual Stage Turbocharger and Exhaust Brake..5002
          Exhaust Gas Recirculation (EGR) System..5002
          Intake, Inlet and Exhaust Manifolds..5002
          Fuel and High-pressure Oil Systems..5003
          Engine Brake..5004
          Air Compressor and Power Steering Pump..5004
          Oil System Module Assembly..5005
          Oil Pan and Oil Suction Tube..5005
          Front Cover, Cooling System, and Related Components..5005
          Cylinder Head and Valve Train..5006
          Flywheel and Flywheel Housing..5006
          Power Cylinders..5006
          Crankcase, Crankshaft, and Camshaft..5006
      Table of Contents..5007
        Tool Ordering Information..5009
        Special Tools..5009
          Mounting Engine on Engine Stand..5009
          Dual Stage Turbocharger and Exhaust Brake..5009
          Exhaust Gas Recirculation (EGR) System..5009
          Intake, Inlet and Exhaust Manifolds..5010
          Fuel and High-pressure Oil Systems..5010
          Engine Brake..5010
          Oil System Module Assembly..5010
          Oil Pan and Oil Suction Tube..5010
          Front Cover, Cooling System, and Related Components..5011
          Cylinder Head and Valve Train..5011
          Flywheel and Flywheel Housing..5012
          Power Cylinders..5013
          Crankcase, Crankshaft, and Camshaft..5013
        Photos of Essential Tools..5014
  tables..4237
    MaxxForce? DT, 9, and 10 Diesel Engines..4237
    Water Pump Pulley Diameters and Spin Ratios..4717
    Fan Drive Configurations Diameters and Ratios (Spin-on)..4717
    Fan Drive Configurations Diameters and Ratios (DriveMaster?) ? Single Drive Belt..4718
    Fan Drive Configurations Diameters and Ratios (DriveMaster?) ? Dual Drive Belt..4718
    Valve Seat Insert Selection Chart..4763
    Valve Specifications..4790
    Valve Spring Specifications..4791
    Cylinder Head and Valve Train Specifications..4791
    Flywheel Housing..4831
    Crankshaft Pilot..4831
    Flywheel..4831
    Flywheel Resurfacing Specifications..4831
    Piston Ring Gauge Pin Selection..4845
    Connecting Rod Specifications..4887
    Piston Specifications ? MaxxForce? DT..4887
    Piston Specifications ? MaxxForce? 9 and 10..4888
    Piston Ring Specifications (in 116.573 mm diameter gage ring)..4888
    Piston Pin Specifications..4888
    Cylinder Sleeve Specifications..4889
    Crankcase Specifications ..4947
    Camshaft Specifications ..4948
    Camshaft Bearing Specifications..4948
    Crankshaft Specifications..4949
    Crankshaft Specifications (continued)..4950
    Water Pump Pulley Diameters and Spin Ratios..4982
    Fan Drive Configurations Diameters and Ratios (Spin-on)..4982
    Fan Drive Configurations Diameters and Ratios (DriveMaster?) ? Single Drive Belt..4983
    Fan Drive Configurations Diameters and Ratios (DriveMaster?) ? Dual Drive Belt..4983
    Valve Specifications..4984
    Valve Spring Specifications..4985
    Cylinder Head and Valve Train Specifications..4985
    Flywheel Housing..4986
    Crankshaft Pilot..4986
    Flywheel..4987
    Flywheel Resurfacing Specifications..4987
    Connecting Rod Specifications..4987
    Piston Specifications ? MaxxForce? DT..4988
    Piston Specifications ? MaxxForce? 9 and 10..4989
    Piston Ring Specifications (in 116.573 mm diameter gage ring)..4989
    Piston Pin Specifications..4989
    Cylinder Sleeve Specifications..4990
    Crankcase Specifications ..4991
    Camshaft Specifications ..4992
    Camshaft Bearing Specifications..4992
    Crankshaft Specifications..4993
    Crankshaft Specifications (continued)..4994
    Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs..4999
0000002383 - Engine Service Manual 2010 MaxxForce 7..5022
  toc..5024
    Table of Contents..5024
    SAFETY TERMINOLOGY..5028
    SAFETY INSTRUCTIONS..5028
      Table of Contents..5030
        Engine Identification..5032
          Engine Serial Number..5032
          Engine Serial Number Example..5032
          Emission Label..5032
          Engine Accessories..5032
          Engine Description..5033
            Standard Features..5034
            Optional Features..5035
            Thermal Management Valve (TMV)..5035
            Chassis-mounted Features..5035
          Engine Components..5036
        Air Management System..5041
          Air Management Components and Air Flow..5041
            Air Flow..5042
          Charge Air Cooler (CAC)..5042
          Charge Air Cooler Outlet Temperature (CACOT) Sensor..5042
          Dual Turbocharger Assembly..5044
            High-pressure Turbocharger..5045
            Turbocharger 1 Compressor Outlet Temperature (TC1COT) Sensor..5045
            Thermal Management Valve (TMV) (optional)..5045
            Low-pressure Turbocharger..5045
            Turbocharger 1 Wastegate Control (TC1WC) Solenoid..5045
          Exhaust Gas Recirculation (EGR) System..5046
            EGR Flow..5046
            EGR Control Valve and Position Sensor..5047
            Engine Throttle Valve (ETV) and Position Sensor..5048
          Aftertreatment (AFT) System..5049
            AFT Control System..5049
            Sensors..5049
            Diesel Oxidation Catalyst (DOC)..5049
            Diesel Particulate Filter (DPF)..5049
            AFT Conditions and Responses..5049
        Fuel System..5050
          Fuel System Components..5050
          High-pressure Fuel System..5051
            High-pressure Fuel Pump (HPFP) Assembly..5051
            Internal Transfer Pump (ITP)..5051
            Fuel Pressure Control Valve (FPCV)..5051
            Fuel Volume Control Valve (FVCV)..5052
            Fuel Rail Pressure (FRP) Sensor..5052
            High-pressure Piezo Common Rail (HPCR) System..5052
            Return Fuel System..5052
          Low-pressure Fuel System..5054
            Fuel Pump..5054
            Primary Fuel Filter..5054
            Secondary Fuel Filter..5054
            Fuel Cooler..5054
          Fault Detection/Management..5054
        Engine Lubrication System..5055
          Lubrication System Components and Oil Flow..5055
        Cooling System..5057
          Cooling System Components and Flow..5057
            Water Pump..5057
            Front Crankcase Cover Flow..5058
            Thermostats..5058
            Deaeration Tank..5058
            Radiator Shutters (220 Horsepower only)..5058
            Fuel Coolant Valve (FCV)..5058
        Engine Speed Position System..5059
        Electronic Control System..5060
          Electronic Control System Components..5060
            Operation and Function..5062
            Reference Voltage (VREF)..5062
            Signal Conditioner..5062
            Microprocessor..5062
            Microprocessor Memory..5062
            Flash Memory..5062
            RAM..5062
            Engine Fan Control (EFC)..5063
            Inlet Air Heater (IAH)..5063
            Actuator Control..5063
          Actuators..5063
            H-Bridge Circuit..5063
            Exhaust Gas Recirculation (EGR) Valve and Control..5063
            ETV and Engine Throttle Position Sensor..5064
          Engine and Vehicle Sensors..5064
            Thermistor Sensors..5064
            Variable Capacitance Sensors..5065
            Micro Strain Gauge (MSG) Sensor..5065
            MSG Sensors..5065
            Magnetic Pickup Sensors..5066
            Magnetic Pickup Sensors..5066
            Potentiometer..5066
            Potentiometer..5066
            Switches..5067
            Switches..5067
          Inlet Air Heater (IAH) System..5068
      Table of Contents..5070
        Engine Preparation..5072
          Cleaning the Engine..5072
          Draining Coolant and Engine Oil..5072
        Mounting Engine ..5074
      Table of Contents..5078
        Diagnostics and Troubleshooting Publications..5080
        Location of Engine Electronic Components..5081
        Description of Engine Electronic Components..5085
          Charge Air Cooler Outlet Temperature (CACOT) Sensor..5085
          Camshaft Position (CMP) Sensor..5085
          Crankshaft Position (CKP) Sensor..5085
          Engine Control Module (ECM)..5086
          Engine Coolant Temperature (ECT1) Sensor..5086
          Engine Oil Pressure (EOP) Sensor..5087
          Engine Oil Temperature (EOT) Sensor..5087
          Engine Fuel Temperature (EFT) Sensor..5087
          Exhaust Gas Recirculation (EGR) Valve ..5088
          Exhaust Gas Temperature (EGT) Sensor..5088
          Exhaust Gas Recirculation Temperature (EGRT) Sensor..5088
          Engine Throttle Valve (ETV) ..5089
          Fuel Heater (optional)..5090
          Fuel Pump..5090
          Fuel Rail Pressure (FRP) Sensor..5091
          Intake Air Heater (IAH) ..5091
          Intake Air Heater (IAH) Relay..5092
          Intake Manifold Pressure (IMP) Sensor..5092
          Intake Manifold Temperature (IMT) Sensor..5092
          Mass Air Flow / Air Inlet Temperature (MAF / AIT) Sensor..5093
          Thermal Management Valve (TMV) (optional)..5093
          Turbocharger 1 Compressor Outlet Temperature (TC1COT) Sensor..5093
          Turbocharger 1 Wastegate Control (TC1WC) Solenoid..5094
          Water In Fuel (WIF) Sensor..5094
        Removal..5095
          Mass Air Flow / Air Inlet Temperature (MAF / AIT) Sensor..5095
          Charge Air Cooler Outlet Temperature (CACOT) Sensor..5096
          Crankshaft Position (CKP) Sensor..5096
          Camshaft Position (CMP) Sensor..5097
          Engine Coolant Temperature (ECT1) Sensor..5097
          Engine Throttle Valve (ETV)..5098
          Intake Air Heater (IAH)..5099
          Exhaust Gas Recirculation (EGR) Valve Assembly ..5099
          Exhaust Gas Recirculation Temperature (EGRT) Sensor..5100
          Intake Manifold Temperature (IMT) Sensor and Intake Manifold Pressure (IMP) Sensor..5100
          Thermal Management Valve (TMV)..5101
          Turbocharger 1 Compressor Outlet Temperature (TC1COT) Sensor..5102
          Turbocharger 1 Wastegate Control (TC1WC) Solenoid..5102
          Engine Oil Temperature (EOT) Sensor and Engine Oil Pressure (EOP) Sensor..5103
          Water In Fuel (WIF) Sensor..5103
          Fuel Pump..5104
          Fuel Heater (optional) and Fuel Delivery Pressure (FDP) Sensor (optional)..5104
          Engine Fuel Temperature (EFT) Sensor..5105
          Exhaust Gas Temperature (EGT) Sensor..5105
          Engine Harness..5106
          Harness Channel Shield Assemblies..5110
          Intake Air Heater (IAH) Relay and Relay Support..5111
          Fuel Rail Pressure (FRP) Sensor..5112
          Under Valve Cover (UVC) Harnesses..5112
        Cleaning and Inspection..5115
          Main Engine Wiring Harness..5115
          Harness Retainers and Stud Clips..5115
          Sensors and Valves..5115
          Engine Control Module..5115
        Installation..5116
          Under Valve Cover (UVC) Harnesses..5116
          Fuel Rail Pressure (FRP) Sensor..5118
          Intake Air Heater (IAH) Relay and Relay Support..5118
          Harness Channel Shield Assemblies..5119
          Engine Harness..5121
          Exhaust Gas Temperature (EGT) Sensor..5125
          Fuel Heater (optional) and Fuel Delivery Pressure (FDP) Sensor (optional)..5126
          Fuel Pump..5126
          Water In Fuel (WIF) Sensor..5127
          Engine Fuel Temperature (EFT) Sensor..5127
          Engine Oil Temperature (EOT) Sensor and Engine Oil Pressure (EOP) Sensor..5128
          Turbocharger 1 Wastegate Control (TC1WC) Solenoid..5128
          Turbocharger 1 Compressor Outlet Temperature (TC1COT) Sensor..5129
          Thermal Management Valve (TMV)..5129
          Intake Manifold Temperature (IMT) Sensor and Intake Manifold Pressure (IMP) Sensor..5130
          Exhaust Gas Recirculation Temperature (EGRT) Sensor..5131
          Exhaust Gas Recirculation (EGR) Valve Assembly..5131
          Intake Air heater (IAH)..5131
          Engine Throttle Valve (ETV)..5132
          Engine Coolant Temperature (ECT1) Sensor..5133
          Camshaft Position (CMP) Sensor..5133
          Crankshaft Position (CKP) Sensor..5134
          Charge Air Cooler Outlet Temperature (CACOT) sensor..5134
          Mass Air Flow / Air Inlet Temperature (MAF / AIT) Sensor..5135
      Table of Contents..5138
        Exploded Views..5140
        Removal..5142
          EGR Valve Assembly..5142
          EGR Cooler..5145
          EGR Mixer Assembly..5146
          Distribution Duct and Manifold Mixer..5147
          EGR Coolant Supply and Return Tubes..5150
        Cleaning, Inspection, and Testing..5152
          EGR System Components..5152
          Manifold Mixer..5152
          Exhaust Gas Recirculation (EGR) Cooler Pressure Test..5153
            EGR Leak Detection Kit..5153
            Installation and Testing of EGR Cooler..5153
        Installation..5155
          EGR Coolant Supply and Return Tubes..5155
          EGR Manifold Mixer..5156
          EGR Cooler..5162
          EGR Valve Assembly..5164
      Table of Contents..5166
        Description..5168
          Exploded Views..5168
        Removal..5171
          Exhaust Tubes..5172
          Exhaust Manifolds..5174
            Left Exhaust Manifold..5174
            Right Exhaust Manifold..5175
          Pump Cover Heat Shields ..5176
          Dual Turbocharger Heat Shields..5177
          Turbocharger Oil Supply Tube Assembly..5178
          Air Duct Assembly, Relief Tube Assembly, Wastegate Tube Assembly, and TC1WC Solenoid..5180
          Dual Turbocharger Assembly ..5181
        Cleaning, Inspection, and Testing..5185
          Dual Turbocharger Assembly and Related Parts..5185
          Dual Turbocharger Assembly Cleaning and Inspection..5185
          Check Free Rotation and Housing Rub..5192
          Check Axial End Play..5193
          TC1WC Wastegate Actuator Set Procedure..5194
          Exhaust Manifolds..5195
          Manifold Warp Test for Exhaust Manifolds..5195
        Installation..5196
          Dual Turbochargers..5196
          TC1WC Solenoid, Wastegate Hose Assembly, Relief Tube Assembly, and Air Duct Assembly..5199
          Turbocharger Oil Supply Tube..5200
          Dual Turbocharger Heat Shields..5202
          Pump Cover Heat Shields ..5202
          Exhaust Manifolds..5204
            Right Exhaust Manifold..5204
            Left Exhaust Manifold..5205
          Exhaust Tubes..5207
      Table of Contents..5210
        Exploded Views..5212
        Removal..5215
          Air Compressor Coolant Supply and Return Hoses..5215
          Air Compressor Oil Supply Tube, Oil Supply and Return Hose..5216
          Air Compressor Assembly..5217
          Belt Tensioner, Flat Idler Pulleys, and Secondary Freon Compressor Bracket..5218
          Lifting Eye and Optional Belt Tensioner..5219
          Air Compressor Bracket..5219
          Power Steering Suction and Pressure Tube Assemblies..5220
          Power Steering Pump..5221
        Cleaning and Testing..5222
          All Components..5222
          Power Steering Pump Idler Gear Backlash Measurement..5222
        Installation..5223
          Power Steering Pump..5223
          Power Steering Suction and Pressure Tube Assemblies..5223
          Air Compressor Bracket..5224
          Lifting Eye and Optional Belt Tensioner..5225
          Belt Tensioner, Flat Idler Pulleys, and Secondary Freon Compressor Bracket..5225
          Air Compressor Assembly..5226
          Air Compressor Oil Return Hose, Oil Supply Hose, Oil Supply Tube..5227
          Air Compressor Coolant Supply and Return Hoses..5228
      Table of Contents..5232
        Exploded Views..5234
        Removal..5239
          High-pressure Fuel Tube Assemblies..5239
          Draining the Low-pressure Fuel System..5241
          Pump to Cooler Hose and Filter to Pump Hose Assemblies..5242
          Injector Return Hose Assembly..5244
          High-pressure Fuel Pump Assembly..5245
          Fuel Injectors and Fuel Rail Assemblies..5249
          Oil Level Tube Assembly and Coolant Return Hose..5251
          Fuel Coolant Supply Tube Assembly..5252
          Fuel Filter and Cooler Assembly..5252
          Fuel Filter Cooler Assembly and Filter Cooler Pump Module Support..5253
          Primary Fuel Filter, Secondary Fuel Filter, and Fuel Housing Cover..5254
          Fuel Pump..5255
          Fuel Heater Port Cover, Diagnostic Valve, Pressure Regulator, and Engine Fuel Temperature (EFT) Sensor..5256
          Fuel Heater (Optional) and Fuel Delivery Pressure (FDP) Sensor (Optional)..5257
          Water In Fuel (WIF) Sensor and Water Drain Valve..5258
        Inspection..5259
          Fuel Filter and Fuel Hose Inspection..5259
          Fuel Filter in Low-Pressure Line at High-Pressure Pump..5259
        Flushing the Low-pressure Fuel System..5261
        Installation..5264
          Water In Fuel (WIF) Sensor and Water Drain Valve..5264
          Fuel Heater Port Cover, Diagnostic Valve, Pressure Regulator, and Engine Fuel Temperature (EFT) Sensor..5265
          Fuel Heater (Optional) and Fuel Delivery Pressure (FDP) Sensor (Optional)..5266
          Fuel Pump..5267
          Primary Fuel Filter, Secondary Fuel Filter, and Fuel Housing Cover..5268
          Primary Fuel Filter Assembly..5268
          Secondary Fuel Filter Assembly..5269
          Fuel Filter Cooler Assembly and Filter Cooler Pump Module Support..5270
          Fuel Filter and Cooler Assembly..5271
          Fuel Coolant Supply Tube Assembly..5271
          Oil Level Tube Assembly and Coolant Return Hose..5272
          High-Pressure Fuel Pump Assembly..5272
          Fuel Injectors and Fuel Rail Assemblies..5276
          Injector Return Hose Assembly..5279
          Pump to Cooler Hose and Filter to Pump Hose Assemblies..5280
          Priming the High-pressure Fuel System..5283
      Table of Contents..5288
        Exploded Views..5290
        Removal..5292
          Alternator and Refrigerant Compressor Mounting Bracket..5292
          Front Engine Mounting Support..5293
          Thermostat Housing and Thermostats..5294
          Fan Drive..5295
          Water Pump Assembly..5295
          Crank Power Takeoff (PTO) for Air Compressor Pulley (if equipped)..5297
          Vibration Damper..5297
          Front Crankcase Cover Assembly..5298
        Cleaning, Inspection, and Testing..5299
          Vibration Damper..5299
          Vibration Damper Runout..5299
          Front Crankcase Cover and Water Pump Assembly..5299
          Thermostat Assemblies..5299
        Installation..5301
          Front Crankcase Cover..5301
          Vibration Damper..5302
          Crank Power Takeoff (PTO) for Air Compressor Pulley (if equipped)..5303
          Water Pump Assembly..5303
          Fan Drive..5304
          Thermostat Housing and Thermostats..5305
          Front Engine Mounting Support..5306
          Alternator and Refrigerant Compressor Mounting Bracket..5307
      Table of Contents..5310
        Exploded Views..5312
        Removal..5315
          Oil Cooler Assembly..5315
          Oil Cooler Assembly Leak Test (Coolant Side)..5316
            Oil Cooler Assembly Leak Test Procedure..5316
            Disassembly..5316
            Service Parts..5316
            Assembly..5317
          Oil Cooler Cover Assembly..5318
          Front Crankshaft Oil Seal..5318
          Oil Pump Assembly..5320
          Oil Level Tube assembly..5321
          Oil Pan Plugs and Oil Level Gauge Tube Gasket..5321
          Oil Filter Assembly..5322
          Oil Pan..5322
          Lube Oil Suction Tube..5322
        Cleaning, Inspection, and Measurement..5324
          Cleaning and Inspection..5324
          Oil Pump Rotor Assembly..5324
          Oil Pressure Regulator Components..5325
        Installation..5326
          Lube Oil Suction Tube..5326
          Oil Pan..5326
          Oil Pan Plugs and Oil Level Gauge Tube Gasket..5327
          Oil Filter Assembly..5327
          Oil Level Tube Assembly..5328
          Oil Pump Housing Assembly..5328
          Front Crankshaft Oil Seal..5330
          Oil Cooler Assembly..5330
      Table of Contents..5334
        Exploded Views..5336
        Removal..5340
          Balance Duct and Balance Tube Flange..5340
          Draft Tube Assembly..5342
          Lifting Eye and Jet Pump Tube Assembly..5342
          Breather Cover Assembly and Filter with variable impactor..5343
          Right Valve Cover..5344
          Oil Fill Tube Assembly..5344
          Left Valve Cover..5345
          Left Valve Cover and Intake Manifold Base Assembly..5347
          Right Valve Cover and Intake Manifold Base Assembly..5349
          Dual Fulcrum Plates Assemblies..5350
          Rocker Arm Support, Push Rods, and Valve Bridges..5351
          Cylinder Heads..5351
          Roller Hydraulic Cam Followers..5353
          Valves..5354
          Fuel Injector Sleeves..5354
          Dual Fulcrum Plate Assemblies..5356
        Cleaning, Inspection, and Testing..5358
          Cylinder Head and Crankcase Components..5358
          Cylinder Head Inspection ? Valves Installed..5358
          Cylinder Head Inspection ? Valves Removed..5361
          Valve Seats..5362
          Valves..5362
          Valve Guides..5363
          Valve Springs..5364
          Valve Stem Keys..5365
          Push Rods..5365
          Fuel Injector Sleeve Bore and Gallery..5365
          Dual Rocker Fulcrums..5365
        Installation..5366
          Dual Fulcrum Plate Assemblies..5366
          Fuel Injector Sleeves..5367
          Valves..5368
          Roller Hydraulic Cam Followers..5369
          Cylinder Heads..5370
            Installation..5370
            Tightening Sequence for Cylinder Head Bolts..5373
          Rocker Arm Supports, Push Rods, and Valve Bridges..5375
          Right Valve Cover and Intake Manifold Base Assembly..5378
          Left Valve Cover and Intake Manifold Base Assembly..5380
          Left Valve Cover..5382
          Oil Fill Tube Assembly..5382
          Right Valve Cover..5383
          Breather Cover Assembly and Variable Impactor..5383
          Lifting eye and jet pump tube assembly..5385
          Draft Tube Assembly..5385
          Balance Duct and Balance Tube Flange..5386
      Table of Contents..5392
        Exploded Views..5394
        Removal..5400
          Engine Mount Rear Brackets..5400
          Flywheel Assembly (Manual Transmission)..5401
          Flex Plate flywheel Assembly (Automatic Transmission)..5402
          Crankshaft Rear Oil Seal and Wear Sleeve..5402
          Crankshaft Rear Oil Seal Carrier and Power Steering Idler Gear Assembly..5403
          Crankshaft Flange..5404
          Flywheel Housing and Power Steering Idler Shaft..5405
        Cleaning, Inspection, and Measurement..5407
          All Components..5407
          Flex Plate Flywheel Assembly (Automatic Transmission)..5407
          Flywheel Assembly (Manual Transmission)..5407
          Flywheel Surface Runout..5407
          Flywheel Housing Runout..5408
          Backlash Measurement for Power Steering Idler Gear Assembly..5408
        Installation..5409
          Flywheel Housing..5409
          Power Steering Idler Shaft..5409
          Crankshaft Flange..5411
          Power Steering Idler Gear Assembly and Crankshaft Rear Oil Seal Carrier..5412
          Crankshaft Rear Oil Seal and Wear Sleeve..5413
          Flex Plate Flywheel Assembly (Automatic Transmission)..5415
          Flywheel Assembly (Manual Transmission)..5416
          Engine Mount Rear Brackets..5417
      Table of Contents..5420
        Exploded View..5422
        Removal..5423
          Piston Protrusion Measurement..5424
          Connecting Rod Side Clearance Measurement..5424
          Connecting Rod and Piston Assembly..5425
          Piston Disassembly..5426
        Cleaning, Inspection, and Measurement..5428
          Cleaning and Inspection..5428
          Piston Measurement..5428
          Piston Rings..5430
          Connecting Rods..5430
          Connecting Rod Bore Out-of-round Measurement..5431
          Connecting Rod Bearing Fit Measurement..5432
          Piston Pin Inspection..5432
        Installation..5434
          Piston Assembly..5434
          Connecting Rod and Piston Assembly..5436
      Table of Contents..5442
        Exploded View..5444
        Removal..5446
          Lower Crankcase Assembly..5446
          Crankshaft Assembly..5447
          Piston Cooling Tubes..5448
          Camshaft Assembly..5448
          Camshaft Bushings..5449
          Coolant Heater..5450
        Cleaning, Inspection, and Measurement..5451
          Camshaft Gear Backlash Measurement..5451
          Camshaft End Play Measurement..5451
          Crankshaft End Play Measurement..5452
          Crankcase Assembly..5452
            Crankcase Cleaning..5452
            Crankcase Inspection and Measurement..5454
            Cylinder Deglazing..5455
          Crankshaft Assembly..5455
          Main Bearing Fit Check..5456
          Piston Cooling Tubes..5457
          Camshaft Assembly..5457
          Measuring Camshaft Bushings..5458
          Coolant Heater..5459
        Installation..5460
          Camshaft Bushings..5460
          Camshaft Assembly..5460
          Piston Cooling Tubes..5461
          Crankshaft Assembly..5461
          Lower Crankcase Assembly..5462
          Coolant Heater..5465
      Table of Contents..5468
        Abbreviations and Acronyms..5470
          Abbreviations and Acronyms..5470
      Table of Contents..5474
        Terminology..5476
          Terminology..5476
            Terms..5476
      Table of Contents..5486
        Dual Turbocharger, Exhaust Manifolds, and Piping..5488
        Air Compressor and Power Steering Pump..5488
        Fuel System..5488
        Front Cover, Cooling System, and Related Components..5488
        Oil Cooler, Oil Pump, Oil Filter, and Oil Pan..5489
        Cylinder Head and Valve Train..5490
        Flywheel and Flywheel Housing..5491
        Power Cylinders..5491
        Crankcase, Crankshaft, and Camshaft..5493
      Table of Contents..5494
        General Torque..5496
          Bolt Identification..5496
          General Torque Guidelines..5497
          Standard Torque Charts..5498
          Using a Torque Wrench Extension..5499
        Special Torques..5500
          Mounting Engine on Stand..5500
          Engine Electrical..5500
          Exhaust Gas Recirculation (EGR) System..5500
          Dual Turbocharger, Exhaust Manifolds, and Piping..5501
          Air Compressor and Power Steering Pump..5501
          Fuel System..5502
          Front Cover, Cooling System, and Related Components..5502
          Oil Cooler, Oil pump, Oil Filter, and Oil Pan..5502
          Cylinder Heads, Valve Covers, and Valve Train..5503
          Flywheel and Flywheel Housing..5503
          Power Cylinders..5503
          Crankcase, Crankshaft, and Camshaft..5503
      Table of Contents..5504
        Special Tools..5506
        Mounting Engine on Stand..5506
        Engine Electrical..5506
        Exhaust Gas Recirculation (EGR) System..5506
        Dual Turbocharger, Exhaust Manifolds, and Piping..5507
        Air Compressor and Power Steering Pump..5507
        Fuel System..5507
        Front Cover, Cooling System, and Related Components..5508
        Oil Cooler, Oil Pump, Oil Filter, and Oil Pan..5508
        Cylinder Heads, Valve Covers, and Valve Train..5509
        Flywheel Assembly and Flywheel Housing..5510
        Power Cylinders..5510
        Crankcase, Crankshaft, and Camshaft..5511
        Special Tools ..5512
           Essential Tools..5512
  tables..5026
    Technical Service Literature..5026
    MaxxForce? 7 Features and Specifications..5033
    Flywheel Assembly and Flywheel Housing..5418
    Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs..5498
    Thread Diameter (mm)..5498
    Thread Pitch (mm)..5498
    Torque..5498
0000002464 - Engine Service Manual 2007 MaxxForce 7..5521
  toc..5523
    Highlights..5523
    SAFETY TERMINOLOGY..5529
    SAFETY INSTRUCTIONS..5529
      Table of Contents..5531
        Engine Identification..5533
          Engine Serial Number..5533
          Engine Serial Number Example..5533
          Engine Accessories..5533
          Engine Description..5534
            Standard Features..5535
            Optional Features..5536
            Chassis Mounted Features..5536
          Engine Component Locations..5537
        Air Management System..5542
          Air Management Components and Air Flow..5542
            Air Flow..5543
          Charge Air Cooler (CAC)..5543
          Variable Geometry Turbocharger (VGT) Assembly..5544
            VGT closed loop system..5544
            VGT control..5545
          Exhaust Gas Recirculation (EGR) System..5546
            EGR Flow..5546
            EGR Valve..5547
            Intake Throttle Valve (ITV)..5548
          Aftertreatment (AFT) System..5548
            AFT Control System..5548
            Sensors..5548
            Diesel Oxidation Catalyst (DOC)..5548
            Diesel Particulate Filter (DPF)..5548
            AFT Conditions and Responses..5548
        Fuel System..5549
          Fuel System Components..5549
            Low-pressure Fuel System..5553
            Low-pressure fuel pump..5553
            Primary fuel filter assembly..5553
            Fuel primer pump..5553
            Secondary fuel filter assembly..5553
            Fuel cooler..5553
            High-pressure Fuel System..5553
            High-pressure Fuel Pump (HPFP) assembly..5553
            Internal Transfer Pump (ITP)..5553
            Fuel Volume Control Valve (FVCV)..5553
            Fuel Pressure Control Valve (FPCV)..5554
            Fuel Rail Pressure (FRP) sensor..5554
            High-pressure Piezo Common Rail (HPCR) System..5554
            Fault Detection/Management..5554
            Return Fuel System..5554
        Engine Lubrication System ..5555
          Lubrication System Components and Oil Flow..5555
            Oil Flow..5555
        Cooling System..5558
          Cooling System Components and Flow..5558
            Water Pump..5558
            Front Crankcase Cover Flow..5558
            Thermostats..5559
            Deaeration Tank..5559
            Radiator Shutters..5559
            Fuel Coolant Valve (FCV)..5559
        Electronic Control System..5560
          Electronic Control System Components..5560
            Operation and Function..5560
            Reference Voltage (VREF)..5560
            Signal Conditioner..5561
            Microprocessor..5561
            Microprocessor memory..5561
            Flash Memory..5561
            RAM..5561
            Actuator Control..5561
          Actuators..5561
            H-bridge Circuit..5562
            Exhaust Gas Recirculation (EGR) Valve and Control..5562
            Intake Throttle Valve (ITV) Actuator and Position Sensor..5562
            Glow Plug Relay..5562
          Engine and Vehicle Sensors..5562
            Thermistor Sensors..5562
            Thermistor Sensors..5562
            Variable Capacitance Sensors..5563
            Variable Capacitance Sensors..5563
            Micro Strain Gauge (MSG) Sensor..5563
            MSG Sensors..5563
            Magnetic Pickup Sensors..5564
            Magnetic Pickup Sensors..5564
            Potentiometer..5564
            Potentiometer..5564
            Switches..5565
            Switches..5565
          Glow Plug Control System..5566
      Table of Contents..5567
        Mounting Engine ..5569
      Table of Contents..5573
        Engine Electronic Components..5575
        Description of Engine Sensors, Valves, and Actuators..5579
          Crankshaft Position (CKP) Sensor..5579
          Camshaft Position (CMP) Sensor..5579
          Exhaust Back Pressure (EBP) Sensor..5579
          Engine Coolant Temperature (ECT) Sensor..5580
          Engine Oil Temperature (EOT) Sensor..5580
          Engine Oil Pressure (EOP) Sensor..5580
          Engine Fuel Pressure (EFP) Sensor (optional)..5580
          Engine Fuel Temperature (EFT) Sensor..5581
          Water in Fuel (WIF) Sensor..5581
          Fuel Heater..5581
          Manifold Air Temperature (MAT) Sensor..5581
          Manifold Absolute Pressure (MAP) Sensor..5582
          Intake Throttle Valve (ITV)..5582
          Fuel Rail Pressure (FRP) Sensor..5582
          Exhaust Gas Recirculation (EGR) Valve ..5583
          Variable Geometry Turbocharger (VGT) Actuator..5583
        Removal..5584
          Crankshaft Position (CKP) Sensor..5584
          Camshaft Position (CMP) Sensor..5584
          Exhaust Back Pressure (EBP) Sensor..5585
          Engine Coolant Temperature (ECT) Sensor..5585
          Engine Oil Temperature (EOT) Sensor and Engine Oil Pressure (EOP) Sensor..5585
          Engine Fuel Temperature (EFT) Sensor and Engine Fuel Pressure (EFP) Sensor..5586
          Water In Fuel (WIF) Sensor..5586
          Fuel Heater..5586
          Manifold Air Temperature (MAT) Sensor and Manifold Absolute Pressure (MAP) Sensor..5587
          Intake Throttle Valve (ITV)..5587
          Exhaust Gas Recirculation (EGR) Valve Connector..5587
          Variable Geometry Turbocharger (VGT) Actuator..5587
          Glow Plug Harness Assemblies..5588
          Glow Plug Relay..5588
          Electronic Control Module (ECM) and Support..5588
          Under Valve Cover (UVC) Harnesses..5590
          Fuel Rail Pressure (FRP) Sensor..5591
          Main Engine Wiring Harness..5591
        Cleaning and Inspection..5592
          Main Engine Wiring Harness..5592
          Sensors and Valves..5592
          Glow Plug Relay..5592
          Glow Plug Harness..5592
          ECM..5592
        Installation..5593
          Main Engine Wiring Harness..5593
          Fuel Rail Pressure (FRP) Sensor..5593
          Under Valve Cover (UVC) Harnesses..5594
          Electronic Control Module (ECM) and Support..5595
          Glow Plug Relay..5596
          Glow Plug Harness Assemblies..5596
          Variable Geometry Turbocharger (VGT) Actuator..5596
          Exhaust Gas Recirculating (EGR) Valve Connector..5596
          Intake Throttle Valve (ITV) Connector..5597
          Manifold Air Temperature (MAT) Sensor and Manifold Absolute Pressure (MAP) Sensor..5597
          Fuel Heater..5597
          Water In Fuel (WIF) Sensor..5598
          Engine Fuel Temperature (EFT) Sensor and Engine Fuel Pressure (EFP) Sensor..5598
          Engine Oil Temperature (EOT) Sensor and Engine Oil Pressure (EOP) Sensor..5599
          Engine Coolant Temperature (ECT) Sensor..5599
          Exhaust Back Pressure (EBP) Sensor..5599
          Camshaft Position (CMP) Sensor..5600
          Crankshaft Position (CKP) Sensor..5600
      Table of Contents..5603
        Exploded Views..5605
        Removal..5609
          Exhaust Gas Recirculation (EGR) Valve Assembly..5609
          Exhaust Gas Recirculation (EGR) Cooler..5610
          Intake Throttle Valve (ITV) and Exhaust Gas Recirculation (EGR) Valve Elbow Housing..5613
        Cleaning, Inspection, and Testing..5614
          Clean and Inspect Exhaust Gas Recirculation (EGR) System Components..5614
          Exhaust Gas Recirculation (EGR) Valve Assembly..5614
          Exhaust Gas Recirculation (EGR) Cooler..5614
          Exhaust Gas Recirculation (EGR) Valve Elbow Housing..5614
        Installation..5615
          Intake Throttle Valve (ITV) and Exhaust Gas Recirculation (EGR) Valve Elbow Housing..5615
          Exhaust Gas Recirculation (EGR) Cooler..5615
          Exhaust Gas Recirculation (EGR) Valve Assembly..5618
      Table of Contents..5621
        Description..5623
          Exploded View..5623
          Operation..5624
        Removal..5625
          Left Exhaust Tube..5625
          Right Exhaust Tube..5626
          Variable Geometry Turbocharger (VGT) Assembly and Components..5626
          Turbo Actuator Assembly..5630
        Cleaning and Inspection..5631
          Variable Geometry Turbocharger (VGT) Assembly and Related Parts Cleaning..5631
          Inspection..5631
          Check Free Rotation and Housing Rub..5631
          Check Axial End Play..5631
        Installation..5633
          Turbo Actuator Assembly..5633
          Variable Geometry Turbocharger (VGT) Assembly and Components..5634
          Right Exhaust Tube..5637
          Left Exhaust Tube..5638
      Table of Contents..5641
        Exploded Views..5643
          Air Compressor..5643
          Power Steering/Fuel Pump and Related Components..5644
        Removal..5645
          Air Compressor..5645
          Air Compressor Bracket and Components..5646
          Power Steering Lines..5648
          Power Steering/Fuel Pump..5649
        Cleaning..5650
          All Components..5650
        Installation..5650
          Power Steering/Fuel Pump..5650
          Power Steering Lines..5650
          Air Compressor Bracket and Components..5652
          Air Compressor..5653
      Table of Contents..5657
        Exploded Views..5659
        Removal..5664
          Primary Fuel Filter Element..5664
          Secondary Fuel Filter Element..5665
          Primary Fuel Filter Assembly and Tubing..5665
          Fuel Primer Pump Assembly and Tubing..5667
          Secondary Fuel Filter and Tubing..5669
          Tubing to High-pressure Fuel Pump (HPFP) Assembly ..5672
          High-pressure Fuel Pump Assembly..5676
          Fuel Cooler Assembly..5678
          Fuel Injectors and Fuel Rail to Injectors Tube Assemblies..5678
        Inspection..5678
        Installation..5679
          Fuel Injectors and Fuel Rail to Injectors Tube Assemblies..5679
          Fuel Cooler Assembly..5679
          High-pressure Fuel Pump Assembly..5680
          Tubing to High-pressure Fuel Pump (HPFP) Assembly ..5681
          Secondary Fuel Filter and Tubing..5686
          Fuel Primer Pump Assembly and Tubing..5690
          Primary Fuel Filter Assembly and Tubing..5691
          Secondary Fuel Filter Element..5693
          Primary Fuel Filter Element..5693
      Table of Contents..5697
        Exploded Views..5699
          Exhaust Manifolds..5699
          Intake Manifold..5700
        Removal..5701
          Exhaust Manifolds..5701
            Left Exhaust Manifold..5701
            Right Exhaust Manifold..5702
          Intake Manifold..5703
        Cleaning, Inspection, and Testing..5704
          Intake and Exhaust Manifolds..5704
          Manifold Warp Test for Exhaust Manifolds..5704
        Installation..5705
          Intake Manifold..5705
          Exhaust Manifolds..5706
            Right Exhaust Manifold..5707
            Left Exhaust Manifold..5708
      Table of Contents..5711
        Exploded Views..5713
        Removal..5721
          Alternator and Freon? Mounting Bracket..5721
          Front Engine Mount Bracket..5722
          Thermostat Assemblies and Housing..5722
          Fan Drive..5723
          Water Pump Assembly..5723
          Vibration Damper..5724
          Front Oil Seal and Wear Sleeve..5725
          Front Crankcase Cover..5726
          Oil Pump Housing Assembly..5727
        Cleaning, Inspection, and Testing..5728
          Vibration Damper..5728
          Oil Gerotor Pump..5728
          Front Crankcase Cover and Water Pump Assembly..5729
          Thermostat Assembly..5729
        Installation..5731
          Oil Pump Housing Assembly..5731
          Front Crankcase Cover..5731
          Front Oil Seal and Wear Sleeve..5732
          Vibration Damper..5733
          Water Pump Assembly..5734
          Fan Drive..5735
          Thermostat Assemblies and Housing..5735
          Front Engine Mount Bracket..5736
          Alternator and Freon? Mounting Bracket..5736
      Table of Contents..5741
        Exploded Views..5743
        Removal..5747
          Valve Covers and Related Components..5747
            Breather Assembly and Components..5747
            Left Valve Cover..5750
            Right Valve Cover..5751
          Fuel Injector and Rail Assemblies..5751
          Glow Plugs..5753
          Valve Cover Base..5753
          Rocker Arm Support, Push Rods, and Valve Bridges..5754
          Cylinder Heads..5755
          Roller Hydraulic Cam Followers..5756
          Valves..5757
          Fuel Injector Sleeves..5757
          Glow Plug Sleeves..5758
          Dual Fulcrum Plate Assemblies..5759
        Cleaning, Inspection, and Testing..5761
          Cylinder Head and Crankcase Components..5761
          Cylinder Head Inspection ? Valves Installed..5761
          Cylinder Head Inspection ? Valves Removed..5764
          Push Rods..5765
          Valves..5765
          Valve Springs..5766
          Valve Stem Keys..5767
          Fuel Injector Sleeve Bore and Gallery..5767
          Glow Plug Sleeve Bore..5767
          Dual Rocker Fulcrums..5767
        Installation..5769
          Dual Fulcrum Plate Assemblies..5769
          Glow Plug Sleeves..5770
          Fuel Injector Sleeves..5770
          Valves..5771
          Roller Hydraulic Cam Followers..5772
          Cylinder Heads..5774
          Rocker Arm Supports, Push Rods, and Valve Bridges..5776
          Valve Cover Base..5778
          Glow Plugs..5779
          Fuel Injector and Rail Assemblies..5779
          Valve Covers and Related Components..5782
            Right Valve Cover..5782
            Left Valve Cover..5782
            Breather Assembly and Components..5783
      Table of Contents..5789
        Exploded Views..5791
        Removal..5794
          Oil Filter Housing and Oil Filter Base Assemblies..5794
          Oil Cooler Cover Assembly..5795
        Cleaning, Inspection, and Testing..5797
          Oil Cooler Cover and Oil Filter Base Assemblies..5797
          Oil Cooler Cover Assembly Leaks (Coolant Side)..5797
        Installation..5798
          Oil Cooler Cover Assembly..5798
          Oil Filter Housing and Oil Filter Base Assemblies..5798
      Table of Contents..5803
        Exploded Views..5805
        Removal..5811
          Engine Mount Rear Brackets..5811
          Flywheel Assembly (Manual Transmission)..5812
          Flex Plate flywheel Assembly (Automatic Transmission)..5813
          Crankshaft Rear Oil Seal and Wear Sleeve..5813
          Crankshaft Rear Oil Seal Carrier and Power Steering Idler Gear Assembly..5814
          Crankshaft Flange..5815
          Flywheel Housing and Power Steering Idler Shaft..5816
        Cleaning, Inspection, and Measurement..5818
          Flex Plate Flywheel Assembly (Automatic Transmission)..5818
          Flywheel Assembly (Manual Transmission)..5818
          Flywheel Surface Runout..5818
          Flywheel Housing Runout..5819
          Backlash Measurement for Power Steering Idler Gear Assembly..5819
        Installation..5820
          Flywheel Housing..5820
          Power Steering Idler Shaft..5820
          Crankshaft Flange..5822
          Power Steering Idler Gear Assembly and Crankshaft Rear Oil Seal Carrier..5823
          Crankshaft Rear Oil Seal and Wear Sleeve..5824
          Flex Plate Flywheel Assembly (Automatic Transmission)..5826
          Flywheel Assembly (Manual Transmission)..5827
          Engine Mount Rear Brackets..5828
      Table of Contents..5831
        Exploded Views..5833
        Removal..5834
          Lower Oil Pan..5835
          Oil Pickup Tube..5836
          Upper Oil Pan..5836
        Cleaning and Inspection..5836
          Lower Oil Pan..5836
          Oil Pickup Tube..5836
          Upper Oil Pan..5837
        Installation..5837
          Upper Oil Pan..5837
          Oil Pickup Tube..5837
          Lower Oil Pan..5838
      Table of Contents..5841
        Exploded View..5843
        Removal..5844
          Preliminary Checks..5844
          Connecting Rod and Piston Assembly..5845
          Piston Disassembly..5847
        Cleaning and Inspection..5848
          Pistons..5848
          Piston Rings..5850
          Connecting Rods..5850
          Connecting Rod Bore Out-of-round Check..5850
          Connecting Rod Bearing Fit Check..5851
          Piston Pin Inspection..5852
        Installation..5853
          Piston Assembly..5853
          Connecting Rod and Piston Assembly..5854
      Table of Contents..5859
        Exploded View..5861
        Removal..5862
          Preliminary Checks..5862
          Lower Crankcase Assembly..5864
          Crankshaft Assembly..5864
          Piston Cooling Tubes..5865
          Camshaft Assembly..5865
          Camshaft Bushings..5866
          Coolant Heater..5866
        Cleaning, Inspection, and Testing..5867
          Crankcase Assembly..5867
            Crankcase Cleaning..5867
            Crankcase Inspection..5868
            Cylinder Deglazing..5869
          Crankshaft Assembly..5869
          Main Bearing Fit Check..5870
          Piston Cooling Tubes..5871
          Camshaft Assembly..5871
          Measuring Camshaft Bushings..5872
          Coolant Heater..5872
        Installation..5873
          Camshaft Bushings..5873
          Camshaft Assembly..5873
          Piston Cooling Tubes..5874
          Crankshaft Assembly..5874
          Lower Crankcase Assembly..5875
          Coolant Heater..5877
      Table of Contents..5881
        Abbreviations and Acronyms..5883
          Abbreviations and Acronyms..5883
      Table of Contents..5887
        Terminology..5889
          Terms..5889
      Table of Contents..5895
        Variable Geometry Turbocharger (VGT)..5897
        Fuel System..5897
        Intake and Exhaust Manifolds..5897
        Front Cover, Cooling System, and Related Components..5898
        Cylinder Head and Valve Train..5898
        Oil Cooler and Filter Housing..5900
        Flywheel and Flywheel Housing..5900
        Crankcase, Crankshaft, and Camshaft..5902
      Table of Contents..5905
        General Torque..5907
          Bolt Identification..5907
          General Torque Guidelines..5908
          Standard Torque Charts..5909
          Using a Torque Wrench Extension..5910
        Special Torques..5911
          Mounting Engine on Stand..5911
          Engine Electrical..5911
          Exhaust Gas Recirculation (EGR) System..5911
          Variable Geometry Turbocharger (VGT)..5912
          Air Compressor and Power Steering/Fuel Pump..5912
          Fuel System..5913
          Intake and Exhaust Manifolds..5914
          Front Cover, Cooling System, and Related Components..5916
          Cylinder Head and Valve Train..5917
          Oil Cooler and Filter Housing..5919
          Flywheel and Flywheel Housing..5919
          Lower Oil Pan, Upper Oil Pan, and Oil Pickup Tube..5920
          Power Cylinders..5920
          Crankcase, Crankshaft, and Camshaft..5921
      Table of Contents..5923
        Special Tools..5925
          Mounting Engine on Stand..5925
          Engine Electrical..5925
          Exhaust Gas Recirculation (EGR) System..5925
          Variable Geometry Turbocharger (VGT)..5925
          Air Compressor and Power Steering/Fuel Pump..5925
          Fuel System..5926
          Intake and Exhaust Manifolds..5926
          Front Cover, Cooling System, and Related Components..5926
          Cylinder Head and Valve Train..5927
          Oil Cooler and Filter Housing..5928
          Flywheel and Flywheel Housing..5928
          Power Cylinders..5928
          Crankcase, Crankshaft, and Camshaft..5929
        Special Tools ..5930
          Essential Tools..5930
  tables..5523
    Summary of Changes..5523
    Technical Service Literature..5527
    International? MaxxForce? 7 Features and Specifications..5534
    The Air Management System (AMS) includes the following:..5543
    Mounting Engine on Stand..5571
    Mounting Engine on Stand..5571
    Engine Electrical..5601
    Engine Electrical..5601
    Exhaust Gas Recirculation (EGR) System..5619
    Exhaust Gas Recirculation (EGR) System..5619
    Variable Geometry Turbocharger (VGT) Shaft..5639
    Turbocharger Assembly Bolts and Clamps..5639
    Turbocharger..5639
    Air Compressor and Power Steering/Fuel Pump..5655
    Power Steering/Fuel Pump..5655
    Fuel Filter..5695
    Fuel System Components..5695
    Fuel System..5695
    Intake, Inlet, and Exhaust Manifolds..5710
    Intake, Inlet, and Exhaust Manifolds..5710
    Intake, Inlet, and Exhaust Manifolds..5710
    Front Cover, Cooling System, and Related Components..5738
    Front Cover, Cooling System, and Related Components..5739
    Front Cover, Cooling System, and Related Components..5739
    Cylinder Head and Valve Train..5786
    Cylinder Head and Valve Train..5787
    Cylinder Head and Valve Train..5788
    Oil Cooler and Oil Filter ..5801
    Oil Cooler Cover and Oil Filter Housing..5801
    Oil Cooler..5801
    Flywheel Assembly and Flywheel Housing..5829
    Lower Oil Pan..5839
    Power Cylinders..5857
    Power Cylinders..5858
    Power Cylinders..5858
    Crankcase, Crankshaft, and Camshaft..5878
    Crankcase, Crankshaft, and Camshaft..5879
    Crankcase, Crankshaft, and Camshaft..5879
    Variable Geometry Turbocharger (VGT) Shaft..5897
    Fuel Filter..5897
    Intake, Inlet, and Exhaust Manifolds..5897
    Front Cover, Cooling System, and Related Components..5898
    Cylinder Head and Valve Train..5898
    Oil Cooler and Oil Filter ..5900
    Flywheel and Flywheel Housing..5900
    Power Cylinders..5900
    Crankcase, Crankshaft, and Camshaft..5902
    Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs..5909
    Thread Diameter (mm)..5909
    Thread Pitch (mm)..5909
    Torque..5909
    Mounting Engine on Stand..5911
    Engine Electrical..5911
    Exhaust Gas Recirculation (EGR) System..5911
    Turbocharger Assembly Bolts and Clamps..5912
    Air Compressor and Power Steering/Fuel Pump..5912
    Fuel System Components..5913
    Intake, Inlet, and Exhaust Manifolds..5915
    Front Cover, Cooling System, and Related Components..5916
    Cylinder Head and Valve Train..5918
    Oil Cooler Cover and Oil Filter Housing..5919
    Flywheel and Flywheel Housing..5920
    Lower Oil Pan..5920
    Power Cylinders..5920
    Crankcase, Crankshaft, and Camshaft..5921
    Mounting Engine on Stand..5925
    Engine Electrical..5925
    Exhaust Gas Recirculation (EGR) System..5925
    Turbocharger..5925
    Power Steering/Fuel Pump..5925
    Fuel System..5926
    Intake, Inlet, and Exhaust Manifolds..5926
    Front Cover, Cooling System, and Related Components..5926
    Cylinder Head and Valve Train..5927
    Oil Cooler..5928
    Flywheel and Flywheel Housing..5928
    Power Cylinders..5928
    Crankcase, Crankshaft, and Camshaft..5929
0000002581 - 2007 MaxxForce DT, 9, and 10 Engine Diagnostic Manual..5936
  toc..5938
    Highlights..5938
    Safety Terminology..5944
    Safety Instructions..5944
    Work Area..5944
    Safety Equipment..5944
    Protective Measures..5944
    Vehicle..5944
    Engine..5944
    Fire Prevention..5944
    Batteries..5944
    Compressed Air..5945
    Tools..5945
    Fluids Under Pressure..5945
    Fuel..5945
    Removal of Tools, Parts, and Equipment..5945
      Table of Contents..5946
        Engine Identification..5948
          Engine Serial Number..5948
          Engine Serial Number Examples..5948
          Engine Serial Number Codes..5948
          Engine Emission Label..5948
          Engine Accessory Labels..5948
          Engine Description..5949
            Standard Features..5950
            Optional Features..5951
            Optional Cold Climate Features..5951
            Chassis Mounted Features..5951
          Engine Component Locations..5952
        Air Management System..5957
          Air Flow..5958
          Air Management Components..5958
            Charge Air Cooler (CAC)..5958
            Exhaust Gas Recirculation (EGR) System..5959
            EGR Flow..5960
            EGR Control Valve..5960
            EGR Closed Loop System..5960
            Variable Geometry Turbocharger (VGT)..5961
            VGT Closed Loop System..5962
            VGT Control..5962
            Aftertreatment (AFT) System..5963
            AFT Control System..5963
            Sensors..5963
            Diesel Oxidation Catalyst (DOC)..5963
            Diesel Particulate Filter (DPF)..5963
            AFT Conditions and Responses..5963
        Fuel Management System..5964
          ICP System..5965
            High-Pressure Oil Flow..5965
            ICP Closed Loop System..5966
            ICP Control System..5967
            Fuel Injector..5968
            Fuel Injector Features..5968
            Injector Coils and Spool Valve..5968
            Intensifier Piston and Plunger..5968
            Plunger and Barrel..5968
            Injector Needle..5968
            Fuel Injector Operation..5969
            Fill Stage..5969
            Injection..5969
            End of Injection..5969
        Fuel Supply System..5970
          Fuel Supply System Flow..5971
        Engine Lubrication System..5974
          Oil Flow..5975
        Engine Cooling System..5977
          Cooling System Flow..5978
          Cooling System Components..5978
            Coolant Heater (optional)..5978
            Thermostat Operation..5979
        Electronic Control System..5979
          Electronic Control System Components..5979
            Operation and Function..5980
            Reference Voltage (VREF)..5981
            Signal Conditioner..5981
            Microprocessor..5981
            Microprocessor Memory..5981
            ROM..5981
            RAM..5981
            Actuator Control..5982
          Actuators..5982
            EGR Valve..5982
            IAH Relays..5982
            Intake Throttle Actuator and Position Sensor..5982
          Engine and Vehicle Sensors and Switches..5983
            Thermistor Sensors..5983
            Aftertreatment Sensors..5983
            ECT Sensor..5984
            EOT Sensor..5984
            IAT Sensor..5984
            MAT Sensor..5984
            Variable Capacitance Sensors..5985
            EGDP Sensor..5985
            EFP Sensor..5985
            EOP Sensor..5985
            EBP Sensor..5985
            MAP Sensor..5985
            Magnetic Pickup Sensors..5986
            CKP Sensor..5986
            CMP Sensor..5986
            VSS..5986
            Micro Strain Gauge (MSG) Sensors..5987
            BCP..5987
            ICP..5987
            Potentiometer..5988
            APS..5988
            Switches..5989
            DDS..5989
            ECL..5989
            IVS..5989
            WIF..5989
          Intake Throttle Valve..5990
        Diamond Logic? Brake System..5991
        BCP..5992
        BSV..5992
        Brake Pressure Relief Valve..5992
        EBP..5992
        High-Pressure Oil Manifold..5992
        VGT..5992
          Brake Operation Modes..5992
          Coast Mode..5992
          Latched Mode..5992
          Cruise Mode..5992
          Exhaust Brake System..5992
          Operation..5992
          Engine Brake System..5993
          Operation..5993
      Table of Contents..5996
        Standard Features..5998
          Electronic Governor Control..5998
          American Trucking Association (ATA) Datalink ..5998
          Service Diagnostics..5998
          Event Logging System..5998
          Electronic Speedometer and Tachometer..5998
          Aftertreatment System..5998
          Engine Fuel Pressure (EFP) Monitor..5998
          Inlet Air Heater (IAH)..5998
          Fast Idle Advance..5998
          Cold Ambient Protection (CAP)..5999
          Coolant Temperature Compensation..5999
          Engine Crank Inhibit (ECI)..5999
          Change Engine Oil Interval Message..5999
        Optional Features..6000
          Road Speed Limiting..6000
          Cruise Control..6000
          Traction Control..6000
          Diamond Logic? Brake System..6000
          Engine Warning Protection System (EWPS)..6000
          Idle Shutdown Timer (IST)..6000
          IST for California ESS Compliant Engines..6000
          Engine Idle Shutdown Timer (Federal?Optional)..6001
          Electronic Fan (EFAN)..6001
          Radiator Shutter Enable (RSE)..6001
      Table of Contents..6002
        MasterDiagnostics? Software..6004
          Open Application..6004
          Choose COM Device..6004
          Retrieve Engine Information..6004
          Open Diagnostic Form..6004
          Open MasterDiagnostics? Software..6004
        Electronic Service Tool (EST) Communication Diagnostics..6005
          IC4 Interface Device Self Test..6005
        Communications (COM)..6007
          Open Communications..6007
          Close Communications..6007
        Diagnostic Trouble Codes (DTCs)..6008
          Reading DTCs with EST..6008
          DTC Help Menu..6009
          Clearing DTCs..6011
        Session Files..6012
          Opening Session File..6012
          Adding and Deleting Session Parameter Identifiers (PIDs)..6012
          Closing Session File..6014
          VIN+ Session..6014
        Snapshots..6016
          Opening Specific Snapshots..6016
          Opening Basic Snapshots..6016
          Snapshot Set-Up..6018
            Snapshot Trigger using Active DTCs..6018
            Snapshot Trigger using Parameter Identifier (PID)..6019
            Sample Rates, Pre-Trigger, and Post-Trigger Times..6021
            Snapshot PID List..6022
            Rename REC Files..6023
            Manual Trigger Snapshots..6024
          Replay Snapshot Graphic..6025
        Diagnostic Tests..6027
          Key-On Engine-Off Tests..6027
            Standard Test..6027
            Injector Test..6028
            Output State Low Test..6029
            Output State High Test..6030
            Inlet Air Heater Output State Test..6031
          Key-On Engine-Running Tests..6032
            Standard Test..6032
            Engine Aftertreatment Test..6032
            Air Management Test..6033
            VGT Test..6034
          Continuous Monitoring ? Troubleshooting Intermittent Connections..6035
          Injector Disable Test..6036
          Auto Run Feature..6037
          Relative Compression..6038
        Reset Engine Change Oil Message..6039
          Reset Message with EST..6039
        General Information..6039
          Installed MasterDiagnostics? Version..6039
          Approved Interface Cable..6039
      Table of Contents..6040
        Description..6042
        Coolant System..6042
          Combustion Leaks to Coolant..6042
          Symptom..6042
          Tools..6042
          Possible Causes..6042
          Procedure..6042
          Coolant Leak to Exhaust/Intake..6044
          Symptoms..6044
          Tools..6044
          Possible Causes..6044
            EGR Cooler Inspection..6044
            Procedure..6044
            Injector Sleeve Inspection..6045
            Procedure..6045
            Cylinder Head Leak Test..6046
          Coolant in Lube Oil..6047
          Symptom..6047
          Tools..6047
          Possible Causes..6047
            Coolant System Inspection..6047
            Procedure..6047
            Front Cover Inspection..6049
          Coolant Over-temperature..6050
          Symptoms..6050
          Tools..6050
          Possible Causes..6050
            Coolant System Inspection..6050
            Temperature Sensor Validation Test..6052
            Cooling System Operating Pressure Test..6052
        Fuel System..6053
          Priming Fuel System..6053
          Fuel Pressure, Aeration, and Supply..6054
          Symptom..6054
          Tools..6054
          Possible Causes..6054
            Fuel Pressure and Aeration..6054
            Purpose..6054
            Tools..6054
            Possible Causes..6054
            Procedure..6054
            Fuel Filter Housing Pressure..6055
            Purpose..6055
            Tools..6055
            Procedure..6055
            Fuel Inlet Restriction..6056
            Purpose..6056
            Tools..6056
            Possible Causes..6056
            Procedure..6056
            Fuel Pump Operation..6057
            Purpose..6057
            Tools..6057
            Procedure..6057
            Alternate Fuel to Fuel Pump Test..6058
            Purpose..6058
            Tools..6058
            Procedure..6058
            Alternate Fuel Supply to Fuel Filter Housing..6058
            Purpose..6058
            Tools..6058
            Procedure..6058
            Combustion Leaks to Fuel..6059
        Lubrication System..6060
          Low Oil Pressure..6060
          Symptom..6060
          Tools..6060
          Possible Causes..6060
            Oil Inspection..6060
            Oil Pressure Regulator Inspection..6061
            Oil and Crankcase Inspection..6062
            Oil Pump Inspection..6063
            Front Cover Inspection..6063
          Lube Oil in Coolant..6064
          Symptom..6064
          Tools..6064
          Possible Causes..6064
          Procedure..6064
      Table of Contents..6066
        Diagnostic Form EGED-375..6068
          Header Information..6069
          Enter Header Information..6069
          Enter Vehicle Information..6069
          Enter Performance Specification Information..6069
          Verify ECM Calibration with Vehicle Specifications..6069
        Required Test Procedures..6071
          1. Initial Ignition Switch ON (Do not start)..6071
          Purpose..6071
          Tools..6071
          Possible Causes..6071
          WAIT TO START lamp does not illuminate..6071
          No injector pre-cycle..6071
          No turbocharger pre-cycle..6071
          WATER IN FUEL lamp illuminates..6071
          Procedure..6071
          2. Engine Cranking..6072
          Purpose..6072
          Tools..6072
          Possible Causes..6072
          Engine will not turn over..6072
          Insufficient rpm..6072
          Insufficient oil pressure..6072
          Procedure..6072
          3. Visual Inspection..6073
          Purpose..6073
          Tools..6073
            Engine Oil..6073
            Fuel Level..6073
            Engine Coolant Level..6073
            Charge Air Cooler (CAC) System..6073
            Electrical System..6073
            Exhaust System..6073
          4. DTCs and ECM Calibration..6074
          Purpose..6074
          Tools..6074
            Checking ECM Calibration..6074
            Checking for DTCs..6074
            Status: Indicates active or inactive DTCs..6074
          5. EST Data List..6075
          Purpose..6075
          Tools..6075
          Procedure..6075
          6. KOEO Tests..6076
            6.1 Standard Test..6076
            Purpose..6076
            Tools..6076
            Possible Causes..6076
            Procedure..6076
            6.2 KOEO Injector Test..6076
            Purpose..6076
            Tools..6076
            Possible Causes..6076
            Procedure..6076
          7. EGR Valve and ITV Operation..6077
          Purpose..6077
          Tools..6077
          Possible Causes..6077
          Procedure..6077
        Special Test Procedures..6078
          Main Power Voltage to ECM..6078
          Purpose..6078
          Tools..6078
          Possible Causes..6078
          Low battery voltage..6078
          Low or no battery voltage to the ECM..6078
          Procedure..6078
          Inlet Air Heater (IAH) System..6079
          Purpose..6079
          Tools..6079
          Possible Causes..6079
            Amperage Draw..6079
            Procedure..6079
            Voltage at Element..6080
            Element Continuity..6081
            Wiring Harness Continuity and Resistance..6082
            Relay Operation..6082
          Fuel System..6084
            Fuel Quality..6084
            Purpose..6084
            Tools..6084
            Possible Causes..6084
            Procedure..6084
            Fuel Pressure and Aeration..6085
            Purpose..6085
            Tools..6085
            Possible Causes..6085
            Procedure..6085
            Fuel Inlet Restriction..6086
            Purpose..6086
            Tools..6086
            Possible Causes..6086
            Procedure..6086
          Injection Control Pressure..6087
            ICP Unplugged Test..6087
            Purpose..6087
            Tools..6087
            Possible Causes..6087
            Procedure..6087
            ICP System Test..6087
            Purpose..6087
            Tools..6087
            Possible Causes..6087
            Procedure..6087
            IPR Control System Test..6088
            Purpose..6088
            Tools..6088
            Possible Causes..6088
            Procedure..6088
            High-Pressure Oil Pump Test..6089
            Purpose..6089
            Tools..6089
            Possible Causes..6089
            Procedure..6089
            IPR Block-Off Test..6090
            Purpose..6090
            Tools..6090
            Possible Causes..6090
            Procedure..6090
            High-Pressure Oil Rail Leak Test..6091
            Purpose..6091
            Tools..6091
            Possible Causes..6091
            Procedure..6091
      Table of Contents..6092
        Diagnostic Form EGED-380..6094
          Header Information..6095
          Enter Header Information..6095
          Enter Vehicle Information..6095
          Enter Performance Specification Information..6095
          Verify ECM Calibration with Vehicle Specifications..6095
        Test Procedures..6097
          1. Visual Inspection..6097
          Purpose..6097
          Tools..6097
            Engine Oil..6097
            Fuel Level..6097
            Engine Coolant Level..6097
            Charge Air Cooler (CAC) System..6097
            Electrical System..6097
            Exhaust System..6098
          2. Fuel System..6098
            2.1 Fuel Quality..6098
            Purpose..6098
            Tools..6098
            Possible Causes..6098
            Procedure..6098
            2.2 Fuel Pressure and Aeration..6099
            Purpose..6099
            Tools..6099
            Possible Causes..6099
            Procedure..6099
            2.3 Fuel Inlet Restriction..6100
            Purpose..6100
            Tools..6100
            Possible Causes..6100
            Procedure..6100
          3. Sensor Compare..6101
          Purpose..6101
          Tools..6101
          Possible Causes..6101
          Procedure..6101
          4. DTCs and ECM Calibration..6102
          Purpose..6102
          Tools..6102
            Checking ECM Calibration..6102
            Checking for DTCs..6102
            Status: Indicates active or inactive DTCs..6102
          5. KOEO Standard Test..6103
          Purpose..6103
          Tools..6103
          Possible Causes..6103
          Procedure..6103
          6. EGR Valve and ITV Operation..6103
          Purpose..6103
          Tools..6103
          Possible Causes..6103
          Procedure..6103
          7. KOEO Injector Test..6104
          Purpose..6104
          Tools..6104
          Possible Causes..6104
          Procedure..6104
          8. KOER Standard Test..6104
          Purpose..6104
          Tools..6104
          Possible Causes..6104
          Procedure..6104
          9. KOER Air Management Test..6105
            9.1 Air Management Test..6105
            Purpose..6105
            Tools..6105
            Possible Causes..6105
            Procedure..6105
            9.2 VGT Test..6106
            Purpose..6106
            Tools..6106
            Procedure..6106
            9.3 VGT Actuator Linkage Test..6107
            Possible Causes..6107
            Procedure..6107
          10. Torque Converter Stall (Automatic only)..6108
          Purpose..6108
          Tools..6108
          Possible Causes..6108
          Procedure..6108
          11. Road Test (Full load, rated speed)..6108
          Purpose..6108
          Tools..6108
          Unacceptable Boost Possible Causes..6108
          Unacceptable Injection Control Pressure Possible Causes..6108
          Unacceptable Fuel Pressure Possible Causes..6109
          Procedure..6109
          12. Injector Disable..6110
          Purpose..6110
          Tools..6110
          Possible Causes..6110
          Procedure..6110
          13. Relative Compression..6111
          Purpose..6111
          Tools..6111
          Possible Causes..6111
          Procedure..6111
          14. Crankcase Pressure..6111
          Purpose..6111
          Tools..6111
          Possible Causes..6111
          Procedure..6111
          15. Intake Restriction..6114
          Purpose..6114
          Tools..6114
          Possible Causes (Option 1 and 2)..6114
            Option 1..6114
            Option 2..6114
          16. Exhaust Restriction..6115
          Purpose..6115
          Tools..6115
          Possible Causes..6115
          Procedure..6115
          17. Injection Control Pressure..6116
            17.1 ICP System Test..6116
            Purpose..6116
            Tools..6116
            Possible Causes..6116
            Procedure..6116
            17.2 IPR Control System Test..6117
            Purpose..6117
            Tools..6117
            Possible Causes..6117
            Procedure..6117
            17.3 High-Pressure Oil Pump Test..6118
            Purpose..6118
            Tools..6118
            Possible Causes..6118
            Procedure..6118
            17.4 IPR Block-Off Test..6119
            Purpose..6119
            Tools..6119
            Possible Causes..6119
            Procedure..6119
            17.5 High-Pressure Oil Rail Leak Test..6120
            Purpose..6120
            Tools..6120
            Possible Causes..6120
            Procedure..6120
          18. Valve Lash and Engine Brake Lash..6120
          Purpose..6120
          Tools..6120
          Possible Causes..6120
          Valve Lash for Intake and Exhaust Valves..6120
            Adjusting Valve Lash ..6120
            Brake Lash..6122
      Table of Contents..6124
        Description..6128
          Section Information..6128
        Electronic Control System Diagnostics Form..6129
          EGED-385 Diagnostic Form Example..6129
        Sensor and Actuator Locations..6130
          Engine Mounted Components..6130
          Vehicle Mounted Components..6135
        Diagnostic Procedure Process..6135
          Description..6135
          Pin-Grip Inspection..6135
            Diagnostics with EST..6135
            Diagnostics without EST..6135
          Sensor End Diagnostics (with MasterDiagnostics?)..6136
            Sensor End Diagnostics (2-Wire)..6136
            Sensor End Diagnostics (3-Wire)..6139
          Pin-point Diagnostics (without MasterDiagnostics? software)..6142
          Actuator Operational Voltage Check ? Output State Test..6143
          Harness Resistance Check..6144
          Operational Voltage Check..6145
        Circuit Diagnostics..6146
          ACT PWR Relay (Actuator Power)..6146
          Function..6146
          Tools..6146
            ACT PWR Relay Pin-point Diagnostics..6147
            ACT PWR Circuit Operation..6149
            Fault Detection / Management..6149
          AFT System (Aftertreatment)..6150
          Function..6151
          Tools..6151
            AFT System Diagnostics..6152
            AFT System Operation..6155
            Diesel Oxidation Catalyst (DOC)..6157
            Diesel Particulate Filter (DPF)..6157
            Regeneration..6157
            Passive Rolling Regeneration..6157
            Onboard Cleanliness Test (EST enabled)..6157
            Parked Regeneration Switch..6157
            Inhibit Regeneration Switch (optional)..6157
            DPF Soot Loading Percentage..6157
            DPF Ash Loading Percentage..6158
            DPF Status Lamp..6158
            High Exhaust System Temperature Indicator (HEST)..6158
          AMS (Air Management System)..6159
          Function..6159
          Tools..6159
            AMS Diagnostics..6160
            AMS Operation..6163
            VGT portion..6163
            EGR portion..6163
          APS/IVS (Accelerator Position Sensor and Idle Validation Switch)..6164
          Function..6164
          Sensor Location..6164
          Tools..6164
            APS/IVS Sensor End Diagnostics..6165
            APS/IVS Pin-point Diagnostics..6167
            APS/IVS Circuit Operation..6169
            APS..6169
            IVS..6169
            APS Auto-Calibration..6169
            Fault Detection / Management..6169
          ATA (American Trucking Association) Datalink..6170
          Function..6170
          Location..6170
          Tools..6170
            ATA Pin-point Diagnostics..6171
            ATA Operation..6172
            EST Connector..6172
            EGC..6172
            Fault Detection / Management..6172
            Repair Information..6172
          BCP Sensor (Brake Control Pressure)..6173
          Function..6173
          Sensor Location..6173
          Tools..6173
            BCP Sensor End Diagnostics..6174
            BCP Pin-point Diagnostics..6176
            BCP Circuit Operation..6177
            Fault Detection / Management..6177
          BOO/BPS (Brake On/Off) / (Brake Pressure Switch)..6178
          Function..6178
          Location..6178
          Tools..6178
            Brake Switch Circuits Pin-point Diagnostics..6179
            Brake Switch Circuit Operation..6180
            Fault Detection/Management..6180
          BSV (Brake Shut-off Valve)..6181
          Function..6181
          Valve Location..6181
          Tools..6181
            BSV Pin-point Diagnostics..6182
            BSV Circuit Operation..6183
            Fault Detection / Management..6183
          CAN Communications (Controller Area Network) (Public)..6184
          Function..6184
          Location..6184
          Tools..6184
            CAN (Public) Pin-point Diagnostics..6185
            CAN (Public) Circuit Operation..6186
            Public CAN versus Private CAN..6186
            EST Connector..6187
            EGC..6187
            ESC or MSM Module..6187
            Repair Information..6187
          CCS (Cruise Control System)..6188
          Function..6188
          Location..6189
          Tools..6189
            Cruise Control System Pin-point Diagnostics ..6189
          CKP Sensor (Crankshaft Position)..6190
          Function..6190
          Sensor Location..6190
          Tools..6190
            CKP Pin-point Diagnostics..6191
            CKP Circuit Operation..6192
            Fault / Detection Management..6192
          CMP Sensor (Camshaft Position)..6193
          Function..6193
          Sensor Location..6193
          Tools..6193
            CMP Pin-point Diagnostics..6194
            CMP Circuit Operation..6195
            Fault / Detection Management..6195
          Cylinder Balance..6196
            Cylinder Balance Operation..6196
            Cylinder Balance Diagnostics..6197
          EBP Sensor (Exhaust Back Pressure)..6199
          Function..6199
          Sensor Location..6199
          Tools..6199
            EBP Sensor End Diagnostics..6200
            EBP Pin-point Diagnostics..6202
            EBP Circuit Operation..6203
            Fault Detection / Management..6203
          ECI Circuit (Engine Crank Inhibit)..6204
          Function..6204
          Location..6204
          Tools..6204
            ECI Circuit Diagnostics..6205
            ECI Circuit Operation..6208
            DDS Circuit..6208
            Ignition Switch..6208
            ECI Circuit..6208
            Electronic Control Module (ECM)..6208
            Starter Relay..6208
            Clutch Switch..6208
            Neutral Switch..6208
            WTEC MD with Auto Neutral..6208
            Fault Detection / Management..6208
          ECL Switch (Engine Coolant Level)..6209
          Function..6209
          Location..6209
          Tools..6209
            ECL Pin-point Diagnostics..6210
            ECL Circuit Operation..6211
            Fault Detection / Management..6211
          ECM PWR (Electronic Control Module Power)..6212
          Function..6212
          ECM Location..6212
          Tools..6212
            ECM PWR Pin-point Diagnostics..6213
            ECM PWR Circuit Operation..6216
            Fault Detection / Management..6216
          ECM Self Diagnostics (Electronic Control Module)..6217
          Fault Detection / Management..6218
            ECM Self Diagnostic Trouble Codes (DTCs)..6219
          ECT Sensor (Engine Coolant Temperature)..6223
          Function..6224
          Sensor Location..6224
          Tools..6224
            ECT Sensor End Diagnostics..6225
            ECT Pin-point Diagnostics..6227
            ECT Circuit Operation..6227
            Coolant Temperature Compensation..6228
            Engine Warning and Protection (EWPS)..6228
            Fault Detection / Management..6228
          EFAN Control (Engine Fan Control)..6229
          Function..6229
          Location..6229
          Tools..6229
            EFAN Circuit Diagnostics..6230
            EFAN Circuit Operation..6232
            EFAN Programmable Parameters..6232
            Fault Detection / Management..6232
          EFP Sensor (Engine Fuel Pressure)..6233
          Function..6233
          Sensor Location..6233
          Tools..6233
            EFP Sensor End Diagnostics..6234
            EFP Pin-point Diagnostics..6236
            EFP Circuit Operation..6237
            Fault Detection / Management..6237
          EGDP Sensor (Exhaust Gas Differential Pressure)..6238
          Function..6239
          Sensor Location..6239
          Tools..6239
            EGDP Sensor End Diagnostics..6240
            EGDP Pin-point Diagnostics..6242
            EGDP Circuit Operation..6243
          EGR Actuator (Exhaust Gas Recirculation)..6244
          Function..6244
          Component Location..6245
          Tools..6245
            EGR Pin-point Diagnostics..6245
            EGR Circuit Operation..6248
            CAN (private) Circuit Operation..6248
            CAN (private) versus CAN (public)..6248
            CAN Repair Information..6248
          EGT1 Sensor (Exhaust Gas Temperature 1)..6249
          Function..6249
          Sensor Location..6249
          Tools..6249
            EGT1 Sensor End Diagnostics..6250
            EGT1 Pin-point Diagnostics..6252
            EGT1 Circuit Operation..6253
          EGT2 Sensor (Exhaust Gas Temperature 2)..6254
          Function..6254
          Sensor Location..6254
          Tools..6254
            EGT2 Sensor End Diagnostics..6255
            EGT2 Pin-point Diagnostics..6257
            EGT2 Circuit Operation..6258
          EGT3 Sensor (Exhaust Gas Temperature 3)..6259
          Function..6259
          Sensor Location..6259
          Tools..6259
            EGT3 Sensor End Diagnostics..6260
            EGT3 Pin-point Diagnostics..6262
            EGT3 Circuit Operation..6263
          EOP Sensor (Engine Oil Pressure)..6264
          Function..6264
          Sensor Location..6264
          Tools..6264
            EOP Sensor End Diagnostics..6265
            EOP Pin-point Diagnostics..6267
            EOP Circuit Operation..6268
            Fault Detection / Management..6268
          EOT Sensor (Engine Oil Temperature)..6269
          Function..6270
          Fast Idle Advance..6270
          Sensor Location..6270
          Tools..6270
            EOT Sensor End Diagnostics..6271
            EOT Pin-point Diagnostics..6273
            EOT Circuit Operation..6274
            Fault Detection / Management..6274
          EWPS (Engine Warning and Protection System)..6275
          Function..6275
            EWPS Programmable Parameters..6276
          IAH System (Inlet Air Heater)..6279
          Function..6279
          Component Location..6279
          Tools..6279
            IAH Pin-point Diagnostics..6280
            IAH Circuit Operation..6284
            Diagnostic Trouble Codes (DTCs)..6284
          IAT Sensor (Intake Air Temperature)..6285
          Function..6285
          Sensor Location..6285
          Tools..6285
            IAT Sensor End Diagnostics..6286
            IAT Pin-point Diagnostics..6288
            IAT Circuit Operation..6288
            Fault Detection / Management..6289
          ICP Sensor (Injection Control Pressure)..6290
          Function..6290
          Sensor Location..6290
          Tools..6290
            ICP Sensor End Diagnostics..6291
            ICP Pin-point Diagnostics..6293
            ICP Circuit Operation..6294
            Fault Detection / Management..6294
          ICP System (Injection Control Pressure)..6295
          Function..6296
          System Component Location..6296
          Tools..6296
            ICP System Diagnostics..6297
            ICP System Operation..6299
            Mechanical Operation..6299
            Electrical Operation..6299
            Fault Detection / Management..6300
          Injector Circuits..6301
          Function..6301
          Component Location..6301
          Tools..6301
            Injector 1 Checks..6302
            Injector 2 Checks..6304
            Injector 3 Checks..6306
            Injector 4 Checks..6308
            Injector 5 Checks..6310
            Injector 6 Checks..6312
            Injector Circuit Operation..6314
            High Side Drive Output..6314
            Low Side Drive Return..6314
            Fault Detection / Management..6314
            KOEO Injector Test..6314
          IPR (Injection Pressure Regulator)..6315
          Function..6315
          IPR Location..6315
          Tools..6315
            IPR Pin-point Diagnostics..6316
            IPR Circuit Operation..6318
            Fault Detection / Management..6318
          IST System (Idle Shutdown Timer)..6319
            Function..6319
            Tools..6319
            Engine Idle Shutdown timer for California ESS Compliant Engines..6320
            Engine Idle Shutdown Timer (Federal - Optional)..6321
            Common Enable Conditions for All Federal IST Options..6321
            Federal IST Mode 1: PTO Operation Option Enable Conditions..6321
            Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions..6321
            Federal IST Mode 3: Tamper Proof Option Enable Conditions..6321
            Fault Detection / Management..6321
          ITV (Intake Throttle Valve)..6322
          Function..6323
          Component Location..6323
          Tools..6323
            ITV Actuator End Diagnostics..6324
            ITV Actuator Pin-point Diagnostics..6326
            ITV Actuator Circuit Operation..6327
            ITVP sensor..6327
            ITV actuator..6327
            Fault Detection / Management..6327
          MAP Sensor (Manifold Absolute Pressure)..6328
          Function..6328
          Sensor Location..6328
          Tools..6328
            MAP Sensor End Diagnostics..6329
            MAP Pin-point Diagnostics..6331
            MAP Circuit Operation..6332
            Fault Detection / Management..6332
          MAT Sensor (Manifold Air Temperature)..6333
          Function..6333
          Sensor Location..6333
          Tools..6333
            MAT Sensor End Diagnostics..6334
            MAT Pin-point Diagnostics..6336
            MAT Circuit Operation..6336
            Fault Detection / Management..6337
          RSE (Radiator Shuttle Enable)..6338
          Function..6338
          Tools..6338
            RSE Circuit Diagnostics..6339
            RSE Circuit Operation..6340
            Fault Detection / Management..6340
            Diagnostic Trouble Codes (DTCs)..6340
          Tachometer Output Circuit..6341
            Tachometer Pin-point Diagnostics..6342
            Tachometer Circuit Operation..6342
            Diagnostic Trouble Codes (DTCs)..6342
          VGT (Variable Geometry Turbocharger) Actuator..6343
          Function..6343
          Component Location..6344
          Tools..6344
            VGT Actuator End Diagnostics..6344
            VGT Actuator Circuit Operation..6347
            CAN (private) Circuit Operation..6347
            CAN (private) versus CAN (public)..6347
            CAN Repair Information..6347
          VREF (Reference Voltage)..6348
          Function..6348
          Tools..6349
            VREF Pin-point Diagnostics..6350
            VREF Circuit Operation..6354
            Fault Detection / Management..6354
          VSS (Vehicle Speed Sensor)..6355
          Function..6355
          Tools..6355
          VREF Pin-point Diagnostics..6356
            VSS Pin-point Diagnostics (Manual Transmissions)..6356
            VSS Pin-point Diagnostics (Allison Transmissions)..6358
            VSS Circuit Operation (Manual and Allison Transmissions)..6359
            Fault Detection / Management..6359
          WIF Sensor (Water In Fuel)..6360
          Function..6360
          Sensor Location..6360
          Tools..6360
            WIF Pin-point Diagnostics..6361
            WIF Circuit Operation..6362
            Fault Detection/Management..6362
      Table of Contents..6364
        Electrical Tools..6366
          3-Banana Plug Harness..6366
          4-Pin Actuator Breakout Harness..6366
          8-Pin Injector Harness..6366
          16-Pin Breakout Harness..6366
          180-Pin Breakout Box..6367
          500 Ohm Resistor Harness..6367
          Actuator Breakout Harness (IPR)..6367
          Amp Clamp..6368
          APS/IVS Sensor Breakout Harness..6368
          Breakout Harnesses Kit..6368
          Breakout Harnesses Kit..6369
          Digital Multimeter (Fluke 88V)..6369
          EGR Valve Breakout Harness..6370
          EZ-Tech? Electronic Service Tool (EST)..6370
            MasterDiagnostics? Software..6370
          Exhaust Pressure Breakout Harness..6371
          Exhaust Temperature Breakout Harness..6371
          EZ-Tech? Interface Kit..6371
          ITV Breakout Harness ..6371
          MAT Breakout Harness ..6372
          Pressure Sensor Breakout Harness ..6372
          Relay Breakout Harness..6372
          Relay Breakout Harness..6372
          Temperature Sensor Breakout Harness..6373
          Temperature Sensor Breakout Harness..6373
          Terminal Test Adapter Kit..6373
        Mechanical Tools..6373
          Charge Air Cooler Test Kit..6373
          Pressure Vacuum Module..6374
          Crankcase Pressure Test Adapter..6374
          Fuel Inlet Restriction Adapter..6375
          Fuel/Oil Pressure Test Coupler..6375
          Fuel Pressure Gauge..6375
          Fuel Pressure Test Kit..6376
          Fuel Test Fitting..6376
          Gauge Bar Tool..6376
          ICP System Test Adapter..6377
          ICP Test Kit..6377
          Inline Shut-off Valve..6377
          IPR Test Adapter..6377
          Digital Manometer..6378
          Slack Tube Manometer..6378
          UV Leak Detection Kit..6379
          Vacuum Pump and Gauge..6380
        Electronic Circuit Testing..6380
          Electrical Theory..6380
            Voltage..6380
            Ohm's Law ..6380
          Using the Digital Multimeter..6381
            Test Meters..6382
            Jumper Wires..6382
            Voltmeter..6383
            Ammeter..6384
            Ohmmeter..6385
            Measuring Duty Cycle with FLUKE 88..6387
          Troubleshooting..6389
      Table of Contents..6390
        Abbreviations and Acronyms..6392
          Abbreviations and Acronyms..6392
      Table of Contents..6396
        Terminology..6398
          Terms..6398
      Table of Contents..6404
        All Ratings..6406
        MaxxForce? DT (7.6L)..6410
          210 hp @ 2600 rpm (12NSK)..6410
          225 hp @ 2600 rpm (12NSM)..6411
          225 hp @ 2600 rpm (12NSL)..6412
          230 hp @ 2400 rpm (12NSV)..6413
          245 hp @ 2600 rpm (12NSG)..6414
          255 hp @ 2600 rpm (12NSZ)..6415
          260 hp @ 2400 rpm (12NTA)..6416
          285 hp @ 2400 rpm (12NTB)..6417
          300 hp @ 2400 rpm (12NSH)..6418
          300 hp @ 2400 rpm (12)..6419
        MaxxForce? 9 (9.3L)..6420
          300 hp @ 2200 rpm (12NTC)..6420
          310 hp @ 2200 rpm (12NSJ)..6422
          330 hp @ 2200 rpm (12NSX)..6423
        MaxxForce? 10 (9.3L)..6424
          310 hp @ 2100 rpm (12NST)..6424
          310 hp @ 2200 rpm (12NSU)..6426
          330 hp @ 2100 rpm (12NSP)..6427
          330 hp @ 2200 rpm (12NSW)..6428
          350 hp @ 2100 rpm (12NSN)..6429
          350 hp @ 2200 rpm (12NSY)..6430
      Table of Contents..6432
        Diagnostic Trouble Codes..6434
      Table of Contents..6442
        Description..6444
  tables..5938
    Summary of Changes..5938
    Technical Service Literature..5942
    MaxxForce? DT, 9, and 10 Diesel Engines..5949
    Example..6038
    Example..6038
    Valve and brake lash adjustments (inches) with piston 1 at TDC compression..6121
    Valve and brake lash adjustments (inches) with piston 6 at TDC compression..6121
    Example..6137
    Example..6137
    Example..6137
    Example..6138
    Example..6140
    Example..6140
    Example..6140
    Example..6141
    Example..6141
    Example..6142
    Example..6143
    Example..6144
    Example..6145
    Voltage Checks at 16-Pin Connector..6148
    Voltage Checks at Relay..6148
    Main Power Relay Resistance Check..6148
    Harness Resistance Check on Relay Power Circuits..6149
    Alert Levels of DPF Soot Loading..6152
    Active Rolling Regeneration..6156
    Manual Parked Regeneration..6156
    Manual Parked Regeneration Procedure..6157
    DTC 2351 - EBP below desired level..6161
    DTC 2352 - EBP above desired level..6161
    DTC 2388 - EGR flow excessive - possible leak to atmosphere..6162
    DTC 2389 - EGR flow insufficient - possible plugged system..6162
    DTC 3346 - AMT - EBP unable to build during EGR test..6162
    DTC 3348 - AMT - EBP too high during EGR test..6163
    Sensor Circuit Check..6166
    Connector Voltage Check..6167
    Connector Resistance Check to Engine GND..6167
    Harness Resistance Check..6168
    Operational Voltage Check..6168
    Connector Voltage Check - EST..6171
    Harness Resistance Check..6171
    Sensor Circuit Check..6175
    Connector Voltage Check..6176
    Connector Resistance Check to Engine GND..6176
    Under Valve Cover Resistance Check..6177
    Harness Resistance Check..6177
    Brake Switch Circuits..6179
    Voltage Check..6180
    Harness Resistance Check..6180
    Connector Voltage Check..6182
    Connector Resistance Checks to GND..6182
    Actuator Resistance Check..6183
    Harness Resistance Check..6183
    Connector Voltage Check..6185
    EST Communication Check..6186
    Harness Resistance Check..6186
    Switch Checks..6189
    Sensor and Circuit Resistance Check..6191
    Harness Resistance Check..6192
    Operational Checks..6192
    Sensor and Circuit Resistance Check..6194
    Harness Resistance Check..6194
    Operational Checks..6195
    Sensor Circuit Check..6201
    Connector Voltage Check..6202
    Connector Resistance Check to GND..6202
    Harness Resistance Check..6203
    Voltage Check at Relay..6206
    Voltage Check at ECM..6206
    Harness Resistance Check ? ECM to Relay..6207
    Harness Resistance Check ? Relay to Battery..6207
    Operational Voltage Check..6207
    Connector Voltage Check..6210
    Connector Resistance Check to GND..6210
    Switch Resistance Check..6210
    Harness Resistance Check..6211
    Voltage Checks at Relay..6214
    Voltage Checks at ECM..6214
    Harness Resistance Check..6215
    Harness Resistance Check on Relay Power Circuits..6215
    DTC 1151 - BAP signal out-of-range HIGH..6219
    DTC 1152 - BAP signal out-of-range LOW..6219
    DTC 5382 - ECM Error - over temperature..6219
    DTC 5618 - ECM Error - SPI-BUS error 1..6219
    DTC 5619 - ECM Error - SPI-BUS error 2..6219
    DTC 5627 - ECM Error - Checksum program..6219
    DTC 5628 - ECM Error - Checksum dataset..6219
    DTC 5632 - ECM Error - Random Access Memory (RAM) - CPU self-test fault..6220
    DTC 5633 - ECM Error - CPU Load above maximum..6220
    DTC 5634 - ECM Error - MQPS daisy chain failure..6220
    DTC 5635 - ECM Error - OCT daisy chain failure..6220
    DTC 5636 - ECM Error - QPS daisy chain failure..6220
    DTC 5641 - ECM Error - CC monitoring..6220
    DTC 5642 - ECM Error - Fuel Cut Off monitoring..6221
    DTC 5643 - ECM Error - Post Inj monitoring..6221
    DTC 5644 - ECM Error - Engine speed limitation..6221
    DTC 5645 - ECM Error - EEPROM failure..6221
    DTC 5646 - ECM Error - Engine Speed monitoring..6221
    DTC 5647 - ECM Error - PVS monitoring..6221
    DTC 5648 - ECM Error - PTO monitoring..6221
    DTC 5649 - ECM Error - A/D conversion monitoring..6222
    DTC 5651 - ECM Error - MFMA monitoring..6222
    DTC 5652 - ECM Error - NVMY monitoring..6222
    DTC 5653 - ECM Error - PPS monitoring..6222
    DTC 5654 - ECM Error - CAN monitoring..6222
    DTC 5655 - ECM Error - Service Tool monitoring..6222
    DTC 5656 - ECM Error - Processor monitoring..6222
    Sensor Circuit Check..6226
    Connector Voltage Check..6227
    Connector Resistance Checks to GND..6227
    Harness Resistance Check..6227
    Voltage Check at EFAN Connector - Output State Test..6230
    Voltage Check at Relay - Output State Test..6231
    Harness Resistance Check..6231
    Sensor Circuit Check..6235
    Connector Voltage Check..6236
    Connector Resistance Check to GND..6236
    Harness Resistance Check..6237
    Sensor Circuit Check..6241
    Connector Voltage Check..6242
    Connector Resistance Checks to GND..6242
    Harness Resistance Check..6243
    Connector Voltage Check..6247
    Harness Resistance Check..6247
    Sensor Circuit Check..6251
    Connector Voltage Check..6252
    Connector Resistance Checks to GND..6252
    Harness Resistance Check..6252
    Sensor Circuit Check..6256
    Connector Voltage Check..6257
    Connector Resistance Checks to GND..6257
    Harness Resistance Check..6257
    Sensor Circuit Check..6261
    Connector Voltage Check..6262
    Connector Resistance Checks to GND..6262
    Harness Resistance Check..6262
    Sensor Circuit Check..6266
    Connector Voltage Check..6267
    Connector Resistance Check to GND..6267
    Harness Resistance Check..6268
    Sensor Circuit Check..6272
    Connector Voltage Check..6273
    Connector Resistance Checks to GND..6273
    Harness Resistance Check..6273
    Voltage Check on Relay Switch ? Output State Test..6281
    Voltage Check on Relay Coil ? Output State Test..6281
    Amperage Draw Check..6282
    Element Resistance Check..6282
    Harness Resistance Check ? Relay Coil Circuits..6283
    Harness Resistance Check ? Relay Switch Circuits..6283
    Sensor Circuit Check..6287
    Connector Voltage Check..6288
    Connector Resistance Checks to GND..6288
    Harness Resistance Check..6288
    Sensor Circuit Check..6292
    Connector Voltage Check..6293
    Connector Resistance Check to GND..6293
    Under Valve Cover Resistance Check to Engine GND..6293
    Harness Resistance Check..6294
    Injector 1 ? Resistance Checks Through Harness and Injector..6302
    Injector 1 - Injector Resistance Checks..6303
    Injector 1 ? Harness Resistance Check..6303
    Injector 2 ? Resistance Through Valve Cover Check..6304
    Injector 2 ? Coil Resistance Check..6304
    Injector 2 ? Harness Resistance Check..6305
    Injector 3 ? Resistance Through Valve Cover Check..6306
    Injector 3 ? Coil Resistance Check..6306
    Injector 3 ? Harness Resistance Check..6307
    Injector 4 ? Resistance Through Valve Cover Check..6308
    Injector 4 ? Coil Resistance Check..6308
    Injector 4 ? Harness Resistance Check..6309
    Injector 5 ? Resistance Through Valve Cover Check..6310
    Injector 5 ? Coil Resistance Check..6310
    Injector 5 ? Harness Resistance Check..6311
    Injector 6 ? Resistance Through Valve Cover Check..6312
    Injector 6 ? Coil Resistance Check..6312
    Injector 6 ? Harness Resistance Check..6313
    Connector Voltage Check..6316
    Operational Voltage Check ? Output State Test..6316
    Actuator Resistance Check..6317
    Harness Resistance Check..6317
    ITV Actuator Circuit Check..6325
    Connector Voltage Check..6326
    Connector Resistance Check to GND..6326
    Harness Resistance Check..6327
    Sensor Circuit Check..6330
    Connector Voltage Check..6331
    Connector Resistance Check to GND..6331
    Harness Resistance Check..6331
    Sensor Circuit Check..6335
    Connector Voltage Check..6336
    Connector Resistance Checks to GND..6336
    Harness Resistance Check..6336
    Voltage Check at RSE Connector - Output State Test..6339
    Harness Resistance Check..6340
    Circuit End Voltage Check..6342
    Harness Resistance Check..6342
    Connector Voltage Check..6345
    Harness Resistance Check..6345
    Operational Visual Inspection - Output State Test..6346
    VREF Voltage Check..6351
    Connector Resistance Check to GND..6351
    Harness Resistance Check..6353
    Connector Voltage Check..6356
    Sensor Resistance Check..6356
    Harness Resistance Check..6357
    Resistance Check..6358
    Operational Check..6358
    Voltage Check..6362
    Connector Resistance Check to GND..6362
    Harness Resistance Check..6362
    Key-On Engine-Off..6406
    Engine Cranking..6406
    Low Idle, no load, stabilized engine operating temperature..6406
    High Idle, no load, stabilized engine operating temperature..6407
    Full load, rated speed on highway, stabilized engine operating temperature(MaxxForce? DT at 2300 engine rpm and MaxxForce? 9 & 10 at 2000 engine rpm)..6407
    Component Specifications..6408
    Inlet Air Heater..6409
    Actuator Output State Test..6409
    Key-On Engine-Running VGT Test..6409
0000002664 - Manuel de Reparation Moteurs 2010 MaxxForce 7..6447
0000003081 - Diagnostic Manual Aftertreatment Symptom-Based Diagnostic and Inspection Manual MaxxForce DT, 9, 10, 11, 13 and 15 (EPA 10)..6950
  toc..6952
    Table of Contents..6952
      Foreword..6954
      Safety information..6955
        Safety Terminology..6955
        Safety Instructions..6955
        Work Area..6955
        Safety Equipment..6955
        Protective Measures..6955
        Vehicle..6956
        Engine..6956
        Fire Prevention..6956
        Batteries..6956
        Compressed Air..6956
        Tools..6957
        Fluids Under Pressure..6957
        Fuel..6957
        Removal of Tools, Parts, and Equipment..6957
      MaxxForce? DT, 9 and 10 Aftertreatment System Diagnostics..6958
        3.1. Start Diagnostics here: Engine and Aftertreatment System Operational Checks..6958
        Overview..6958
        Tools Required..6958
        Operational Checks ? Start Aftertreatment Diagnostics Here..6958
        3.2. Symptom 1 (Medium Duty): Frequent Parked Regens With No Active Fault Codes (More Than One Parked Regen Per Day)..6961
        3.3. Symptom 2 (Medium Duty): Engine No Start / Starts and Stalls..6970
        3.4. Symptom 3 (Medium Duty): SPN 3719 or SPN 3936 Active Only or Frequent Regens (More Than One Parked Regen Per Day)..6977
        3.5. Symptom 4 (Medium Duty): SPN 3719 Or SPN 3936 and Other Active Fault Codes..6987
        3.6. Symptom 5 (Medium Duty) : Black Smoke..6997
      MaxxForce? DT, 9 and 10 ServiceMaxx? Snapshots..7004
        4.1. Graph 1: Air Management System Test (Good)..7004
        Graph Analysis:..7004
        Actions:..7005
        4.2. Graph 2: Air Management System Test (bad)..7006
        Graph Analysis:..7006
        Actions:..7006
        4.3. Graph 3: 0 to 60 mph Test (ICP Desired and ICP)..7007
        Graph Analysis..7007
        Actions..7007
        4.4. Graph 4: 0 to 60 mph Test (Engine Speed, Engine Load, IMP, EBP, and APP1)..7008
        Graph Analysis..7008
        Actions..7009
        4.5. Graph 5: Normal Exhaust Gas Temperatures (Efficient DOC AND Unrestricted AFI)    ..7010
        Graph Analysis:..7010
        Actions:..7011
        4.6. Graph 6: Erratic exhaust Gas Temperatures ..7012
        Graph Analysis:..7012
        Actions:..7012
        4.7. Graph 7: Low Exhaust Gas Temperatures (Restricted AFI)..7013
        Graph Analysis:..7013
        Actions:..7014
        4.8. Soot Load Level vs. Exhaust Gas Target Temperature Chart..7015
      Aftertreatment System Operation..7016
        5.1. MaxxForce? DT, 9 and 10 ..7016
      Component Descriptions (Theory of Operation)..7019
        6.1. MaxxForce? DT, 9 and 10 ..7019
        Diesel Oxidation Catalyst (DOC)..7019
        Diesel Particulate Filter (DPF)..7019
        Downstream Injection (DSI) Unit..7020
        Engine Control Module (ECM)..7021
        Engine Throttle Valve (ETV)..7022
        Exhaust Back Pressure Valve (EBPV)..7023
        Exhaust Gas Recirculation (EGR) Valve..7024
        Pre-Diesel Oxidation Catalyst (PDOC)..7025
      Aftertreatment System Fault Codes..7028
        7.1. MaxxForce? DT, 9 and 10 (EPA 10)..7028
      Aftertreatment System Event Chart..7031
        8.1. MaxxForce? DT, 9 and 10..7031
      MaxxForce? 11,13 and 15 Aftertreatment System Diagnostics..7032
        9.1. Start Diagnostics Here: Engine and Aftertreatment System Operational Checks..7032
        Overview..7032
        Tools Required..7032
        Operational Checks ? Start Aftertreatment Diagnostics Here..7033
        9.2. Symptom 1 (Heavy Duty): Frequent Parked Regens With No Active Fault Codes (More Than One Parked Regen Per Day)..7036
        9.3. Symptom 2 (Heavy Duty): Engine No Start / Starts and Stalls..7044
        9.4. Symptom 3 (Heavy Duty): SPN 3719 Active Only or Frequent Regens (More Than One Parked Regen Per Day)..7049
        9.5. Symptom 4 (Heavy Duty): SPN 3719 and Other Active Fault Codes ..7057
        9.6. Symptom 5 (Heavy duty): Black Smoke ..7066
      MaxxForce? 11, 13 and 15 ServiceMaxx? Snapshots..7073
        10.1. Graph 1: Air Management System Test (Good)..7073
        Graph Analysis:..7073
        Actions:..7074
        10.2. Graph 2: Air Management System Test (Bad)..7075
        Graph Analysis:..7075
        Actions:..7076
        10.3. Graph 3: Lug Down Test (Engine Speed, FRP, and FRPD)..7077
        Graph Analysis:..7077
        Actions:..7078
        10.4. Graph 4: Lug Down Test (Engine Speed and TC1TOP)..7079
        Graph Analysis:..7079
        Actions:..7079
        10.5. Graph 5: Lug Down Test (Engine Speed, APP1, Vehicle Speed, and IMP)..7080
        Graph Analysis:..7080
        10.6. Graph 6: Normal Exhaust Gas Temperatures (Efficient DOC AND Unrestricted AFI)..7082
        Graph Analysis:..7082
        Actions:..7083
        10.7. Graph 7: Inverted exhaust Gas Temperatures (Inefficient DOC)..7084
        Graph Analysis:..7084
        Actions:..7085
        10.8. Graph 8: Low Exhaust Gas Temperatures (Restricted AFI)..7086
        Graph Analysis:..7086
        Actions:..7087
      Aftertreatment System Operation..7088
        11.1. MaxxForce? 11, 13 and 15 ..7088
      Component Descriptions (Theory of Operation)..7091
        12.1. MaxxForce? 11 and 13 ..7091
        Air Control Valve (ACV) Assembly..7091
        Diesel Oxidation Catalyst (DOC)..7092
        Diesel Particulate Filter (DPF)..7092
        Downstream Injection (DSI) Unit..7093
        Engine Control Module (ECM)..7094
        Engine Throttle Valve (ETV)..7095
        Exhaust Back Pressure Valve (EBPV)..7096
        Exhaust Gas Recirculation (EGR) Valve..7097
        Pre-Diesel Oxidation Catalyst (PDOC)..7098
        Turbochargers..7099
      Aftertreatment System Fault Codes..7100
        13.1. MaxxForce? 11, 13 and 15..7100
      Aftertreatment System Event Chart..7104
        14.1. MaxxForce? 11, 13 and 15..7104
      Regen Inhibitors and Entry Conditions..7105
        15.1. Regen Inhibitors..7105
        Overview..7105
        15.2. Entry Conditions..7109
        Overview..7109
      DPF and DOC Reuse Guidelines..7112
        16.1. MaxxForce? DT, 9, and 10; MaxxForce? 11, 13 and 15..7112
          16.1.1. Diesel Particulate Filter (DPF) Inlet - Clean..7113
          16.1.2. Diesel Particulate Filter (DPF) Inlet - Dirty, but Reusable..7114
          16.1.3. Diesel Particulate Filter (DPF) Inlet - Face Plugged..7115
          16.1.4. Diesel Particulate Filter (DPF) - Melted..7116
          16.1.5. Diesel Particulate Filter (DPF) - Cracked but Reusable..7117
          16.1.6. Diesel Particulate Filter (DPF) Inlet- Ash on Face..7118
          16.1.7. Diesel Particulate Filter (DPF) - Excessive Brick Shift..7119
          16.1.8. Diesel Particulate Filter (DPF) - Moderate Brick Shift..7120
          16.1.9. Diesel Oxidation Catalyst (DOC) Outlet - Dirty but Reusable..7121
          16.1.10. Diesel Oxidation Catalyst (DOC) - Separation..7122
          16.1.11. Diesel Oxidation Catalyst (DOC) - Melted..7123
          16.1.12. Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter (DPF) - Damaged Sensor Port Threads..7124
      Abbreviations and Acronyms..7125
      Terminology..7134
  tables..6971
    Table 21Example TC1TOP (Actual) Calculations..6971
    Signal Values:..6975
    Signal Values:..6975
    Table 182Check Active Regen Inhibitors..7106
    Table 183Check Parked Regen Inhibitors..7107
    Table 184Parked Regen Checks..7108
    Table 185Entry Conditions for an Active Regen..7109
    Table 187Entry Conditions for a Parked Regen..7111
0000003201 - Engine Wiring Schematic Form MaxxForce 7 (EPA 10) with HD-OBD..7147
0000003221 - Engine Wiring Schematic Form MaxxForce DT, 9, and 10 (EPA 10) with HD-OBD..7149
0000003381 - Performance Diagnostics MaxxForce 7 EPA 10, 2013 HD-OBD..7151
0000003382 - Hard Start and No Start Diagnostics MaxxForce 7 EPA 10, 2013 HD-OBD..7163
0000004281 - Manuel de Diagnostics Manuel d'inspection et de diagnostic bas? sur le sympt?me de post-traitement (MaxxForce DT, 9, 10, 11, 13 et 15 (EPA 10))..7176
0000004282 - Manual de Diagnostico Manual de inspecci?n y diagn?stico basado en s?ntomas de postratamiento (MaxxForce? DT, 9, 10, 11, 13 y 15 (EPA 10))..7384
1172039R1 - MaxxForce 7 Engine Operation and Maintenance Manual..7592
1172072R1 - MaxxForce DT, 9, and 10 Engine Operation and Maintenance Manual..7701
Advanced Electrical Technical Information..7788
  Preface..7792
  Overview of Electrical System..7793
  Multiplexing..7794
    SAE J1939..7794
      J1939 Data Link Cable..7795
      Network Topology..7797
      Terminating Resistor..7798
      Logic States..7800
      Arbitration..7800
      Message Structure..7801
      Error Checking..7802
      Naming Convention for the J1939 Data Links..7803
    Other Data Links..7803
      J1708 Drivetrain Data Link..7803
      Switch Data Link..7803
  Electrical System Controller (ESC)..7804
    Electrical 101..7805
      Bias..7817
        Zero Volt Reference (ZVR)..7819
    ESC Inputs..7820
      Digital Inputs..7820
      Analog Inputs..7824
        10V ( 1233(  = 0.008A or 8mA..7826
        Diagnosable Switches..7827
        A More Challenging Diagnosable Switch..7831
      Switch data link..7838
        Switch Packs..7838
        3-Switch Packs..7840
      J1939 Drivetrain Data Link Inputs..7840
      Body Builder Data Link Inputs..7840
    ESC Outputs..7841
      High Side Controlled Outputs..7841
        1A FET Devices..7842
        10A FET Devices..7842
        20A FET Devices..7842
        Virtual Fusing (10A & 20A FETs)..7842
          Type I Virtual Fusing (Headlights and Wipers)..7842
          Type II Virtual Fusing (All Others)..7842
      Low Side Controlled Outputs..7843
      Switch data link Control..7844
      J1939 Drivetrain Data Link Control..7844
      Body Builder Data Link Control..7844
    ESC Power Supply..7845
    ESC Ground..7845
    ESC Memory..7845
    Single Power Lead ESC Differences..7845
    Electronic Gauge Cluster (EGC)..7846
      Gauge Cluster Revisions..7848
    Pyrometer Ammeter Module (PAM)..7850
    Auxiliary Gauge-Switch Pack (AGSP)..7850
  How It All Works Together..7851
    Horns..7851
      Electric (city) Horn..7851
      Air Horn..7851
    Vehicle Lighting..7852
      Dome Light..7852
      Turn Signals and Hazard Flashers..7853
        Turn Signals With Combination Rear Stop-Turn Lights..7853
        Turn Signals With Separate Rear Stop-Turn Lights..7853
        Trailer Turn Lights..7854
      Brake Lights..7854
        Brake Lights With Combination Rear Stop-Turn Lights..7854
        Brake Lights With Separate Rear Stop-Turn Lights..7854
      Headlights..7854
      Tail, Marker, Clearance Lights..7856
      Marker Interrupt..7857
      Daytime Running Lights..7857
      Fog Lights..7857
      Work Light..7857
    HVAC System..7858
      A/C Clutch Control System..7858
        Normal A/C Operation..7860
        Abnormal A/C System Operation and Diagnostics..7862
      HVAC Control System..7864
        Blower motor..7864
        HVAC Air Control Doors..7864
    Engine Related Systems..7867
      Cruise Control..7867
      Engine Crank (with International Engines)..7872
      Engine Crank (Caterpillar and Cummins)..7876
      Ether Start..7878
      On-Off Engine Fan Drive..7878
      Compression Brake (Caterpillar and Cummins Engines)..7878
      Exhaust Brake (International I6)..7879
    Warning Lights, Gauges and Messages..7880
      Check Electrical System LED..7880
        Earlier ESC Software Revisions..7880
          Later ESC Software Revisions..7880
      Seat Belt Reminder LED..7880
      Low Washer Fluid Level LED..7880
      Water in Fuel LED..7880
      Park Brake Warning Light..7881
      Traction Control Warning LED..7881
      Check A/C LED..7881
      Engine Warning LEDs..7881
      Automatic Transmission Warning LEDs..7881
      Axle Oil Temperature..7881
      Voltmeter..7881
      Engine Messages (International Engines)..7881
      Fuel Gauge (single tank)..7882
      Dual Fuel Tank System (Earlier 5-Wire Transfer Pump)..7882
      Dual Fuel Tank System (2-Wire Transfer Pump)..7885
      Hydro-Max (Built Prior to Mid-2003)..7886
      Hydro-Max (w/Single-Power Lead ESC Built After Mid-2003)..7888
      Air Pressure Gauges..7889
    Power Windows and Locks..7891
      Wabco Hydraulic ABS..7893
        ABS Warning Lamp..7893
        Drive Axle ABS Event..7896
        Hydraulic ABS Fault Codes..7897
        Miscellaneous Hydraulic ABS Information..7897
      Bendix Air ABS..7898
        Drive Axle ABS Event..7898
        Air ABS Warning Lamp..7898
        Traction Control..7899
        Trailer ABS Warning Light..7899
        Air ABS Diagnostics..7899
      Wabco Air ABS..7899
    Allison Automatic Transmissions..7900
      World Transmission Series..7900
      LCT 2000 Series..7901
    Driver Visibility Features..7902
      Mirror Heat..7902
      Windshield Wipers..7903
        ESC Wiper Inputs..7903
        ESC Wiper Outputs..7904
        Wiper Low Speed Operation..7905
        Wiper High Speed Operation..7906
        Wiper Park..7907
        Intermittent Operation..7908
        Washer Operation..7908
    Air Controlled Optional Devices..7909
      4-Pack Air Solenoid Module..7909
        7-Pack Air Solenoid Module..7909
      Power Divider Lock (PDL)..7910
      Differential Lock..7910
      Sliding Fifth Wheel Lock Release..7910
      Air Suspension Dump (prior to Late-2003)..7910
      Air Suspension Dump (after Late-2003)..7911
      Air Horn..7911
      Other Air Operated Features..7911
  Body Builder Applications..7912
    Body Builder Data Link..7912
    Remote Power Modules..7913
    Remote Engine Speed Control Module..7916
  Electrical Troubleshooting..7917
    High Impedance Voltmeters..7917
    Reverse Battery Operation..7919
    Fault Codes..7919
    Troubleshooting the J1939 Drivetrain Data Link..7920
    Some Quick Tests..7921
    INTUNE..7922
  Assessment..7923
EGED-355-2 - Hard Start and No Start Diagnostics MaxxForce 7 2007 through 2009 Model Years..7928
EGED-365 - MaxxForce 7 Electronic Control System Diagnostics MY2007 & up..7930
EGES-335-1 - MaxxForce DT, 9, and 10 Engine Service Manual..7932
  EGES-335-1 PDF Index..7932
  EGES3351a..7933
  EGES3351b..8055
  EGES3351c..8179
  EGES3351d..8273
  EGES3351e..8437
EGES-335-2 - MaxxForce DT, 9, and 10 Engine Engine Service Manual..8571
EGES-345 - MaxxForce 7 Engine Service Manual..9075
  EGES-345 PDF Index..9075
  EGES345a..9076
  EGES345b..9204
  EGES345c..9332
EGES-345-1 - MaxxForce 7 Engine Service Manual Model Years 2007-2009..9476
EGES-345-1 - MaxxForce 7 Engine Service Manual..9888
  EGES-345-1 PDF Index..9888
  EGES3451a..9889
  EGES3451b..10017
  EGES3451c..10143
EGES-350-2 - Maxxforce 7 Diesel Engine Diagnostic_Troubleshooting Manual 2007 through 2009 Model Years..10287
  Diagnostic Trouble Code..10287
  EGES-350-2 PDF Index..10296
  EGES3502a..10297
  EGES3502b..10451
  EGES3502c..10683
EGES-370-2 - MaxxForce DT, 9, and 10 Diagnostic_Troubleshooting Manual..10755
  Diagnostic Trouble Code..10755
  EGES-370-2 PDF Index..10763
  EGES3702a..10764
  EGES3702b..10892
  EGES3702c..11190
EGES-390 - Maxxforce 5 Diesel Engine Engine Service Manual 2007..11286
  EGES-390 PDF Index..11286
  EGES390a..11287
  EGES390b..11393
  EGES390c..11479
  EGES390d..11573
EGES-395 - Maxxforce 5 Diagnostic_Troubleshooting Manual..11711
  Diagnostic Trouble Code (DTC)..11711
  EGES-395 PDF Index..11717
  EGES395a..11718
  EGES395b..11900
  EGES395c..12104
EGES-450-1 - MaxxForce DT, 9 and 10 Diesel Engines Service Manual Model Year 2010 and Up..12168
EGES-455-1 - Diagnostic Trouble Code..12715
EGES-455-1 - MaxxForce DT, 9, and 10 Engine Diagnostic_Troubleshooting Manual 2011..12723
EGES-480-1 - MaxxForce 7 Diesel Engine Service Manual Model Year 2010 and Up..13243
EGES-485-1 - Diagnostic Manual 2010 MaxxForce 7 Engine..13727
  toc..13729
    Table of Contents..13729
    Safety Terminology..13733
    Safety Instructions..13733
    Work Area..13733
    Safety Equipment..13733
    Protective Measures..13733
    Vehicle..13733
    Engine..13733
    Fire Prevention..13733
    Batteries..13733
    Compressed Air..13734
    Tools..13734
    Fluids Under Pressure..13734
    Fuel..13734
    Removal of Tools, Parts, and Equipment..13734
      Table of Contents..13735
        Engine Identification..13737
          Engine Serial Number..13737
          Engine Serial Number Example..13737
          Emission Label..13737
          Engine Accessories..13737
          Engine Description..13738
            Standard Features..13739
            Optional Features..13740
            Chassis-mounted Features..13740
          Engine Components..13741
        Air Management System..13746
          Air Management Components and Air Flow..13746
            Air Flow..13747
          Charge Air Cooler (CAC)..13747
          Dual Turbocharger Assembly..13748
            High-pressure Turbocharger..13749
            Low-pressure Turbocharger..13749
            Turbocharger 1 Wastegate Control (TC1WC) Solenoid..13749
          Exhaust Gas Recirculation (EGR) System..13750
            EGR Flow..13750
            EGR Control Valve and Position Sensor..13751
            Engine Throttle Valve (ETV) and Position Sensor..13752
          Aftertreatment (AFT) System..13753
            AFT Control System..13753
            Sensors..13753
            Diesel Oxidation Catalyst (DOC)..13753
            Diesel Particulate Filter (DPF)..13753
            AFT Conditions and Responses..13753
        Fuel System..13754
          Fuel System Components..13754
          High-pressure Fuel System..13755
            High-pressure Fuel Pump (HPFP) Assembly..13755
            Internal Transfer Pump (ITP)..13755
            Fuel Pressure Control Valve (FPCV)..13755
            Fuel Volume Control Valve (FVCV)..13756
            Fuel Rail Pressure (FRP) Sensor..13756
            High-pressure Piezo Common Rail (HPCR) System..13756
            Return Fuel System..13756
          Low-pressure Fuel System..13758
            Fuel Pump..13758
            Primary Fuel Filter..13758
            Secondary Fuel Filter..13758
            Fuel Cooler..13758
          Fault Detection/Management..13758
        Engine Lubrication System..13759
          Lubrication System Components and Oil Flow..13759
        Cooling System..13761
          Cooling System Components and Flow..13761
            Water Pump..13761
            Front Crankcase Cover Flow..13762
            Thermostats..13762
            Deaeration Tank..13762
            Radiator Shutters (220 Horsepower only)..13762
            Fuel Coolant Valve (FCV)..13762
        Engine Speed Position System..13763
        Electronic Control System..13764
          Electronic Control System Components..13764
            Operation and Function..13766
            Reference Voltage (VREF)..13766
            Signal Conditioner..13766
            Microprocessor..13766
            Microprocessor Memory..13766
            Flash Memory..13766
            RAM..13766
            Engine Fan Control (EFC)..13767
            Inlet Air Heater (IAH)..13767
            Actuator Control..13767
          Actuators..13767
            H-Bridge Circuit..13767
            Exhaust Gas Recirculating (EGR) Valve and Control..13767
            ETV and Engine Throttle Position Sensor..13768
          Engine and Vehicle Sensors..13768
            Thermistor Sensors..13768
            Variable Capacitance Sensors..13769
            Micro Strain Gauge (MSG) Sensor..13769
            MSG Sensors..13769
            Magnetic Pickup Sensors..13770
            Magnetic Pickup Sensors..13770
            Potentiometer..13770
            Potentiometer..13770
            Switches..13771
            Switches..13771
          Inlet Air Heater (IAH) System..13772
      Table of Contents..13773
        Standard Features..13775
          Electronic Governor Control..13775
          SAE J1939 Data Link - also known as CAN (public)..13775
          SAE J1587 Data Link - also known as the American Trucking Association (ATA) data link...13775
          Service Diagnostics..13775
          Event Logging System..13776
          Electronic Speedometer and Tachometer..13776
          Aftertreatment (AFT) System..13776
          Fuel Delivery Pressure (FDP) Monitor..13776
          Inlet Air Heater (IAH)..13776
          Fast Idle Advance..13776
          Cold Ambient Protection (CAP)..13776
          Coolant Temperature Compensation (CTC)..13777
          Engine Crank Inhibit (ECI)..13777
        Optional Features..13777
          Change Oil Service Interval..13777
          Road Speed Limiting (RSL)..13777
          Cruise Control..13777
          Traction Control..13777
          Exhaust Back Pressure Valve (EBPV)..13777
          Engine Warning Protection System (EWPS)..13778
          Idle Shutdown Timer (IST)..13778
          IST for California ESS Compliant Engines..13778
          Engine Idle Shutdown Timer (IST for Federal?Optional)..13778
          Electronic Fan (EFAN)..13778
          Radiator Shutter Enable (RSE)..13779
          In Cab Power Take-Off (PTO) Control..13779
          Remote Accelerator Pedal Position (RAPP)..13779
      Table of Contents..13781
        Connecting EST with ServiceMaxx? Software to Engine..13783
        Viewing Diagnostic Trouble Codes..13783
          Diagnostic Trouble Codes (DTCs)..13783
          Suspect Parameter Number (SPN) ..13783
          Failure Mode Indicator (FMI)..13783
          Active and Previously Active DTCs..13783
        Service Bay Tests..13784
          Key On, Engine Off (KOEO) Tests..13784
          Tools..13784
            KOEO Standard Test..13784
            KOEO Output State Low and High..13785
            KOEO Intake Air Heater..13787
            KOEO Continuous Monitor Test..13788
            Relative Compression Test..13788
          Key On, Engine Running (KOER) Tests..13789
            KOER Standard Test..13789
            KOER Air Management Test..13790
            KOER Cylinder Cutout Test..13791
        ServiceMaxx? Procedures..13792
          KOEO Fuel Pump Prime..13792
          KOER MAF Sensor Calibrate Procedure..13793
      Table of Contents..13795
        Coolant System..13797
          Air Compressor Leak Test..13797
          Tools..13797
          Combustion Leaks to Coolant..13798
          Symptom..13798
          Possible Causes..13798
          Tools..13798
            Combustion Leak Test..13798
          Coolant Leak to Exhaust/Intake..13799
          Symptoms..13799
          Possible Causes..13799
          Tools..13799
            EGR Cooler Inspection..13799
          Coolant in Lube Oil..13800
          Symptom..13800
          Possible Causes..13800
          Tools..13800
            Lube Oil Contamination..13801
            Front Cover Inspection..13802
            Cylinder Head Leak Test..13802
          Coolant Over-Temperature..13803
          Symptom..13803
          Possible Causes..13803
          Tools..13803
            Coolant Over-Temperature Diagnostics and Repair..13804
            Temperature Sensor Validation Test..13805
            Cooling System Operating Pressure Test..13805
        Engine Inspection..13806
        Symptom..13806
        Possible Causes..13806
        Low Power..13806
        Rough Idle..13806
        Tools..13806
          Low Power (Turbocharger Assembly and Actuator)..13806
          Rough Idle..13806
          Engine and Flexplate Balance Inspection..13807
        Electrical System..13808
          ECM Reset (Intermittent Engine Stumble)..13808
          Symptom..13808
          Possible Causes..13808
            Diagnostics for Engine Stumble..13808
        Fuel System..13809
          Excessive Fuel Consumption..13809
          Symptom..13809
          Possible Causes..13809
          Operator effects..13809
          Application effects..13809
          Chassis effects..13809
          Engine effects..13809
            Verifying Excessive Fuel Consumption Complaints..13810
          Fuel in Coolant..13810
          Symptom..13810
          Possible Causes..13810
          Tools..13810
            Fuel in Coolant Leakage Test (Low-pressure)..13810
            Fuel in Coolant Leakage Test (High-pressure)..13811
          Fuel In Lube Oil..13812
          Symptom..13812
          Possible Causes..13812
          Leaking fuel under the valve cover..13812
          Porous cylinder head..13812
          Tools..13812
            Verifying Fuel Dilution from Oil System..13812
            Fuel to Exhaust..13812
            Symptom..13812
            Possible Causes..13812
          Air or Combustion Leaks to Fuel..13812
          Possible Causes..13812
            Air or Combustion Leak to Fuel Test..13813
            Low Fuel Pressure and Aeration..13813
            Symptom..13813
            Possible Causes..13814
          Water In Fuel (WIF) Check..13814
          Possible Causes..13814
          Tools..13814
            Drain Water from Primary Fuel Filter..13814
        Lubrication System..13815
          Low Oil Pressure..13815
          Possible Causes..13815
          Tools..13815
             Low Oil Pressure Diagnostics..13815
      Table of Contents..13817
        Diagnostics Form..13819
          Diagnostics Form Header Information..13820
          Enter Diagnostics Form Header Information..13820
        Test Procedures..13822
          1. Initial Key On Check..13822
          Purpose..13822
          Tools..13822
          Procedure..13822
          Possible Causes..13822
          WAIT TO START lamp does not illuminate..13822
          WARN ENGINE lamp stays illuminated..13822
          2. Visual Inspection..13823
          Purpose..13823
          Tools..13823
            Engine Oil..13823
            Engine Coolant Level..13823
            Electrical System..13823
            Exhaust System..13823
            Intake Air System and Charge Air Cooler (CAC)..13824
            2.1 Fuel Level Check..13824
            2.2 Fuel Quality Check..13824
            Purpose..13824
            Tools..13824
            Possible Causes..13824
            Procedure..13824
          3. EST Connection and Data Recording..13825
          Purpose..13825
            Monitoring Engine Systems using an EST..13825
            Tools..13825
            Procedure..13825
          4. Check for DTCs..13826
          Purpose..13826
          Tools..13826
          Procedure..13826
          5. Engine Cranking..13826
          Purpose..13826
            Monitoring Engine Systems using an EST..13826
            Tools..13826
            Procedure..13827
            Possible Causes..13827
            Low battery voltage..13827
            Low cranking rpm..13827
            Low Fuel Rail Pressure..13828
            Monitoring FRP using a Breakout Harness..13828
            Tools..13828
            Procedure..13828
            Possible Causes..13828
        Special Test Procedures..13829
          Inlet Air Heater (IAH) Test..13829
          Purpose..13829
          Tools..13829
          Possible Causes..13829
            Amperage Draw..13829
            Procedure..13829
          Low-pressure Fuel System ..13830
            LP.1 - Electrical Fuel Pump Check..13831
            Purpose..13831
            Tools..13831
            Procedure..13831
            LP.2 - Fuel Pressure Test..13831
            Purpose..13831
            Tools..13831
            Check Fuel Delivery Pressure Using the EST ..13831
            Check Fuel Delivery Pressure Manually..13831
            LP.3 - Fuel Aeration Check..13832
            Purpose..13832
            Tools..13832
            Possible Causes..13832
            Procedure..13832
            LP.4 - Fuel Thermal Valve Check..13833
            Purpose..13833
            Tools..13833
            LP.5 - Fuel Pump Dead Head Test..13834
            Purpose..13834
            Tools..13834
            Procedure..13834
            LP.6 - Alternative Fuel Supply Test..13834
            Purpose..13834
            Possible Causes (High and Low Restriction)..13834
            Tools..13834
            Procedure..13834
            LP.7 - Return Fuel Flow Test..13835
            Purpose..13835
            Tools..13835
            Procedure..13835
            LP.8 - Fuel Return Restriction Test..13835
            Purpose..13835
            Tools..13835
            Procedure..13835
          High-pressure Fuel System Tests..13836
            HP.1 - Fuel Pressure Control Valve (FPCV) and Fuel Volume Control Valve (FVCV) Check..13836
            Purpose..13836
            Possible Causes..13836
            Tools..13837
            Procedure..13837
            HP.2 - FPCV and FVCV Resistance Check..13837
            Purpose..13837
            Possible Causes..13837
            Tools..13837
            Procedure..13837
            HP.3 - Fuel Rail Leak Check..13838
            Purpose..13838
            Possible Causes..13838
            Tools..13838
            Procedure..13838
            HP.4 - High-pressure Fuel Pump (HPFP) Dead Head Test..13839
            Possible Causes..13839
            Tools..13839
            Procedure..13839
            HP.5 - Injector Leak Isolation Check (Left Bank)..13840
            Purpose..13840
            Possible Causes..13840
            Tools..13840
            Procedure..13840
            HP.6 - Injector Leak Isolation Check (Right Bank)..13840
            Purpose..13840
            Possible Causes..13840
            Tools..13840
            Procedure..13840
      Table of Contents..13841
        Diagnostic Form..13843
          Diagnostics Form Header Information..13844
          Enter Diagnostics Form Header Information..13844
        Test Procedures..13846
          1. Initial Key On Check..13846
          Purpose..13846
          Tools..13846
          Procedure..13846
          Possible Causes..13846
          WAIT TO START lamp does not illuminate..13846
          WARN ENGINE lamp stays illuminated..13846
          2. Visual Inspection..13846
          Purpose..13846
          Tools..13846
            Engine Oil..13847
            Fuel Level..13847
            Engine Coolant Level..13848
            Electrical System..13848
            Exhaust System..13848
            Intake Air System and Charge Air Cooler (CAC)..13848
          3. EST Connection and Data Recording..13848
          Purpose..13848
            Monitoring Engine Systems using an EST..13849
            Tools..13849
            Procedure..13849
          4. Check for DTCs..13849
          Purpose..13849
          Tools..13849
          Procedure..13849
          5. Fuel Quality Check..13850
          Purpose..13850
          Tools..13850
          Possible Causes..13850
          Procedure..13850
          6. Fuel Pressure and Aeration Check..13851
          Purpose..13851
          Tools..13851
          Check Fuel Delivery Pressure Using the EST ..13851
          Check Fuel Delivery Pressure Manually..13851
          7. Engine Low Idle to High Idle..13852
          Purpose..13852
          Tools..13852
          Procedure..13852
          8. Road Test (0?60 mph, Full Throttle)..13853
          Purpose..13853
          Tools..13853
          Procedure..13854
        Special Test Procedures..13855
          Turbocharger Checks (Under Boost)..13855
          Purpose..13855
          Possible Causes..13855
          Procedure..13855
          Wastegate Checks (Over Boost)..13855
          Purpose..13855
          Tools..13855
          Procedure..13855
          Charge Air Cooler (CAC) Checks..13856
          Purpose..13856
          Possible Causes..13856
          Procedure..13856
          Blow-by Test..13856
          Purpose..13856
          Tools..13856
          Possible Causes..13856
          Procedure..13856
          Crankcase Pressure Test..13857
          Purpose..13857
          Tools..13857
          Possible Causes..13857
          Procedure..13857
          Intake Air Restriction Test..13859
          Purpose..13859
          Tools..13859
          Possible Causes..13859
          Procedure..13859
          Relative Compression Test..13859
          Purpose..13859
          Tools..13859
          Possible Causes..13859
          Procedure..13859
          Cylinder Cutout Test..13860
          Purpose..13860
          Tools..13860
          Possible Causes..13860
          Procedure..13860
      Table of Contents..13861
        Description..13865
          Section Information..13865
        Electronic Control System Diagnostics Form..13866
          EGED-505 Diagnostic Form ..13866
        Sensor and Actuator Locations..13867
          Engine Mounted Components..13867
         Diagnostic Procedure Process..13872
          Description..13872
            Pin-grip Inspection..13872
            Diagnostics with EST..13872
            Diagnostics without EST..13872
          Sensor End Diagnostics (with ServiceMaxx? software)..13873
            Sensor End Diagnostics (2-Wire)..13873
            Sensor End Diagnostics (3-Wire)..13875
          Pin-point Diagnostics (without ServiceMaxx? software)..13878
          Actuator Operational Voltage Check ? Output State Test..13878
          Harness Resistance Check..13879
          Operational Voltage Check..13880
        Circuit Diagnostics..13881
          AFT System (Aftertreatment)..13881
          Function..13882
          Tools..13882
            AFT System Diagnostics..13883
            AFT System Operation..13887
            Diesel Oxidation Catalyst (DOC)..13889
            Diesel Particulate Filter (DPF)..13889
            Regeneration..13889
            Passive Rolling Regeneration..13889
            Parked Regeneration Switch..13889
            Inhibit Regeneration Switch (optional)..13889
            DPF Soot Loading Percentage..13889
            DPF Ash Loading Percentage..13889
            DPF Status Lamp..13890
            High Exhaust System Temperature (HEST) Indicator ..13890
          AMS (Air Management System)..13891
          Function..13892
          Tools..13892
            AMS Diagnostics..13893
            AMS Operation..13896
          APP Sensor (Accelerator Pedal Position)..13897
          Function..13897
          Sensor Location..13897
          Tools..13897
            APP Sensor End Diagnostics..13898
            APP Pin-point Diagnostics..13901
            APP Circuit Operation..13903
            Accelerator Pedal Position (APP) sensor..13903
            Fault Detection/Management..13903
          ATA Data Link (American Trucking Association) (SAE J1587) ..13904
          Function..13904
          Location..13904
          Tools..13904
            ATA (SAE J1587) Pin-point Diagnostics..13905
            ATA (SAE J1587) Operation..13906
            Diagnostic Connector..13906
            Electronic Gauge Cluster (EGC)..13906
            Fault Detection/Management..13906
            Repair Information..13906
          Brake Switch Circuits..13907
          Function..13907
          Location..13907
          Tools..13907
            Brake Switch Circuits Pin-point Diagnostics..13908
            Brake Switch Circuit Operation..13910
            Fault Detection/Management..13910
          CAN Communications (Controller Area Network) (J1939) ..13911
          Function..13911
          Location..13911
          Tools..13911
            CAN (J1939) Pin-point Diagnostics..13912
            CAN (J1939) Circuit Operation..13913
            CAN (J1939) versus ATA (SAE J1587)..13913
            Diagnostic Connector..13914
             Electronic Gauge Cluster (EGC)..13914
            Body Controller (BC) or Multiplex System Module (MSM)..13914
            Repair Information..13914
          CCS (Cruise Control Switches)..13915
          Function..13916
          Location..13916
          Tools..13916
            Cruise Control Switches Pin-point Diagnostics ..13916
          CKP Sensor (Crankshaft Position)..13918
          Function..13918
          Sensor Location..13918
          Tools..13918
            CKP Pin-point Diagnostics..13919
            CKP Circuit Operation..13920
            Fault/Detection Management..13920
          CMP Sensor (Camshaft Position)..13921
          Function..13921
          Sensor Location..13921
          Tools..13921
            CMP Pin-point Diagnostics..13922
            CMP Circuit Operation..13923
            Fault/Detection Management..13923
          Cylinder Balance..13924
            Cylinder Balance Operation..13924
            Cylinder Balance Diagnostics..13925
          DOCIT Sensor (Diesel Oxidation Catalyst Inlet Temperature) ..13927
          Function..13927
          Sensor Location..13927
          Tools..13927
            DOCIT Sensor End Diagnostics..13928
            DOCIT Pin-point Diagnostics..13929
            DOCIT Circuit Operation..13930
          DPFDP Sensor (Diesel Particulate Filter Differential Pressure) ..13931
          Function..13931
          Sensor Location..13931
          Tools..13931
            DPFDP Sensor End Diagnostics..13932
            DPFDP Pin-point Diagnostics..13933
            DPFDP Circuit Operation..13934
          DPFIT Sensor (Diesel Particulate Filter Inlet Temperature)..13935
          Function..13935
          Sensor Location..13935
          Tools..13936
            DPFIT Sensor End Diagnostics..13936
            DPFIT Pin-point Diagnostics..13938
            DPFIT Circuit Operation..13938
          DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)..13939
          Function..13939
          Sensor Location..13939
          Tools..13940
            DPFOT Sensor End Diagnostics..13940
            DPFOT Pin-point Diagnostics..13942
            DPFOT Circuit Operation..13942
          ECL Sensor (Engine Coolant Level)..13943
          Function..13943
          Location..13943
          Tools..13943
            ECL Pin-point Diagnostics..13944
            ECL Circuit Operation..13945
            Fault Detection/Management..13945
          ECM PWR Relay (Engine Control Module Power)..13946
          Function..13946
          ECM Location..13946
          Tools..13946
            ECM PWR Pin-point Diagnostics..13947
            ECM PWR Circuit Operation..13950
            Fault Detection/Management..13950
          ECM Self-Diagnostics (Engine Control Module)..13951
          Fault Detection/Management..13952
            ECM Self-Diagnostic DTCs..13952
          ECT1 Sensor (Engine Coolant Temperature 1)..13954
          Function..13954
          Sensor Location..13954
          Tools..13955
            ECT1 Sensor End Diagnostics..13955
            ECT1 Pin-point Diagnostics..13957
            ECT Circuit Operation..13957
            Coolant Temperature Compensation..13958
            Engine Warning Protection System (EWPS)..13958
            Fault Detection/Management..13958
          EFC (Engine Fan Control)..13959
          Function..13959
          Location..13959
          Tools..13959
            EFC Circuit Diagnostics..13960
            EFC Circuit Operation..13962
            EFC Programmable Parameters..13962
            Fault Detection/Management..13962
          EFT Sensor (Engine Fuel Temperature)..13963
          Function..13963
          Sensor Location..13963
          Tools..13963
            EFT Sensor End Diagnostics..13964
            EFT Pin-point Diagnostics..13966
            EFT Circuit Operation..13967
            Fault Detection/Management..13967
          EGR Valve (Exhaust Gas Recirculation)..13968
          Function..13968
          Component Location..13969
          Tools..13969
            EGR Valve End Diagnostics..13969
            EGR Valve Pin-point Diagnostics..13972
            EGR Valve Circuit Operation..13973
            EGR Position (EGRP) sensor..13973
            EGR Actuator..13973
            Fault Detection/Management..13973
          EGRT Sensor (Exhaust Gas Recirculation Temperature)..13975
          Function..13975
          Sensor Location..13975
          Tools..13975
            EGRT Sensor End Diagnostics..13976
            EGRT Pin-point Diagnostics..13977
            EGRT Circuit Operation..13978
            Fault Detection/Management..13978
          EGT Sensor (Exhaust Gas Temperature)..13979
          Function..13979
          Sensor Location..13979
          Tools..13979
            EGT Sensor End Diagnostics..13980
            EGT Pin-point Diagnostics..13981
            EGT Circuit Operation..13982
            Fault Detection/Management..13982
          EOP Sensor (Engine Oil Pressure)..13983
          Function..13983
          Sensor Location..13983
          Tools..13983
            EOP Sensor End Diagnostics..13984
            EOP Pin-point Diagnostics..13986
            EOP Circuit Operation..13987
            Fault Detection/Management..13987
          EOT Sensor (Engine Oil Temperature)..13988
          Function..13988
          Fast Idle Advance..13988
          Sensor Location..13988
          Tools..13989
            EOT Sensor End Diagnostics..13989
            EOT Pin-point Diagnostics..13991
            EOT Circuit Operation..13992
            Fault Detection/Management..13992
          ETV (Engine Throttle Valve)..13993
          Function..13993
          Component Location..13993
          Tools..13994
            ETV End Diagnostics..13994
            ETV Pin-point Diagnostics..13997
            ETV Circuit Operation..13998
            ETP (Engine Throttle Position) sensor..13998
            ETV actuator..13998
            Fault Detection/Management..13998
          EWPS (Engine Warning Protection System)..13999
          Function..14000
            EWPS Programmable Parameters..14001
          Fuel Cooler Control Valve..14004
          Function..14004
          Sensor Location..14004
          Tools..14004
            Fuel Cooler Control Valve Circuit Diagnostics..14005
            Fuel Cooler Control Valve Circuit Operation..14006
          FDP Sensor (Fuel Delivery Pressure)..14007
          Function..14007
          Sensor Location..14007
          Tools..14007
            FDP Sensor End Diagnostics..14008
            FDP Pin-point Diagnostics..14010
            FDP Circuit Operation..14011
            Fault Detection/Management..14011
          FPCV (Fuel Pressure Control Valve)..14012
          Function..14012
          FPCV Location..14012
          Tools..14013
            FPCV Pin-point Diagnostics..14013
            FPCV Circuit Operation..14014
            Fault Detection / Management..14014
          Fuel Pump..14015
          Function..14015
          FPC Location..14015
          Tools..14015
            Fuel Pump Pin-point Diagnostics..14016
            Fuel Pump Actuator..14017
            Fault Detection / Management..14017
          FRP Sensor (Fuel Rail Pressure)..14018
          Function..14018
          Sensor Location..14018
          Tools..14019
            FRP Sensor End Diagnostics..14019
            FRP Pin-point Diagnostics..14021
            FRP Circuit Operation..14022
            Fault Detection/Management..14022
          FRP System ..14023
          Function..14023
          Tools..14024
            FRP System Diagnostics..14024
            FRP System Operation..14025
            Fault Detection/Management..14025
          FVCV (Fuel Volume Control Valve)..14026
          Function..14026
          FVCV Location..14026
          Tools..14027
            FVCV Pin-point Diagnostics..14027
            FVCV Circuit Operation..14028
            Fault Detection/Management..14028
          IAH (Inlet Air Heater)..14029
          Function..14029
          Sensor Location..14029
          Tools..14029
            IAH End Diagnostics..14030
            IAH Circuit Operation..14033
          IMP Sensor (Intake Manifold Pressure)..14034
          Function..14034
          Sensor Location..14034
          Tools..14034
            IMP Sensor End Diagnostics..14035
            IMP Pin-point Diagnostics..14037
            IMP Circuit Operation..14038
            Fault Detection/Management..14038
          IMT Sensor (Intake Manifold Temperature)..14039
          Function..14039
          Sensor Location..14039
          Tools..14039
            IMT Sensor End Diagnostics..14040
            IMT Pin-point Diagnostics..14041
            IMT Circuit Operation..14042
            Fault Detection/Management..14042
          INJ (Injector Circuits)..14043
          Function..14043
          Component Location..14043
          Tools..14043
            Injector 1 Check..14044
            Injector 2 Check..14046
            Injector 3 Check..14047
            Injector 4 Check..14048
            Injector 5 Check..14049
            Injector 6 Check..14050
            Injector 7 Check..14051
            Injector 8 Check..14052
            Injector Circuit Operation..14053
            High Side Drive Output..14053
            Low Side Drive Return..14053
            Fault Detection/Management..14053
          IST System (Idle Shutdown Timer)..14054
          Function..14054
          Tools..14054
            IST Operation..14055
            Idle Shutdown Warning..14055
            Engine Idle Shutdown Timer for California ESS-Compliant Engines..14055
            CARB IST Conditions..14055
            Engine Idle Shutdown Timer (Federal-Optional)..14055
            Federal IST Conditions..14056
            Common Enable Conditions for All Federal IST Options..14056
            Federal IST Mode 1: PTO Operation Option Enable Conditions..14056
            Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions..14056
            Federal IST Mode 3: Tamper Proof Option Enable Conditions..14056
            Fault Detection/Management..14056
          MAF/AIT Sensor (Mass Air Flow/Air Inlet Temperature)..14057
          Function..14057
          Sensor Location..14058
          Tools..14058
            MAF/AIT Sensor End Diagnostics..14058
            MAF/AIT Pin-point Diagnostics..14061
            MAF/AIT Circuit Operation..14063
            MAF Sensor..14063
            AIT Sensor..14063
            Extended Diagnostic Information..14063
            Fault Detection / Management..14063
          OSS (Output Shaft Speed) Sensor..14064
          Function..14064
          Tools..14064
            OSS Pin-point Diagnostics (Manual Transmissions)..14065
            OSS Circuit Operation (Manual and Allison Transmissions)..14066
            Fault Detection/Management..14066
          RSE (Radiator Shutter Enable)..14067
          Function..14067
          Component Location..14067
          Tools..14067
            RSE Circuit Diagnostics..14068
            RSE Circuit Operation..14069
            Fault Detection/Management..14069
          SMC Circuit (Starter Motor Control)..14070
          Function..14070
          Location..14070
          Tools..14070
            SMC Circuit Diagnostics..14071
            SMC Circuit Operation..14075
            Driveline Disengagement Switch (DDS) Circuit..14075
            Ignition Switch..14075
            SMC Circuit..14075
            ECM..14075
            Start Relay..14075
            Clutch Switch..14075
            Neutral Switch..14075
            WTEC MD with Auto Neutral..14075
            Fault Detection/Management..14075
          TACH (Tachometer Output Circuit)..14076
            Tachometer Pin-point Diagnostics..14077
            Tachometer Circuit Operation..14078
            Diagnostic Trouble Codes (DTCs)..14078
          TC1WC Solenoid (Turbocharger 1 Wastegate Control)..14079
          Function..14079
          Sensor Location..14079
          Tools..14079
            TC1WC Circuit Diagnostics..14080
            TC1WC Circuit Operation..14081
            Fault Detection/Management..14081
          TCOT Sensor (Turbocharger Outlet Temperature)..14082
          Function..14082
          Sensor Location..14082
          Tools..14082
            TCOT Sensor End Diagnostics..14083
            TCOT Pin-point Diagnostics..14084
            TCOT Circuit Operation..14085
            Fault Detection/Management..14085
          VREF (Reference Voltage)..14086
          Function..14087
          Tools..14087
            VREF Pin-point Diagnostics..14087
            VREF Circuit Operation..14093
            Fault Detection/Management..14093
          VSO (Vehicle Speed Output)..14094
            Vehicle Speed Output Pin-point Diagnostics..14095
            Vehicle Speed Output Circuit Operation..14096
            Diagnostic Trouble Codes (DTCs) ..14096
          WIF Sensor (Water In Fuel)..14097
          Function..14097
          Sensor Location..14097
          Tools..14097
            WIF Pin-point Diagnostics..14098
            WIF Circuit Operation..14099
            Fault Detection/Management..14099
      Table of Contents..14101
        Diagnostic Trouble Codes..14103
      Table of Contents..14113
        Electrical Tools..14115
          42-Pin Engine to Chassis Interface Cable..14115
          98-Pin Engine and Chassis Cables..14115
          180-Pin Breakout Box..14115
          Digital IR Thermometer..14116
          Digital Multimeter (DMM)..14116
          EXP-1000 HD by Midtronics..14117
          EZ-Tech? Electronic Service Tool (EST)..14117
          International? Electronic Engine Terminal Test Kit..14118
          NAVCoM Interface Kit..14118
          3-Banana Plug Harness..14118
          16-Way Breakout Harness..14119
          500-Ohm Resistor Harness..14119
          Breakout Harness 4485A (APP)..14119
          Breakout Harness 4602 (ECT, EFT, EOT, and IMT)..14119
          Breakout Harness 4760A (DOCIT, DPFIT, and DPFOT)..14120
          Breakout Harness 4761A (DPFDP)..14120
          Breakout Harness 4762 (IPR, EGR, and VGT)..14120
          Breakout Harness 4831 (TC1WC)..14120
          Breakout Harness 4850 (IMP)..14121
          Breakout Harness 4908 (ECM Relay)..14121
          Breakout Harness 4946 (EGT)..14121
          Breakout Harness 4950 (CMP)..14121
          Breakout Harness 4951 (CKP)..14122
          Breakout Harness 4958 (FPCV and FVCV)..14122
          Breakout Harness 4960 (MAF)..14122
          Breakout Harness 4993 (IMT)..14122
          Breakout Harness 6000 (UVC)..14123
          Breakout Harness 6001 (Fuel Pump)..14123
          Breakout Harness 6002 (WIF)..14123
          Breakout Harness 6005 (EBPV)..14123
          Breakout Harness 6025 (IAH)..14124
          Breakout Harness 6038 (FRP)..14124
        Mechanical Tools..14125
          Charge Air Cooler Test Kit..14125
          Clean Fuel Source Tool..14125
          Crankcase Pressure Test Adaptor..14125
          Crankcase Pressure Test Adaptor..14126
          Digital Manometer..14126
          EGR Cooler Leak Detection Kit..14127
          Fuel Inlet Restriction and Aeration Tool..14127
          Fuel/Oil Pressure Test Coupler..14127
          Fuel Pressure Test Kit..14128
          Fuel Rail Block Off Plugs..14128
          Fuel System Caps..14128
          High-pressure Pump Test Fitting..14128
          Fuel Injector Cups..14129
          Inline Shut-off Valve..14129
          Oil Cooler Block Off..14129
          Pressure Test Kit..14130
          Radiator Pressure Test Kit..14130
          Slack Tube? Manometer..14131
          Turbocharger Drain Block Off Plug..14132
          Turbocharger Oil Supply Block Off..14132
          Turbocharger Supply Block Off Plug..14132
          UV Leak Detection Kit..14133
          Vacuum Analyzer and Fuel Pump Tester..14133
      Table of Contents..14135
        Abbreviations and Acronyms..14137
          Abbreviations and Acronyms..14137
      Table of Contents..14141
        Terminology..14143
          Terms..14143
      Table of Contents..14153
        MaxxForce? 7 (6.4L) All Ratings @ 2600 rpm (12NSH)..14155
      Table of Contents..14159
        Signal Values..14161
      Table of Contents..14165
        Description..14167
  tables..13731
    Technical Service Literature..13731
    MaxxForce? 7 Features and Specifications..13738
    Unacceptable Boost Possible Causes..13853
    Unacceptable Fuel Rail Pressure Possible Causes..13853
    Unacceptable Fuel Pressure Possible Causes..13853
    Example..13874
    Example..13874
    Example..13875
    Example..13875
    Example..13876
    Example..13876
    Example..13877
    Example..13877
    Example..13877
    Example..13878
    Example..13879
    Example..13879
    Example..13880
    Alert Levels of DPF Soot Loading..13884
    Active Rolling Regeneration..13888
    Manual Parked Regeneration..13888
    Manual Parked Regeneration Procedure..13889
    Onboard Filter Cleanliness Test (ServiceMaxx? software)..13890
    SPN 1209 and FMI 0 - EBP above desired level..13894
    SPN 1692 and FMI 0 - Boost high/above desired level detected..13894
    SPN 1692 and FMI 17 - KOER STD - Boost unable to achieve desired set-point Pin-Point AMS Fault..13894
    SPN 1692 and FMI 18 - Boost unable to achieve desired set-point..13895
    SPN 2659 and FMI 17 -EGR Flow Rate unable to achieve desired set-point..13895
    SPN 2659 and FMI 20 - EGR high flow rate detected..13895
    SPN 2659 and FMI 21 - EGR low flow rate detected..13896
    Sensor Circuit Check..13900
    Connector Voltage Check..13901
    Connector Resistance Check to GND..13902
    Harness Resistance Check..13902
    Operational Voltage Check..13902
    Connector Voltage Check - EST..13905
    Harness Resistance Check..13906
    Brake Switch Circuits..13909
    Voltage Check..13910
    Harness Resistance Check..13910
    Connector Voltage Check..13912
    EST Communication Check..13913
    Harness Resistance Check..13913
    Switch Checks..13917
    Circuit End Voltage Check..13917
    Sensor and Circuit Resistance Check..13919
    Harness Resistance Check..13919
    Operational Check..13920
    Sensor and Circuit Resistance Check..13922
    Harness Resistance Check..13922
    Operational Check..13923
    Sensor Circuit Check..13929
    Connector Voltage Check..13929
    Connector Resistance Check to GND..13930
    Harness Resistance Check..13930
    Sensor Circuit Check..13933
    Connector Voltage Check..13934
    Connector Resistance Checks to GND..13934
    Harness Resistance Check..13934
    Sensor Circuit Check..13937
    Connector Voltage Check..13938
    Connector Resistance Check to GND..13938
    Harness Resistance Check..13938
    Sensor Circuit Check..13941
    Connector Voltage Check..13942
    Connector Resistance Check to GND..13942
    Harness Resistance Check..13942
    Connector Voltage Check..13944
    Connector Resistance Check to GND..13944
    Sensor Resistance Check..13945
    Harness Resistance Check..13945
    Voltage Check at Relay..13948
    Voltage Check at ECM..13948
    Harness Resistance Check..13949
    Harness Resistance Check on Relay Power Circuits..13949
    SPN 108/FMI 3- BARO signal Out of Range HIGH..13952
    SPN 108/FMI 4 - BARO signal Out of Range LOW..13952
    SPN 628/FMI 12 - ECM Memory Error..13952
    SPN 628/FMI 14 - ECM Programming - EFRC Error..13952
    SPN 629/FMI 2 - ECM Error - Level 2 Monitoring..13953
    SPN 629/FMI 10 - ECM Error - Fuel Injector Circuit Performance Bank B..13953
    SPN 629/FMI 12 - ECM Error - SPI..13953
    SPN 629/FMI 31 - ECM Error - Level 3 Monitoring..13953
    SPN 1136/FMI 0 - ECM Error - Over temperature..13953
    SPN 1136/FMI 1 - ECM Error - Under temperature..13953
    Sensor Circuit Check..13956
    Connector Voltage Check..13957
    Connector Resistance Check to GND..13957
    Harness Resistance Check..13957
    Voltage Check at EFC Connector Output State Test..13961
    Voltage Check at Relay - Output State Test..13961
    Harness Resistance Check..13962
    Sensor Circuit Check..13965
    Connector Voltage Check..13966
    Connector Resistance Check to GND..13966
    Harness Resistance Check..13967
    EGR Valve Circuit Check..13971
    EGR Valve - Standard and Output State Test..13971
    Connector Voltage Check..13972
    Connector Resistance Check to GND..13973
    Harness Resistance Check..13973
    SPN 412 FMI 0 ? EGRT above Critical Temperature..13977
    Sensor Circuit Check..13977
    Connector Voltage Check..13977
    Connector Resistance Check to GND..13977
    Harness Resistance Check..13978
    Sensor Circuit Check..13981
    Connector Voltage Check..13981
    Connector Resistance Check to GND..13981
    Harness Resistance Check..13982
    Sensor Circuit Check..13985
    Connector Voltage Check..13986
    Connector Resistance Check to GND..13986
    Harness Resistance Check..13987
    Sensor Circuit Check..13990
    Connector Voltage Check..13991
    Connector Resistance Check to GND..13991
    Harness Resistance Check..13992
    ETV Circuit Check..13996
    ETV - Standard Test and Output State Test..13996
    Connector Voltage Check..13997
    Connector Resistance Check to GND..13998
    Harness Resistance Check..13998
    Voltage Check at Fuel Cooler Control Valve Connector ? Output State Test..14005
    Harness Resistance Check..14005
    SPN 94 FMI 0 ? Fuel Filter Minder Above Maximum Pressure ..14009
    Sensor Circuit Check..14009
    Connector Voltage Check..14010
    Connector Resistance Check to GND..14010
    Harness Resistance Check..14011
    Actuator/Harness Resistance Check..14014
    Operational Voltage Check - Output Circuit Check..14014
    Connector Voltage Check..14016
    Run Output State Test ? Low..14016
    Run Output State Test ? Low..14016
    Connector Resistance Check to GND..14017
    Harness Resistance Check..14017
    Sensor Circuit Check..14020
    Connector Voltage Check..14021
    Connector Resistance Check to GND..14021
    Under Valve Cover Resistance Check to Engine GND..14022
    Harness Resistance Check..14022
    Actuator/Harness Resistance Check..14028
    Operational Voltage Check - Output Circuit Check..14028
    Voltage Check on Relay Switch ? Output State Test IAH..14031
    Voltage Check on Relay Coil ? Output State Test..14032
    Amperage Draw Check..14032
    Element Resistance Check..14032
    Harness Resistance Check ? Relay Coil Circuits..14032
    Harness Resistance Check ? Relay Switch Circuits..14033
    Sensor Circuit Check..14036
    Connector Voltage Check..14037
    Connector Resistance Check to GND..14037
    Harness Resistance Check..14038
    Sensor Circuit Check..14041
    Connector Voltage Check..14041
    Connector Resistance Check to GND..14041
    Harness Resistance Check..14042
    Injector 1 - Resistance Checks Through Harness and Injector..14044
    Injector 1 - Resistance UVC Checks..14044
    Injector 1 - Harness Resistance Check..14045
    Injector 2 - Resistance Through Valve Cover to Engine GND Check..14046
    Injector 2 - Coil Resistance Check..14046
    Injector 2 - Harness Resistance Check..14046
    Injector 3 - Resistance Through Valve Cover to Engine GND Check..14047
    Injector 3 - Coil Resistance Check..14047
    Injector 3 - Harness Resistance Check..14047
    injector 4 - Resistance Through Valve Cover to Engine GND Check..14048
    Injector 4 - Coil Resistance Check..14048
    Injector 4 - Harness Resistance Check..14048
    Injector 5 - Resistance Through Valve Cover to Engine GND Check..14049
    Injector 5 - Coil Resistance Check..14049
    Injector 5 - Harness Resistance Check..14049
    Injector 6 - Resistance Through Valve Cover to Engine GND Check..14050
    Injector 6 - Coil Resistance Check..14050
    Injector 6 - Harness Resistance Check..14050
    Injector 7 - Resistance Through Valve Cover to Engine GND Check..14051
    Injector 7 - Coil Resistance Check..14051
    Injector 7 - Harness Resistance Check..14051
    Injector 8 - Resistance Through Valve Cover to Engine GND Check..14052
    Injector 8 - Coil Resistance Check..14052
    Injector 8 - Harness Resistance Check..14052
    MAF Calibration Requirements..14059
    MAF Calibration Pre-Checks..14060
    MAF Calibration Procedure ? Using ServiceMaxx? Software..14061
    Connector Voltage Check..14062
    Harness Resistance Check..14063
    Connector Voltage Checks..14066
    Sensor Resistance Check..14066
    Harness Resistance Check..14066
    Voltage Check at RSE Connector - Output State Test..14068
    Harness Resistance Check..14069
    Voltage Check at Start Relay and Starter Solenoid..14073
    Voltage Check at ECM..14073
    Harness Resistance Check - ECM to Relay..14074
    Harness Resistance Check - Relay to Battery..14074
    Operational Voltage Check..14074
    Circuit End Voltage Check..14077
    Harness Resistance Check..14077
    Voltage Check at TC1WC Connector - Output State Test..14080
    Harness Resistance Check..14081
    Sensor Circuit Check..14084
    Connector Voltage Check..14084
    Connector Resistance Check to GND..14084
    Harness Resistance Check..14085
    VREF Voltage Check..14089
    Connector Resistance Check to GND..14090
    Harness Resistance Check..14091
    Harness Resistance Check (cont.)..14092
    Circuit End Voltage Check..14095
    Harness Resistance Check..14095
    Operational Check..14095
    Voltage Check..14099
    Connector Resistance Checks to GND..14099
    Harness Resistance Check..14099
    KOEO (Key ON, Engine OFF)..14155
    Engine cranking..14156
    Low Idle, no load, stabilized engine operating temperature..14156
    High Idle, no load, stabilized engine operating temperature..14156
    Full load, rated speed on highway, stabilized engine operating temperature..14157
    Stabilized engine operating temperature..14157
    Miscellaneous sensors and components..14157
EGES-485-1 - Diagnostic Trouble Code..14170
EGES-540 -  2007-2009 Aftertreatment Unique Diagnostics And Service Information (MaxxForce 5, 7, DT, 9, 10, 11, and 13)..14179
EGES-611 - Manual de Diagn?stico 2007 MaxxForce DT, 9, 10..14215
  toc..14217
    Contenido..14217
    Terminolog?a de seguridad..14221
    Instrucciones de seguridad..14221
    ?rea de trabajo..14221
    Equipo de seguridad..14221
    Medidas de protecci?n..14221
    Veh?culo..14221
    Motor..14221
    Prevenci?n de incendios..14222
    Bater?as..14222
    Aire comprimido..14222
    Herramientas..14222
    L?quidos bajo presi?n..14222
    Combustible..14222
    Extracci?n de herramientas, piezas y equipo..14222
      Contenido..14223
        Identificaci?n del motor..14225
          N?mero de serie del motor..14225
          Ejemplos de n?mero de serie del motor..14225
          C?digos del n?mero de serie del motor..14225
          Etiqueta de emisiones del motor..14225
          Etiquetas de accesorios del motor..14225
          Descripci?n del motor..14226
            Caracter?sticas est?ndar..14228
            Caracter?sticas opcionales..14230
            Funciones opcionales para climas fr?os..14230
            Caracter?sticas montadas en el chasis..14231
          Ubicaci?n de los componentes del motor..14232
        Sistema de gesti?n del aire comprimido..14237
          Flujo de aire..14238
          Componentes de administraci?n de aire..14238
            Enfriador de aire de sobrealimentaci?n (CAC)..14238
            Sistema de recirculaci?n de gas de escape (EGR)..14239
            Flujo de EGR..14240
            V?lvula de control de EGR..14240
            Sistema de bucle cerrado de EGR..14241
            Turbocargador de geometr?a variable (VGT)..14242
            Sistema de bucle cerrado de VGT..14243
            Control de VGT..14243
            Sistema de postratamiento (AFT)..14245
            Sistema de control de AFT..14245
            Sensores..14245
            Catalizador de oxidaci?n diesel (DOC, Diesel Oxidation Catalyst)..14245
            Filtro de part?culas diesel (DPF)..14245
            Respuestas y condiciones de AFT..14245
        Sistema de manejo de combustible..14246
          Sistema de ICP..14247
            Flujo de aceite de alta presi?n..14247
            Sistema de bucle cerrado de ICP..14249
            Sistema de control de IPC..14250
            Inyector de combustible..14251
            Caracter?sticas de los inyectores de combustible..14251
            Bobinas del inyector y v?lvula de carrete..14251
            ?mbolo y pist?n intensificador..14251
            ?mbolo y barril..14251
            Aguja del inyector..14251
            Funcionamiento del inyector de combustible..14252
            Etapa de llenado..14252
            Inyecci?n..14252
            Fin de inyecci?n..14252
        Sistema de alimentaci?n de combustible..14254
          Flujo del sistema de suministro de combustible..14255
        Sistema de lubricaci?n del motor..14259
          Flujo de aceite..14260
        Sistema de enfriamiento del motor..14263
          Flujo del sistema de enfriamiento..14264
          Componentes del sistema de enfriamiento..14264
            Calefactor de refrigerante (opcional)..14264
            Funcionamiento del termostato..14265
        Sistema de control electr?nico..14265
          Componentes del sistema de controles electr?nicos..14265
            Operaci?n y funcionamiento..14266
            Voltaje de referencia (VREF)..14267
            Condicionante de se?al..14267
            MICROPROCESADOR..14267
            Memoria del microprocesador..14267
            ROM..14267
            ?mbolo..14267
            Control del actuador..14268
          los actuadores..14268
            V?lvula de EGR..14268
            Rel?s de IAH..14268
            Activador del acelerador de admisi?n y sensor de posici?n..14268
          Sensores e interruptores del motor y del veh?culo..14269
            Sensores termistores..14269
            Sensores de tratamiento posterior..14269
            Sensor de ECT..14270
            Sensor EOT..14270
            Sensor IAT..14270
            Sensor MAT..14270
            Sensores de capacitancia variable..14271
            Sensor EGDP..14271
            Sensor EFP..14271
            Sensor EOP..14271
            SENSOR EBP..14271
            Sensor de presi?n absoluta del m?ltiple de admisi?n (Manifold Absolute Pressure, MAP)..14271
            Sensores del captador magn?tico..14272
            Sensor de posici?n del cig?e?al (Crankshaft Position Sensor, CKP)..14272
            Sensor de CMP..14273
            VSS..14273
            Sensores del medidor de micro resistencia (MSG)..14274
            BCP..14274
            ICP..14274
            Potenci?metro..14275
            APS..14275
            Interruptores..14276
            DDS..14276
            L?gica de emisores acoplados (Emitter Coupled Logic, ECL)..14276
            IVS..14276
            WIF..14276
          V?lvula del regulador de admisi?n..14277
        Sistema de frenos Diamond Logic?..14278
        BCP..14279
        BSV..14279
        V?lvula de alivio de presi?n de los frenos..14279
        EBP..14279
        M?ltiple de aceite de alta presi?n..14279
        Turbocompresor de geometr?a variable (Variable Geometry Turbo, VGT)..14279
          Modos de funcionamiento de los frenos..14279
          Modo desacoplado..14279
          Modo retenido..14279
          Modo de velocidad de crucero..14279
          Sistema de frenos de escape..14279
          Operaci?n..14280
          Sistema de frenos del motor..14280
          Operaci?n..14280
      Contenido..14283
        Caracter?sticas est?ndar..14285
          Control electr?nico del regulador..14285
          Enlace de datos de la American Trucking Association (ATA)..14285
          Diagn?sticos de servicio..14285
          Sistema de registro de eventos..14285
          Veloc?metro y tac?metro electr?nicos..14285
          Sistema de postratamiento..14285
          Monitor de presi?n de combustible del motor (EFP)..14285
          Calefactor del aire de admisi?n (IAH)..14285
          Avance en ralent? r?pido..14286
          Protecci?n contra temperatura ambiente baja (CAP)..14286
          Compensaci?n de la temperatura del refrigerante (Coolant Temperature Compensation)..14286
          Inhibidor de giro del motor (ECI)..14286
          Mensaje de intervalos Change Engine Oil (cambiar aceite del motor)..14287
        Caracter?sticas opcionales..14288
          Limitaci?n de la velocidad en carretera..14288
          Control de crucero..14288
          Control de tracci?n..14288
          Sistema de frenos Diamond Logic?..14288
          Sistema de advertencia y protecci?n del motor (EWPS)..14288
          Temporizador de apagado por ralent? (IST)..14288
          IST para los Motores que cumplen con el ESS de California..14288
          Temporizador de apagado del ralent? del motor (Federal?Opcional)..14289
          Ventilador electr?nico (EFAN)..14289
          Persiana del radiador activada (RSE)..14289
      Contenido..14291
        Software MasterDiagnostics?..14293
          Abra la aplicaci?n..14293
          Elija el dispositivo COM..14293
          Recupere la informaci?n del motor..14293
          Abra el formulario de diagn?stico..14293
          Abra el software MasterDiagnostics?..14293
        Diagn?stico de comunicaci?n de la Herramienta electr?nica de servicio (EST)..14295
          Autoprueba del dispositivo de la interfaz IC4..14295
        Comunicaciones (COM)..14297
          Abra las comunicaciones..14297
          Comunicaciones cerradas..14297
        C?digos de problemas de diagn?stico (DTC)..14298
          Lectura de DTC con EST..14298
          Men? de ayuda del DTC..14299
          Eliminaci?n de los DTC..14301
        Archivos de la sesi?n..14302
          Abrir el archivo de la sesi?n..14302
          Agregar y borrar los identificadores del par?metro de la sesi?n (PID)..14302
          Cerrar el archivo de la sesi?n..14304
          VIN+ Sesi?n..14304
        Capturas de pantalla..14306
          Abrir capturas de pantalla espec?ficas..14306
          Abrir capturas de pantalla b?sicas..14306
          Configuraci?n de la captura de pantalla..14308
            Activaci?n de la captura de pantalla con los DTC activos..14308
            Activaci?n de la captura de pantalla con el identificador de par?metros (PID)..14309
            Relaciones de muestra, tiempo de activaci?n previa y activaci?n posterior..14311
            Lista de PID de la captura de pantalla..14312
            Renombre los archivos REC..14313
            Capturas de pantalla de la activaci?n manual..14314
          Reproduzca la gr?fica de la captura de pantalla..14315
        Pruebas de diagn?stico..14317
          Pruebas de Llave en encendido con motor apagado..14317
            Prueba est?ndar..14317
            Prueba del inyector..14318
            Prueba de bajo estado de salida..14319
            Prueba de alto estado de salida..14320
            Prueba del estado de salida del calefactor del aire de admisi?n..14321
          Pruebas de llave en encendido con motor funcionando..14322
            Prueba est?ndar..14322
            Prueba de tratamiento posterior del motor..14322
            Prueba de administraci?n de aire..14324
            Prueba de VGT..14325
          Monitoreo continuo ? Conexiones intermitentes de identificaci?n y resoluci?n de problemas..14326
          Prueba de inhabilitaci?n del inyector..14327
          Funci?n de funcionamiento autom?tico..14328
          Compresi?n relativa..14329
        Restablezca el mensaje de Cambio de aceite del motor..14330
          Mensaje de restablecimiento con EST..14330
        Informaci?n general..14330
          Versi?n MasterDiagnostics? instalada..14330
          Cable de interfaz aprobado..14330
      Contenido..14331
        Descripci?n..14333
        Sistema de refrigerante..14333
          Fugas de combusti?n de refrigerante..14333
          Situaci?n..14333
          Herramientas..14333
          Posibles causas..14333
          Procedimiento..14334
          Fuga de refrigerante al escape/admisi?n..14336
          S?ntomas..14336
          Herramientas..14336
          Posibles causas..14336
            Inspecci?n del enfriador de EGR..14336
            Procedimiento..14336
            Inspecci?n de la funda del inyector..14337
            Procedimiento..14337
            Prueba de fugas de la culata de cilindros..14338
          Refrigerante en el aceite de lubricaci?n..14340
          Situaci?n..14340
          Herramientas..14340
          Posibles causas..14340
            Inspecci?n del sistema de refrigerante..14340
            Procedimiento..14340
            Inspecci?n de la cubierta delantera..14343
          Sobretemperatura del refrigerante..14344
          S?ntomas..14344
          Herramientas..14344
          Posibles causas..14344
            Inspecci?n del sistema de refrigerante..14344
            Prueba de validaci?n del sensor de temperatura..14347
            Prueba de presi?n de funcionamiento del sistema de enfriamiento..14347
        Sistema de combustible..14348
          Cebado del sistema de combustible..14348
          Presi?n de combustible, aireaci?n y suministro..14349
          Situaci?n..14349
          Herramientas..14349
          Posibles causas..14349
            Aireaci?n y presi?n del combustible..14349
            Prop?sito..14349
            Herramientas..14349
            Posibles causas..14349
            Procedimiento..14350
            Presi?n del alojamiento del filtro de combustible..14350
            Prop?sito..14350
            Herramientas..14351
            Procedimiento..14351
            Restricci?n de entrada de combustible..14352
            Prop?sito..14352
            Herramientas..14352
            Posibles causas..14352
            Procedimiento..14352
            Funcionamiento de la bomba de combustible..14353
            Prop?sito..14353
            Herramientas..14353
            Procedimiento..14353
            Prueba del combustible alternativo a la bomba de combustible..14354
            Prop?sito..14354
            Herramientas..14354
            Procedimiento..14354
            Suministro de combustible alternativo al alojamiento del filtro de combustible..14354
            Prop?sito..14354
            Herramientas..14354
            Procedimiento..14355
            Fugas de combusti?n al combustible..14355
        Sistema de lubricaci?n..14356
          Baja presi?n del aceite..14356
          Situaci?n..14356
          Herramientas..14356
          Posibles causas..14356
            Inspecci?n del aceite..14356
            Inspecci?n del regulador de la presi?n de aceite..14357
            Inspecci?n de aceite y del c?rter..14359
            Inspecci?n de la bomba del motor..14360
            Inspecci?n de la cubierta delantera..14360
          Aceite lubricante en el refrigerante..14361
          Situaci?n..14361
          Herramientas..14361
          Posibles causas..14361
          Procedimiento..14361
      Contenido..14363
        Formulario de diagn?stico EGED-375..14365
          Informaci?n del encabezado..14366
          Ingrese la informaci?n del encabezado..14366
          Ingrese la informaci?n del veh?culo..14366
          Ingrese la informaci?n de especificaciones del rendimiento..14366
          Verifique la Calibraci?n del ECM con las Especificaciones del veh?culo..14366
        Procedimientos de prueba necesarios..14368
          1. Interruptor de encendido inicial encendido (no arranque)..14368
          Prop?sito..14368
          Herramientas..14368
          Posibles causas..14368
          La luz WAIT TO START (espere para arrancar) no se ilumina..14368
          Sin ciclo previo del inyector..14368
          Sin ciclo previo del turbocargador..14368
          La luz WATER IN FUEL (agua en el combustible) se ilumina..14368
          Procedimiento..14368
          2. Giro del motor..14370
          Prop?sito..14370
          Herramientas..14370
          Posibles causas..14370
          El motor no gira..14370
          RPM insuficiente..14370
          Presi?n de aceite insuficiente..14370
          Procedimiento..14370
          3. Inspecci?n visual..14371
          Prop?sito..14371
          Herramientas..14371
            Aceite de motor..14371
            Nivel de combustible..14371
            Nivel del refrigerante del motor..14371
            Sistema del enfriador de aire de carga (CAC)..14371
            Sistema el?ctrico..14372
            Sistema de escape..14372
          4. DTC y calibraci?n del ECM..14373
          Prop?sito..14373
          Herramientas..14373
            Revise la calibraci?n del ECM..14373
            Detecci?n de c?digos de diagn?stico de fallas..14373
            Estado: indica los DTC activos o inactivos..14373
          5. Lista de datos de EST..14374
          Prop?sito..14374
          Herramientas..14374
          Procedimiento..14374
          6. Pruebas de KOEO..14375
            Prueba est?ndar 6.1..14375
            Prop?sito..14375
            Herramientas..14375
            Posibles causas..14375
            Procedimiento..14375
            Prueba del inyector KOEO 6.2..14375
            Prop?sito..14375
            Herramientas..14375
            Posibles causas..14375
            Procedimiento..14375
          7. Funcionamiento de la v?lvula EGR e ITV..14377
          Prop?sito..14377
          Herramientas..14377
          Posibles causas..14377
          Procedimiento..14377
        Procedimientos de prueba especiales..14378
          Voltaje principal de alimentaci?n al ECM..14378
          Prop?sito..14378
          Herramientas..14378
          Posibles causas..14378
          Voltaje bajo de la bater?a..14378
          Bater?a con bajo voltaje o sin voltaje hacia el ECM..14378
          Procedimiento..14378
          Sistema del calefactor de aire de entrada (IAH)..14379
          Prop?sito..14379
          Herramientas..14379
          Posibles causas..14379
            Consumo de amperaje..14379
            Procedimiento..14379
            Voltaje en el elemento..14381
            Continuidad del elemento..14382
            Resistencia y continuidad del arn?s de cableado...14383
            Operaci?n del rel?..14383
          Sistema de combustible..14385
            Calidad del combustible..14385
            Prop?sito..14385
            Herramientas..14385
            Posibles causas..14385
            Procedimiento..14385
            Aireaci?n y presi?n del combustible..14386
            Prop?sito..14386
            Herramientas..14386
            Posibles causas..14386
            Procedimiento..14386
            Restricci?n de entrada de combustible..14387
            Prop?sito..14387
            Herramientas..14387
            Posibles causas..14387
            Procedimiento..14387
          Sensor de presi?n de control de la inyecci?n..14388
            Prueba de desconexi?n de la presi?n de control de la inyecci?n (ICP)..14388
            Prop?sito..14388
            Herramientas..14388
            Posibles causas..14388
            Procedimiento..14388
            Prueba del sistema de presi?n de control de la inyecci?n (ICP)..14388
            Prop?sito..14388
            Herramientas..14388
            Posibles causas..14388
            Procedimiento..14388
            Prueba del sistema de control de IPR..14390
            Prop?sito..14390
            Herramientas..14390
            Posibles causas..14390
            Procedimiento..14390
            Prueba de la bomba de aceite de alta presi?n..14391
            Prop?sito..14391
            Herramientas..14391
            Posibles causas..14391
            Procedimiento..14391
            Prueba de bloqueo del IPR..14392
            Prop?sito..14392
            Herramientas..14392
            Posibles causas..14392
            Procedimiento..14392
            Prueba de fugas del riel de alta presi?n..14393
            Prop?sito..14393
            Herramientas..14393
            Posibles causas..14393
            Procedimiento..14393
      Contenido..14395
        Formulario de diagn?stico EGED-380..14397
          Informaci?n del encabezado..14398
          Ingrese la informaci?n del encabezado..14398
          Ingrese la informaci?n del veh?culo..14398
          Ingrese la informaci?n de especificaciones del rendimiento..14398
          Verifique la Calibraci?n del ECM con las Especificaciones del veh?culo..14398
        PROCEDIMIENTOS DE PRUEBA..14400
          1. Inspecci?n visual..14400
          Prop?sito..14400
          Herramientas..14400
            Aceite de motor..14400
            Nivel de combustible..14400
            Nivel del refrigerante del motor..14400
            Sistema del enfriador de aire de carga (CAC)..14400
            Sistema el?ctrico..14401
            Sistema de escape..14401
          2. Sistema de combustible..14401
            2.1 Calidad del combustible..14401
            Prop?sito..14401
            Herramientas..14401
            Posibles causas..14401
            Procedimiento..14401
            2.2 Aireaci?n y presi?n del combustible..14403
            Prop?sito..14403
            Herramientas..14403
            Posibles causas..14403
            Procedimiento..14403
            2.3 Restricci?n de la admisi?n de combustible..14405
            Prop?sito..14405
            Herramientas..14405
            Posibles causas..14405
            Procedimiento..14405
          3. Comparaci?n del sensor..14406
          Prop?sito..14406
          Herramientas..14406
          Posibles causas..14406
          Procedimiento..14406
          4. DTC y calibraci?n del ECM..14407
          Prop?sito..14407
          Herramientas..14407
            Revise la calibraci?n del ECM..14407
            Detecci?n de c?digos de diagn?stico de fallas..14407
            Estado: indica los DTC activos o inactivos..14407
          5. Prueba est?ndar de KOEO (Llave en contacto y motor apagado)..14408
          Prop?sito..14408
          Herramientas..14408
          Posibles causas..14408
          Procedimiento..14408
          6. Funcionamiento de la v?lvula EGR e ITV..14408
          Prop?sito..14408
          Herramientas..14408
          Posibles causas..14408
          Procedimiento..14408
          7. Prueba del inyector de KOEO (Llave en contacto y motor apagado)..14410
          Prop?sito..14410
          Herramientas..14410
          Posibles causas..14410
          Procedimiento..14410
          8. Prueba est?ndar de KOER (Llave en contacto y motor encendido)..14410
          Prop?sito..14410
          Herramientas..14410
          Posibles causas..14410
          Procedimiento..14410
          9. Prueba de administraci?n de aire de KOER (Llave en contacto y motor encendido)..14411
            9.1 Prueba de manejo de aire..14411
            Prop?sito..14411
            Herramientas..14411
            Posibles causas..14411
            Procedimiento..14411
            9.2 Prueba VGT..14412
            Prop?sito..14412
            Herramientas..14412
            Procedimiento..14412
            9.3 Prueba de la Uni?n del activador de VGT..14413
            Posibles causas..14413
            Procedimiento..14413
          10. Atasco del convertidor de par de torsi?n (?nicamente autom?tico)..14415
          Prop?sito..14415
          Herramientas..14415
          Posibles causas..14415
          Procedimiento..14415
          11. Prueba en carretera (carga completa, velocidad nominal)..14415
          Prop?sito..14415
          Herramientas..14415
          Causas posibles del repuesto no aceptable..14415
          Posibles causas de la presi?n de control de inyecci?n no aceptables..14416
          Las causas posibles de la presi?n del combustible son inaceptables..14417
          Procedimiento..14417
          12. Desactivaci?n del inyector..14418
          Prop?sito..14418
          Herramientas..14418
          Posibles causas..14418
          Procedimiento..14418
          13. Compresi?n relativa..14419
          Prop?sito..14419
          Herramientas..14419
          Posibles causas..14419
          Procedimiento..14419
          14. Presi?n del c?rter..14420
          Prop?sito..14420
          Herramientas..14420
          Posibles causas..14420
          Procedimiento..14420
          15. Restricci?n de admisi?n..14423
          Prop?sito..14423
          Herramientas..14423
          Posibles causas (Opci?n 1 y 2)..14423
            Opci?n 1..14423
            Opci?n 2..14423
          16. Restricci?n de escape..14424
          Prop?sito..14424
          Herramientas..14424
          Posibles causas..14424
          Procedimiento..14424
          17. Sensor de presi?n de control de la inyecci?n..14425
            17.1 Prueba del sistema de presi?n de control de la inyecci?n (ICP)..14425
            Prop?sito..14425
            Herramientas..14425
            Posibles causas..14425
            Procedimiento..14425
            17.2 Prueba del sistema de control IPR..14426
            Prop?sito..14426
            Herramientas..14426
            Posibles causas..14426
            Procedimiento..14426
            17.3 Prueba de la bomba de aceite de presi?n alta..14428
            Prop?sito..14428
            Herramientas..14428
            Posibles causas..14428
            Procedimiento..14428
            17.4 Prueba de desbloqueo de IPR..14430
            Prop?sito..14430
            Herramientas..14430
            Posibles causas..14430
            Procedimiento..14430
            17.5 Prueba de fuga del riel del aceite de presi?n alta..14431
            Prop?sito..14431
            Herramientas..14431
            Posibles causas..14431
            Procedimiento..14431
          18. Juego libre de las v?lvulas y juego libre del freno de motor..14431
          Prop?sito..14431
          Herramientas..14431
          Posibles causas..14431
          Juego libre de las v?lvulas para las v?lvulas de admisi?n y escape..14432
            Ajuste del juego libre de las v?lvulas..14432
            Juego libre del freno..14434
      Contenido..14437
        Descripci?n..14441
          Informaci?n sobre la secci?n..14441
        Formulario de Diagn?sticos del sistema de control electr?nico..14442
          EGED-385 Ejemplo del formulario de diagn?stico..14442
        Ubicaciones del sensor y activador..14443
          Componentes instalados del motor..14443
          Componentes instalados en el veh?culo..14448
        Proceso de procedimiento de diagn?stico..14448
          Descripci?n..14448
          Inspecci?n de un agarre seguro..14448
            Diagn?sticos con EST..14448
            Diagn?sticos sin EST..14448
          Diagn?sticos finales del sensor (con MasterDiagnostics?)..14450
            Diagn?sticos finales del sensor (2-Cable)..14450
            Diagn?sticos finales del sensor (3-Cable)..14454
          Diagn?sticos de identificaci?n (sin el software?MasterDiagnostics)..14458
          Verificaci?n del voltaje operativo del activador ? Prueba del estado de salida..14459
          Verifique la resistencia del arn?s..14460
          Verificaci?n de voltaje operacional..14461
        Diagn?sticos del circuito..14462
          Rel? ACT PWR (alimentaci?n del activador)..14462
          Funci?n..14462
          Herramientas..14462
            Diagn?sticos paso a paso del rel? ACT PWR..14463
            Funcionamiento del circuito ACT PWR..14465
            Detecci?n/administraci?n de fallas..14465
          Sistema AFT (Postratamiento)..14466
          Funci?n..14467
          Herramientas..14467
            Diagn?sticos del sistema AFT..14468
            Funcionamiento del sistema AFT..14472
            Catalizador de oxidaci?n diesel (DOC, Diesel Oxidation Catalyst)..14474
            Filtro de part?culas diesel (DPF)..14474
            Regeneraci?n..14474
            Regeneraci?n de rodamiento pasivo..14474
            Prueba de limpieza a bordo (EST habilitado)..14475
            Interruptor de regeneraci?n de estacionamiento..14475
            Interrupci?n de regeneraci?n de inhibici?n (opcional)..14475
            Porcentaje de carga de holl?n en el filtro de part?culas de diesel (DPF)..14475
            Porcentaje de carga de cenizas del filtro de part?culas de diesel (DPF)..14475
            Estado de la l?mpara DPF..14475
            Indicador de temperatura alta del sistema de escape (HEST)..14475
          AMS (Sistema de administraci?n de aire)..14476
          Funci?n..14477
          Herramientas..14477
            Diagn?sticos del AMS..14477
            Funcionamiento de AMS..14481
            Parte de VGT..14481
            Parte de EGR..14481
          APS/IVS (Sensor de posici?n del acelerador e interruptor de validaci?n de ralent?)..14482
          Funci?n..14482
          Ubicaci?n del sensor..14482
          Herramientas..14482
            Diagn?stico de extremo del sensor APS/IVS..14483
            Diagn?stico preciso del APS/IVS..14485
            Funcionamiento del circuito del APS/IVS..14487
            APS..14487
            IVS..14487
            Autocalibraci?n de APS..14487
            Detecci?n/administraci?n de fallas..14487
          V?nculo de datos de ATA (American Trucking Association)..14488
          Funci?n..14488
          Ubicaci?n..14488
          Herramientas..14488
            Diagn?stico preciso de ATA..14489
            Funcionamiento de ATA..14490
            Conector de EST..14490
            EGC..14490
            Detecci?n/administraci?n de fallas..14490
            Informaci?n de reparaci?n..14490
          Sensor BCP (Presi?n de control del freno)..14491
          Funci?n..14491
          Ubicaci?n del sensor..14491
          Herramientas..14491
            Diagn?stico de extremo del sensor BCP..14493
            Diagn?stico preciso de BCP..14495
            Funcionamiento del circuito de BCP..14496
            Detecci?n/administraci?n de fallas..14496
          BOO/BPS (Freno encendido/apagado) / (Interruptor de presi?n del freno)..14497
          Funci?n..14497
          Ubicaci?n..14497
          Herramientas..14497
            Diagn?stico preciso de los circuitos del interruptor del freno..14498
            Funcionamiento del circuito del interruptor del freno..14500
            GESTI?N/DETECCI?N DE FALLAS..14500
          BSV (V?lvula de cierre del freno)..14501
          Funci?n..14501
          Ubicaci?n de la v?lvula..14501
          Herramientas..14501
            Diagn?stico preciso de BSV..14502
            Funcionamiento del circuito de BSV..14503
            Detecci?n/administraci?n de fallas..14504
          Comunicaciones de CAN (Red del ?rea del controlador) (P?blica)..14505
          Funci?n..14505
          Ubicaci?n..14505
          Herramientas..14505
            Diagn?stico preciso de CAN (p?blica)..14506
            Funcionamiento del circuito de CAN (p?blica)..14508
            CAN p?blica vs. CAN privada..14508
            Conector de EST..14508
            EGC..14508
            M?dulo de ESC o MSM..14509
            Informaci?n de reparaci?n..14509
          CCS (Sistema de control de velocidad de crucero)..14510
          Funci?n..14510
          Ubicaci?n..14511
          Herramientas..14511
            Diagn?stico preciso del sistema de control de velocidad crucero..14511
          Sensor CKP (posici?n del cig?e?al)..14513
          Funci?n..14513
          Ubicaci?n del sensor..14513
          Herramientas..14513
            Diagn?stico preciso de CKP..14514
            Funcionamiento del circuito de CKP..14515
            Detecci?n/administraci?n de fallas..14515
          Sensor CMP (posici?n del ?rbol de levas)..14516
          Funci?n..14516
          Ubicaci?n del sensor..14516
          Herramientas..14516
            Diagn?sticos de identificaci?n de CMP..14517
            Funcionamiento del circuito de CMP..14518
            Detecci?n/administraci?n de fallas..14518
          Balance del cilindro..14519
            Funcionamiento del balance del cilindro..14519
            Diagn?sticos de balance del cilindro..14520
          Sensor de EBP (contrapresi?n de escape)..14522
          Funci?n..14522
          Ubicaci?n del sensor..14522
          Herramientas..14522
            Diagn?sticos finales del sensor de EBP..14523
            Diagn?sticos de indicaci?n del EBP..14525
            Funcionamiento del circuito de EBP..14526
            Detecci?n/administraci?n de fallas..14526
          Circuito de ECI (inhibici?n de giro del motor)..14527
          Funci?n..14527
          Ubicaci?n..14527
          Herramientas..14527
            Diagn?sticos de circuitos de ECI..14528
            Funcionamiento del circuito de ECI..14532
            Circuito de DDS..14532
            Interruptor de encendido..14532
            Circuito de ECI..14532
            M?dulo electr?nico de control (ECM)..14532
            REL? DEL ARRANCADOR..14532
            Interruptor del embrague..14532
            Interruptor de neutro..14532
            WTEC MD con neutro autom?tico..14532
            Detecci?n/administraci?n de fallas..14533
          Interruptor de ECL (Nivel de refrigerante del motor)..14534
          Funci?n..14534
          Ubicaci?n..14534
          Herramientas..14534
            Diagn?sticos de indicaci?n de ECL..14535
            Funcionamiento del circuito de ECL..14536
            Detecci?n/administraci?n de fallas..14536
          ECM PWR (energ?a del m?dulo de control electr?nico)..14537
          Funci?n..14537
          Ubicaci?n del ECM..14537
          Herramientas..14537
            Diagn?sticos de indicaci?n de PWR del ECM..14538
            Funcionamiento del circuito ECM PWR..14542
            Detecci?n/administraci?n de fallas..14542
          Autodiagn?sticos del ECM (M?dulo de control electr?nico)..14543
          Detecci?n/administraci?n de fallas..14544
            C?digos de problema de autodiagn?stico (DTC) del ECM..14545
          Sensor de ECT (Temperatura del refrigerante del motor)..14550
          Funci?n..14551
          Ubicaci?n del sensor..14551
          Herramientas..14551
            Diagn?sticos finales del sensor de ECT..14552
            Diagn?sticos de identificaci?n de ECT..14554
            Funcionamiento del circuito de ECT..14555
            Compensaci?n de la temperatura del refrigerante (Coolant Temperature Compensation)..14555
            Protecci?n y advertencia del motor (EWPS)..14555
            Detecci?n/administraci?n de fallas..14555
          Control de EFAN (Control del ventilador del motor)..14556
          Funci?n..14556
          Ubicaci?n..14556
          Herramientas..14556
            Diagn?sticos de circuitos de EFAN..14557
            Funcionamiento del circuito EFAN..14559
            Par?metros programables EFAN..14559
            Detecci?n/administraci?n de fallas..14559
          Sensor EFP (presi?n del combustible del motor)..14560
          Funci?n..14560
          Ubicaci?n del sensor..14560
          Herramientas..14560
            Diagn?stico final del sensor EFP..14561
            Diagn?stico de posici?n del pasador de EFP..14563
            Funcionamiento del circuito de EFP..14564
            Detecci?n/administraci?n de fallas..14564
          Sensor EGDP (presi?n del diferencial de gas de escape)..14565
          Funci?n..14566
          Ubicaci?n del sensor..14566
          Herramientas..14566
            Diagn?stico final del sensor EGDP..14567
            Diagn?stico de identificaci?n del EGDP..14569
            Funcionamiento del circuito de EGDP..14570
          Activador de EGR (recirculaci?n del gas de escape)..14571
          Funci?n..14571
          Ubicaci?n de los componentes..14572
          Herramientas..14572
            Diagn?stico de la alarma de EGR..14573
            Funcionamiento del circuito de EGR..14575
            Funcionamiento del circuito CAN (privado)..14575
            CAN (privado) contra CAN (p?blico)..14575
            Informaci?n de reparaci?n CAN..14575
          Sensor EGT1 (temperatura de gas de escape 1)..14576
          Funci?n..14576
          Ubicaci?n del sensor..14576
          Herramientas..14576
            Diagn?stico final del sensor EGT1..14578
            Diagn?stico de posici?n del pasador EGT1..14580
            Funcionamiento del circuito EGT1..14582
          Sensor EGT2 (temperatura de gas de escape 2)..14583
          Funci?n..14583
          Ubicaci?n del sensor..14583
          Herramientas..14583
            Diagn?stico final del sensor EGT2..14584
            Diagn?stico de posici?n del pasador EGT2..14586
            Funcionamiento del circuito EGT2..14587
          Sensor EGT3 (temperatura de gas de escape 3)..14588
          Funci?n..14588
          Ubicaci?n del sensor..14588
          Herramientas..14588
            Diagn?stico final del sensor EGT3..14590
            Diagn?stico de posici?n del pasador EGT3..14592
            Funcionamiento del circuito EGT3..14593
          Sensor EOP (presi?n de aceite del motor)..14594
          Funci?n..14594
          Ubicaci?n del sensor..14594
          Herramientas..14594
            Diagn?stico final del sensor EOP..14595
            Diagn?stico de posici?n del pasador de EOP..14597
            Funcionamiento del circuito de EOP..14598
            Detecci?n/administraci?n de fallas..14598
          Sensor EOT (temperatura de aceite del motor)..14599
          Funci?n..14600
          Avance en ralent? r?pido..14600
          Ubicaci?n del sensor..14600
          Herramientas..14600
            Diagn?stico final del sensor EOT..14601
            Diagn?stico de posici?n del pasador EOT..14603
            Funcionamiento del circuito EOT..14604
            Detecci?n/administraci?n de fallas..14604
          EWPS (sistema de advertencia y protecci?n del motor)..14605
          Funci?n..14605
            Par?metros programables del EWPS..14606
          Sistema del IAH (calefactor del aire de admisi?n)..14610
          Funci?n..14610
          Ubicaci?n de los componentes..14610
          Herramientas..14610
            Diagn?stico de posici?n del pasador del IAH..14611
            Funcionamiento del circuito IAH..14616
            C?digos de problemas de diagn?stico (DTC)..14616
          Sensor IAT (temperatura de aire de admisi?n)..14617
          Funci?n..14617
          Ubicaci?n del sensor..14617
          Herramientas..14617
            Diagn?stico final del sensor IAT..14618
            Diagn?stico de posici?n del pasador de IAT..14620
            Funcionamiento del circuito IAT..14621
            Detecci?n/administraci?n de fallas..14621
          Sensor ICP (presi?n de control de la inyecci?n)..14622
          Funci?n..14622
          Ubicaci?n del sensor..14622
          Herramientas..14622
            Diagn?stico final del sensor ICP..14623
            Diagn?stico de posici?n del pasador de ICP..14625
            Funcionamiento del circuito ICP..14626
            Detecci?n/administraci?n de fallas..14626
          Sistema de ICP (presi?n de control de la inyecci?n)..14627
          Funci?n..14628
          Ubicaci?n del componente del sistema..14628
          Herramientas..14628
            Diagn?stico del sistema de ICP..14629
            Funcionamiento del sistema de ICP..14632
            Funcionamiento mec?nico..14632
            Funcionamiento el?ctrico..14632
            Detecci?n/administraci?n de fallas..14633
          Circuitos del inyector..14634
          Funci?n..14634
          Ubicaci?n de los componentes..14635
          Herramientas..14635
            Revisiones del inyector 1..14635
            Revisiones del inyector 2..14638
            Revisiones del inyector 3..14640
            Revisiones del inyector 4..14642
            Revisiones del inyector 5..14644
            Revisiones del inyector 6..14646
            Funcionamiento del circuito del inyector..14648
            Salida del controlador de lado alto..14648
            Retorno del controlador de lado bajo..14648
            Detecci?n/administraci?n de fallas..14648
            Prueba del inyector de KOEO (Llave en contacto y motor apagado)..14648
          IPR (regulador de presi?n del inyector)..14649
          Funci?n..14649
          Ubicaci?n de IPR..14649
          Herramientas..14649
            Diagn?sticos de identificaci?n de IPR..14651
            Funcionamiento del circuito IPR..14653
            Detecci?n/administraci?n de fallas..14653
          Sistema IST (temporizador de apagado de ralent?)..14654
            Funci?n..14654
            Herramientas..14654
            Temporizador de apagado de ralent? del motor para motores que cumplen con ESS de California..14655
            Temporizador de apagado de ralent? del motor (Federal - opcional)..14657
            Condiciones comunes de activaci?n para todas las opciones de IST federales..14657
            Modo federal IST 1: condiciones de activaci?n de opci?n de funcionamiento de PTO..14657
            Modo IST federal 2: no hay condiciones de activaci?n de opci?n de l?mite de carga liviana/sin carga..14657
            Modo IST federal 3: condiciones de activaci?n de opci?n a prueba de manipulaciones..14657
            Detecci?n/administraci?n de fallas..14658
          ITV (v?lvula del estrangulador de admisi?n)..14659
          Funci?n..14660
          Ubicaci?n de los componentes..14660
          Herramientas..14660
            Diagn?sticos finales del activador de ITV..14661
            Diagn?sticos precisos del activador de ITV..14663
            Funcionamiento del circuito del activador de ITV..14664
            Sensor ITVP..14664
            Activador ITV..14664
            Detecci?n/administraci?n de fallas..14665
          Sensor MAP (presi?n absoluta del m?ltiple)..14666
          Funci?n..14666
          Ubicaci?n del sensor..14666
          Herramientas..14666
            Diagn?sticos finales del sensor MAP..14668
            Diagn?sticos precisos de MAP..14670
            Funcionamiento del circuito de MAP..14671
            Detecci?n/administraci?n de fallas..14671
          Sensor MAT (temperatura del aire del m?ltiple)..14672
          Funci?n..14672
          Ubicaci?n del sensor..14672
          Herramientas..14672
            Diagn?sticos finales del sensor MAT..14673
            Diagn?sticos precisos de MAT..14675
            Funcionamiento del circuito MAT..14676
            Detecci?n/administraci?n de fallas..14676
          RSE (activaci?n de la v?lvula de vaiv?n del radiador)..14677
          Funci?n..14677
          Herramientas..14677
            Diagn?sticos del circuito RSE..14678
            Funcionamiento del circuito RSE..14679
            Detecci?n/administraci?n de fallas..14679
            C?digos de problemas de diagn?stico (DTC)..14679
          Circuito de salida del tac?metro..14680
            Diagn?sticos precisos del tac?metro..14681
            Funcionamiento del circuito del tac?metro..14681
            C?digos de problemas de diagn?stico (DTC)..14682
          Activador del VGT (turbocargador de geometr?a variable)..14683
          Funci?n..14684
          Ubicaci?n de los componentes..14684
          Herramientas..14684
            Diagn?sticos del extremo del activador del VGT..14685
            Funcionamiento del circuito de activador del VGT..14688
            Funcionamiento del circuito CAN (privado)..14688
            CAN (privado) contra CAN (p?blico)..14688
            Informaci?n de reparaci?n CAN..14688
          VREF (Voltaje de referencia)..14689
          Funci?n..14690
          Herramientas..14691
            Diagn?sticos de punto de pasador de VREF..14692
            Funcionamiento del circuito de VREF..14697
            Detecci?n/administraci?n de fallas..14697
          VSS (Sensor de velocidad del veh?culo)..14698
          Funci?n..14698
          Herramientas..14698
          Diagn?sticos de punto de pasador de VREF..14699
            Diagn?sticos de se?alizaci?n de VSS (transmisiones manuales)..14699
            Diagn?sticos de se?alizaci?n de VSS (transmisiones Allison)..14701
            Funcionamiento del circuito de VSS (transmisiones manual y Allison)..14702
            Detecci?n/administraci?n de fallas..14702
          Sensor de WIF (agua en el combustible)..14703
          Funci?n..14703
          Ubicaci?n del sensor..14703
          Herramientas..14703
            Diagn?sticos de se?alizaci?n de WIF..14704
            Funcionamiento del circuito de WIF..14705
            Detecci?n/administraci?n de fallas..14705
      Contenido..14707
        Herramientas el?ctricas..14709
          Arn?s de conectores tipo banana 3..14709
          Arn?s de conexiones del activador de 4 pasadores..14709
          Arn?s del inyector de 8 pasadores..14709
          Arn?s de separaci?n de 16 pasadores..14709
          Caja de conexiones de 180 pasadores..14710
          Arn?s de resistencia de 500 ohmios..14710
          Arn?s de conexiones del activador (IPR)..14710
          Abrazadera amp..14711
          Arn?s de conexiones del sensor de APS/IVS..14711
          Kit del arn?s de conexiones..14711
          Kit del arn?s de conexiones..14712
          Mult?metro digital (Fluke 88V)..14712
          Arn?s de conexiones de la v?lvula de EGR..14713
          Herramienta de servicio electr?nico (EST) EZ-Tech?..14713
            MasterDiagnostics? Software..14713
          Arn?s de conexiones de presi?n del escape..14714
          Arn?s de conexiones de la temperatura de escape..14714
          Kit de interfaz de EZ-Tech?..14714
          Arn?s de conexiones de ITV..14714
          Arn?s de conexiones de MAT..14715
          Arn?s de conexiones del sensor de presi?n..14715
          Arn?s de conexi?n del rel?..14715
          Arn?s de conexi?n del rel?..14715
          Arn?s de conexi?n del sensor de temperatura..14716
          Arn?s de conexi?n del sensor de temperatura..14716
          Kit del adaptador de prueba de la terminal..14716
        Herramientas mec?nicas..14717
          Kit de prueba del enfriador del aire de carga..14717
          M?dulo de vac?o de presi?n..14717
          Adaptador de la prueba de presi?n del c?rter..14717
          Adaptador de restricci?n de entrada de combustible..14718
          Acoplador de prueba de presi?n de aceite/combustible..14718
          Medidor de presi?n de combustible..14718
          Kit de prueba de presi?n de combustible..14719
          Adaptador de prueba de combustible..14719
          Herramienta de la barra del medidor..14719
          Adaptador del prueba del sistema de ICP..14720
          Kit de prueba de ICP..14720
          V?lvula de cierra en l?nea..14720
          Adaptador de prueba de IPR..14721
          Man?metro digital..14721
          Man?metro de tubo flojo..14722
          Kit de detecci?n de fugas de UV..14723
          Medidor y bomba de vac?o..14723
        Prueba del circuito electr?nico..14723
          Teor?a el?ctrica..14723
            Voltaje..14723
            Ley de ohmios..14724
          Uso del mult?metro digital..14725
            Medidores de muestra..14725
            Cables de conexi?n en puente..14726
            Volt?metro..14726
            Amper?metro..14728
            Ohmi?metro..14729
            Midiendo el ciclo de trabajo con FLUKE 88..14731
          Resoluci?n de problemas..14733
      Contenido..14735
        Abreviaciones y acr?nimos..14737
          Abreviaciones y acr?nimos..14737
      Contenido..14741
        Terminolog?a..14743
          T?rminos..14743
      Contenido..14749
        Todas las clasificaciones..14751
        MaxxForce? DT (7.6L)..14755
          210 hp @ 2600 rpm (12NSK)..14755
          225 hp @ 2600 rpm (12NSM)..14757
          225 hp @ 2600 rpm (12NSL)..14758
          230 hp @ 2400 rpm (12NSV)..14759
          245 hp @ 2600 rpm (12NSG)..14760
          255 hp @ 2600 rpm (12NSZ)..14762
          260 hp @ 2400 rpm (12NTA)..14764
          285 hp @ 2400 rpm (12NTB)..14766
          300 hp @ 2400 rpm (12NSH)..14768
          300 hp @ 2400 rpm (12)..14770
        MaxxForce? 9 (9.3L)..14771
          300 hp @ 2200 rpm (12NTC)..14771
          310 hp @ 2200 rpm (12NSJ)..14773
          330 hp @ 2200 rpm (12NSX)..14775
        MaxxForce? 10 (9.3L)..14777
          310 hp @ 2100 rpm (12NST)..14777
          310 hp @ 2200 rpm (12NSU)..14779
          330 hp @ 2100 rpm (12NSP)..14781
          330 hp @ 2200 rpm (12NSW)..14783
          350 hp @ 2100 rpm (12NSN)..14785
          350 hp @ 2200 rpm (12NSY)..14787
      Contenido..14789
        C?digos de diagn?stico de problemas..14791
      Contenido..14801
        Descripci?n..14803
  tables..14219
    Literatura de servicio t?cnico..14219
    Motores diesel MaxxForce? DT, 9 y 10..14226
    Ejemplo..14329
    Ejemplo..14329
    Los ajustes del juego libre de las v?lvulas y freno (pulgadas) con el pist?n 1 en la compresi?n del punto muerto superior..14433
    Los ajustes del juego libre de las v?lvulas y freno (pulgadas) con el pist?n 6 en la compresi?n del punto muerto superior..14434
    Ejemplo..14451
    Ejemplo..14451
    Ejemplo..14452
    Ejemplo..14453
    Ejemplo..14455
    Ejemplo..14455
    Ejemplo..14456
    Ejemplo..14457
    Ejemplo..14457
    Ejemplo..14458
    Ejemplo..14459
    Ejemplo..14460
    Ejemplo..14461
    Verificaciones de voltaje en el conector de 16-pasadores..14464
    Verificaciones de voltaje en el rel?..14464
    Verificaci?n de la resistencia del rel? principal de alimentaci?n..14465
    Verifique la resistencia del arn?s en los circuitos de alimentaci?n del rel?..14465
    Niveles de alerta de la carga de holl?n en el filtro de part?culas de diesel (DPF)..14469
    Active la regeneraci?n de rodamiento..14472
    Regeneraci?n de estacionamiento manual..14473
    Procedimiento de regeneraci?n de estacionamiento manual..14474
    El DTC 2351 - el EBP est? debajo del nivel deseado..14479
    DTC 2352 - EBP sobre el nivel deseado..14479
    DTC 2388 - Flujo del enfriador de recirculaci?n del gas de escape (EGR) excesivo: posible fuga hacia la atm?sfera..14480
    DTC 2389 - Flujo de EGR insuficiente - sistema posiblemente obstruido..14480
    DTC 3346 - AMT - La EBP no se puede acumular durante la prueba de EGR..14480
    DTC 3348 - AMT - EBP demasiado alta durante la prueba de EGR..14481
    Revisi?n del circuito del sensor..14484
    Revisi?n de voltaje del conector..14485
    Revise la resistencia del conector a la TIERRA del motor..14485
    Verifique la resistencia del arn?s..14486
    Verificaci?n de voltaje operacional..14486
    Revisi?n del voltaje del conector - EST..14489
    Verifique la resistencia del arn?s..14490
    Revisi?n del circuito del sensor..14494
    Revisi?n de voltaje del conector..14495
    Revise la resistencia del conector a la TIERRA del motor..14495
    Revisi?n de la resistencia debajo de la cubierta de v?lvula..14496
    Verifique la resistencia del arn?s..14496
    Circuitos del interruptor del freno..14499
    Revisi?n de voltaje..14499
    Verifique la resistencia del arn?s..14500
    Revisi?n de voltaje del conector..14502
    Revisiones de la resistencia del conector a TIERRA..14503
    Revisi?n de resistencia del actuador..14503
    Verifique la resistencia del arn?s..14503
    Revisi?n de voltaje del conector..14507
    Revisi?n de comunicaci?n con EST..14507
    Verifique la resistencia del arn?s..14508
    Revisiones del interruptor..14512
    Revisi?n de resistencia del circuito y sensor..14514
    Verifique la resistencia del arn?s..14515
    Revisiones operacionales..14515
    Revisi?n de resistencia del circuito y sensor..14517
    Revisi?n de la resistencia del arn?s..14518
    Revisiones operacionales..14518
    Revisi?n del circuito del sensor..14524
    Revisi?n de voltaje del conector..14525
    Revisi?n de la resistencia del conector a TIERRA..14525
    Verifique la resistencia del arn?s..14526
    Verificaci?n de voltaje en el rel?..14529
    Verificaci?n de voltaje en el ECM..14530
    Verificaci?n de resistencia del arn?s ? ECM al rel?..14530
    Verificaci?n de resistencia del arn?s ? Rel? a la bater?a..14531
    Verificaci?n de voltaje operacional..14531
    Revisi?n de voltaje del conector..14535
    Verifique la resistencia del conector a TIERRA..14535
    Verificaci?n de resistencia del interruptor..14536
    Verifique la resistencia del arn?s..14536
    Verificaciones de voltaje en el rel?..14539
    Verificaciones de voltaje en el ECM..14540
    Verifique la resistencia del arn?s..14541
    Verifique la resistencia del arn?s en los circuitos de alimentaci?n del rel?..14541
    DTC 1151 - se?al BAP fuera de rango ALTO..14545
    DTC 1152 - se?al BAP fuera de rango BAJO..14545
    DTC 5382 - Error del ECM - sobretemperatura..14545
    DTC 5618 - Error del ECM - error de SPI-BUS 1..14545
    DTC 5619 - Error del ECM - error de SPI-BUS 2..14545
    DTC 5627 - Error del ECM - Programa de suma de comprobaci?n..14545
    DTC 5628 - Error del ECM - conjunto de datos de suma de comprobaci?n..14546
    DTC 5632 - Error del ECM - memoria de acceso aleatorio (RAM) - falla de autoprueba de CPU..14546
    DTC 5633 - Error del ECM - carga de CPU sobre el m?ximo..14546
    DTC 5634 - Error del ECM - falla de cadena daisy de MQPS..14546
    DTC 5635 - Error del ECM - Falla de cadena daisy de OCT..14546
    DTC 5636 - Error del ECM - Falla de cadena daisy de QPS..14546
    DTC 5641 - Error del ECM - Supervisi?n de CC..14547
    DTC 5642 - Error del ECM - Supervisi?n de corte de combustible..14547
    DTC 5643 - Error del ECM - Supervisi?n de inyecci?n posterior..14547
    DTC 5644 - Error del ECM - Limitaci?n de velocidad del motor..14547
    DTC 5645 - Error del ECM - Falla de EEPROM..14547
    DTC 5646 - Error del ECM - Supervisi?n de velocidad del motor..14547
    DTC 5647 - Error del ECM - Supervisi?n de PVS..14547
    DTC 5648 - Error del ECM - Supervisi?n de PTO..14548
    DTC 5649 - Error del ECM - Supervisi?n de conversi?n de A/D..14548
    DTC 5651 - Error del ECM - Supervisi?n de MFMA..14548
    DTC 5652 - Error del ECM - Supervisi?n de NVMY..14548
    DTC 5653 - Error del ECM - Supervisi?n de PPS..14548
    DTC 5654 - Error del ECM - Supervisi?n de CAN..14548
    DTC 5655 - Error del ECM - Supervisi?n de la herramienta de servicio..14548
    DTC 5656 - Error del ECM - Supervisi?n del procesador..14549
    Revisi?n del circuito del sensor..14553
    Revisi?n de voltaje del conector..14554
    Revisiones de la resistencia del conector a TIERRA..14554
    Verifique la resistencia del arn?s..14554
    Verificaci?n de voltaje en el conector de EFAN - Prueba del estado de salida..14557
    Verificaci?n de voltaje en el rel? - Prueba del estado de salida..14558
    Verifique la resistencia del arn?s..14558
    Revisi?n del circuito del sensor..14562
    Revisi?n de voltaje del conector..14563
    Verifique la resistencia del conector a TIERRA..14563
    Verifique la resistencia del arn?s..14564
    Revisi?n del circuito del sensor..14568
    Revisi?n de voltaje del conector..14569
    Revisiones de la resistencia del conector a TIERRA..14569
    Verifique la resistencia del arn?s..14570
    Revisi?n de voltaje del conector..14574
    Verifique la resistencia del arn?s..14575
    Revisi?n del circuito del sensor..14579
    Revisi?n de voltaje del conector..14580
    Revisiones de la resistencia del conector a TIERRA..14580
    Verifique la resistencia del arn?s..14581
    Revisi?n del circuito del sensor..14585
    Revisi?n de voltaje del conector..14586
    Revisiones de la resistencia del conector a TIERRA..14586
    Verifique la resistencia del arn?s..14586
    Revisi?n del circuito del sensor..14591
    Revisi?n de voltaje del conector..14592
    Revisiones de la resistencia del conector a TIERRA..14592
    Verifique la resistencia del arn?s..14592
    Revisi?n del circuito del sensor..14596
    Revisi?n de voltaje del conector..14597
    Verifique la resistencia del conector a TIERRA..14597
    Verifique la resistencia del arn?s..14598
    Revisi?n del circuito del sensor..14602
    Revisi?n de voltaje del conector..14603
    Revisiones de la resistencia del conector a TIERRA..14603
    Verifique la resistencia del arn?s..14603
    Revisi?n de voltaje en el interruptor del rel? ? Prueba del estado de salida..14612
    Revisi?n de voltaje en la bobina del rel? ? Prueba del estado de salida..14613
    Revisi?n de consumo de amperaje..14614
    Revisi?n de resistencia del elemento..14614
    Revisi?n de la resistencia del arn?s ? Circuitos de la bobina del rel?..14615
    Revisi?n de la resistencia del arn?s ? Circuitos del interruptor del rel?..14615
    Revisi?n del circuito del sensor..14619
    Revisi?n de voltaje del conector..14620
    Revisiones de la resistencia del conector a TIERRA..14620
    Verifique la resistencia del arn?s..14620
    Revisi?n del circuito del sensor..14624
    Revisi?n de voltaje del conector..14625
    Verifique la resistencia del conector a TIERRA..14625
    Bajo revisi?n de la resistencia de la tapa de v?lvulas a GND del motor..14626
    Verifique la resistencia del arn?s..14626
    Revisiones de resistencia del inyector 1 ? a trav?s del arn?s y del inyector..14636
    Inyector 1 - Revisiones de resistencia del inyector..14636
    Inyector 1 ? Revisi?n de resistencia del arn?s..14637
    Inyector 2 ? Revisi?n de resistencia en la cubierta de la v?lvula..14638
    Inyector 2 ? Revisi?n de resistencia de la bobina..14639
    Inyector 2 ? Revisi?n de resistencia del arn?s..14639
    Inyector 3 ? Revisi?n de resistencia en la cubierta de la v?lvula..14640
    Inyector 3 ? Revisi?n de resistencia de la bobina..14641
    Inyector 3 ? Revisi?n de resistencia del arn?s..14641
    Inyector 4 ? Revisi?n de resistencia en la cubierta de la v?lvula..14642
    Inyector 4 ? Revisi?n de resistencia de la bobina..14643
    Inyector 4 ? Revisi?n de resistencia del arn?s..14643
    Inyector 5 ? Revisi?n de resistencia en la cubierta de la v?lvula..14644
    Inyector 5 ? Revisi?n de resistencia de la bobina..14645
    Inyector 5 ? Revisi?n de resistencia del arn?s..14645
    Inyector 6 ? Revisi?n de resistencia en la cubierta de la v?lvula..14646
    Inyector 6 ? Revisi?n de resistencia de la bobina..14647
    Inyector 6 ? Revisi?n de resistencia del arn?s..14647
    Revisi?n de voltaje del conector..14651
    Revisi?n de voltaje de funcionamiento ? prueba de estado de salida..14652
    Revisi?n de resistencia del actuador..14652
    Verifique la resistencia del arn?s..14652
    Revisi?n del circuito del activador de ITV..14662
    Revisi?n de voltaje del conector..14663
    Verifique la resistencia del conector a TIERRA..14664
    Verifique la resistencia del arn?s..14664
    Revisi?n del circuito del sensor..14669
    Revisi?n de voltaje del conector..14670
    Verifique la resistencia del conector a TIERRA..14670
    Verifique la resistencia del arn?s..14671
    Revisi?n del circuito del sensor..14674
    Revisi?n de voltaje del conector..14675
    Revisiones de la resistencia del conector a TIERRA..14675
    Verifique la resistencia del arn?s..14675
    Revise el voltaje en el conector RSE: prueba del estado de salida..14678
    Verifique la resistencia del arn?s..14679
    Revisi?n final de voltaje del circuito..14681
    Verifique la resistencia del arn?s..14681
    Revisi?n de voltaje del conector..14686
    Verifique la resistencia del arn?s..14686
    Inspecci?n visual operacional - Prueba del estado de salida..14687
    Verificaci?n del voltaje de VREF..14694
    Verifique la resistencia del conector a TIERRA..14695
    Verifique la resistencia del arn?s..14696
    Revisi?n de voltaje del conector..14699
    Revisi?n de la resistencia del sensor..14700
    Verifique la resistencia del arn?s..14700
    Revisi?n de resistencia..14701
    Revisi?n operacional..14701
    Revisi?n de voltaje..14705
    Verifique la resistencia del conector a TIERRA..14705
    Verifique la resistencia del arn?s..14705
    Llave en contacto y motor apagado (Key-On Engine-Off)..14751
    Giro del motor..14751
    Ralent? bajo, sin carga, temperatura de funcionamiento del motor estabilizada..14751
    Ralent? alto, sin carga, temperatura de funcionamiento del motor estabilizada..14752
    Carga completa, velocidad nominal en carretera, temperatura de funcionamiento del motor estabilizada..14752
    Especificaciones del componente..14753
    Calentador de aire de entrada..14754
    Prueba del estado de salida del actuador..14754
    Prueba de VGT con llave en encendido y motor funcionando..14754
MaxxForce DT, 9, and 10 Engine Features, Descrlptions, and Unique Diagnostics and Repair Procedures (Model Year 2007)..14806

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