International Engines MaxxForce 5/7/DT/9/10 models Diagnostics/Troubleshooting/Service/Repair Manuals
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
0000001624 - 2010 MaxxForce DT, 9, and 10 Engines Diagnostic Manual.pdf
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EGED-355-2 - Hard Start and No Start Diagnostics MaxxForce 7 2007 through 2009 Model Years.pdf
EGED-365 - MaxxForce 7 Electronic Control System Diagnostics MY2007 & up.pdf
EGES-335-1 - MaxxForce DT, 9, and 10 Engine Service Manual.pdf
EGES-335-2 - MaxxForce DT, 9, and 10 Engine Engine Service Manual.pdf
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EGES-345-1 - MaxxForce 7 Engine Service Manual Model Years 2007-2009.pdf
EGES-345 - MaxxForce 7 Engine Service Manual.pdf
EGES-350-2 - Maxxforce 7 Diesel Engine Diagnostic_Troubleshooting Manual 2007 through 2009 Model Years.pdf
EGES-370-2 - MaxxForce DT, 9, and 10 Diagnostic_Troubleshooting Manual.pdf
EGES-390 - Maxxforce 5 Diesel Engine Engine Service Manual 2007.pdf
EGES-395 - Maxxforce 5 Diagnostic_Troubleshooting Manual.pdf
EGES-450-1 - MaxxForce DT, 9 and 10 Diesel Engines Service Manual Model Year 2010 and Up.pdf
EGES-455-1 - Diagnostic Trouble Code.pdf
EGES-455-1 - MaxxForce DT, 9, and 10 Engine Diagnostic_Troubleshooting Manual 2011.pdf
EGES-480-1 - MaxxForce 7 Diesel Engine Service Manual Model Year 2010 and Up.pdf
EGES-485-1 - Diagnostic Manual 2010 MaxxForce 7 Engine.pdf
EGES-485-1 - Diagnostic Trouble Code.pdf
EGES-540 - 2007-2009 Aftertreatment Unique Diagnostics And Service Information (MaxxForce 5, 7, DT, 9, 10, 11, and 13).pdf
EGES-611 - Manual de Diagnóstico 2007 MaxxForce DT, 9, 10.pdf
MaxxForce DT, 9, and 10 Engine Features, Descrlptions, and Unique Diagnostics and Repair Procedures (Model Year 2007).pdf
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
