International/Navistar Trucks DuraStar and WorkStar Series Repair Service Manual

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Price: US$ 99.00

Complete service repair manual with Electrical Wiring Diagrams for International/Navistar Trucks DuraStar (4000-Series) and WorkStar (7000-Series), with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

International/Navistar Trucks Models DuraStar and WorkStar 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: 29,126 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 13.pdf
0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 4.pdf
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Revision 1 (Supersedes 0000001601, 0000001843 & 0000002222) Service Manual.pdf
S13008 - 6 Speed Transmissions Eaton Series FS-5106 and FS-6206 Supersedes CTS-5179 (June 1996) Service Manual.pdf
0000002601 - 3200, RXT, DuraStar, TranStar, TranStar Natural Gas, WorkStar Series Built May 17, 2010 and Later Electrical Circuit Diagrams (Supersedes S08343).pdf
S082503 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built Before 05_20_2003.pdf
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10 Service Manual.pdf
CTS-5122T - 2000, 4000, 8000 Series Built After February 1, 1996 Electrical Circuit Diagrams.pdf
S13016 7 - Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual.pdf
S082504 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models 05_20_2003 to 02_28_2007.pdf
1087481R1 - 1000 Through 4000, 7000, 8000 Series Electrical Circuit Diagrams CTS-4417Circuit Diagrams.pdf
S082503A - Electrical System Troubleshooting Guide Models Built After 05_20_2003 (Apr 2004) Serice Manualpdf
S082504 - Electrical System Troubleshooting Guide Models Built 05_20_2003 to 02_28_2007 (Jan 2008) Service Manual.pdf
S082503 - Electrical System Troubleshooting Guide Models Built 10_16_2000 to 05_20_2003 (Jan 2008) Service Manual.pdf
0000002601 - 4000 Series (Oct 2014) Wiring Diagrams.pdf
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual.pdf
S08322 - 4000 Series (March 2007 to March 2008) Wiring Diagrams.pdf
0000017581 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Series Built March 11, 2004 to September 30, 2005 Electrical Circuit Diagrams  (Supersedes S082854).pdf
S08322 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600, RXT Models Built March 1, 2007 to March 18, 2008 Electrical Circuit Diagrams.pdf
S08315 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, MXT, RXT Models Built Oct. 1, 2005 to Feb. 28, 2007 Electrical Circuit Diagrams.pdf
0000003922 - 4000 Series (Nov 2010) Wiring Diagrams.pdf
S10024 - Eaton Hybrid System Service Manual (Oct 2009).pdf
S08300 - Body Builder Electrical Data Book for Models Built January 2001 to February 28, 2007 Supersedes PBB-73000B (Aug 2008) Service Manual.pdf
0000002842 - 3200, DuraStar, TranStar, WorkStar, and RXT Models Built March, 2008 to May 16, 2010 Electrical Circuit Diagrams (Supersedes S08337) .pdf
S08323A - (2007) 3000 4000 7000 8000 BE CE DuraStar WorkStar TranStar  - Body Builder Data Book.pdf
S08230 - Electrical System Troubleshooting Guide, Supersedes CTS-5300 (July 1999) Service Manual.pdf
S082854 - 4000 Series (2004 to 2005) Wiring Diagrams.pdf
CTS-5122K - 2000 , 4000 and 8000 Series September 1993 and Later Electrical Circuit Diagrams.pdf
0000002322 - DuraStar and TerraStar Cab Service Manual (Supersedes S16026).pdf
0000001844 WorkStar Radiator _ Cooling System (Supersedes S12026) Service Manual.pdf
S082853 - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built September 16, 2003 to March 10, 2004 Electrical Circuit Diagrams.pdf
0000001844 - Radiator, Cooling System Cooling System Service Manual 2013.pdf
S08186X - 2000, 4000, 8000 Models Built October 1, 1999 and After Electrical Circuit Diagrams.pdf
S08186 - 2000, 4000, 8000 Models Built October 1, 1998 To September 30, 1999 Electrical Circuit Diagrams.pdf
S13006H - 6 Speed Transmissions International Model ES52-7A and ESO65-7A 6-Plus Service Manual.pdf
0000003922 - DuraStar, WorkStar, TranStar Series Models Built From November 22, 2010 Electrical Circuit Diagrams  (Supersedes S08353) (Latin America _ Mexico).pdf
0000002324 - SERVICE MANUAL CAB TranStar, WorkStar.pdf
S13009 - 5 Speed Transmissions Spicer ES43-5 and ES53-5 Supersedes CTS-5181 (March 1996) Service Manual.pdf
S16034 - HEAT VENTILATION AIR CONDITIONING (HVAC), TXV System, March 2007 - 2009  3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Models, CXT,   DuraStar, TranStar,  WorkStar and RXT.pdf
0000002842 - 4000 Series (March 2008 to May 2010) Wiring Diagrams.pdf
0000018561 - DuraStar with Cummins Euro 5 ISB Engine Electrical Circuit Diagram Manual (for Latin America and Mexico).pdf
S160263 - CAB 4100, 4200, 4300, 4400, DuraStar, TerraStar 4100, 4200, 4300, 4400, DuraStar, TerraStar Service Manual.pdf
S16046 - 3200 Bus, DuraStar, TerraStar, TranStar, WorkStar Models Heat Ventilation Air Conditioning (HVAC) for 2010 Service Manual.pdf
S08359 - 4400 LHD Euro III Model Built After July, 2011 Electrical Circuit Diagrams (Brazil Market) Circuit Diagrams.pdf
CTS4425 - Electrical System Troubleshooting Guide - U-HAUL 4600UH Service Manual.pdf
S11003 - Spicer 14-Inch (355.6 mm) Stamped Angle-Spring Clutch Supersedes CTS-5140 (March 1996) Service Manual.pdf
S16055 - HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 HVAC DuraStar Vehicle Service Manual.pdf
S082852 - 4000 Series (Jan 2002 to Sep 2002) Wiring Diagrams.pdf
S082852 - 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600 Models Built January 1, 2002 To September 30, 2002 Electrical Circuit Diagrams (Jan 2002) Service Manual.pdf
S16025 - HEAT VENTILATION AIR CONDITIONING (HVAC), Orifice Tube System, Pre-March 2007 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Service Manual.pdf
S08324 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, CXT, DuraStar, RXT, TranStar, and WorkStar Models Built After March 01, 2007 Electrical System Troubleshooting Guide.pdf
0000003046 - Radiator_Cooling System DuraStar Cooling System Service Manual.pdf
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES Built October 1, 2002 and After ELECTRICAL CIRCUIT DIAGRAMS.pdf
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built October 1, 2002 to September 15, 2003 Electrical Circuit Diagrams (Oct 2002) Manual.pdf
S16053 - Heat Ventilation Air Conditioning (HVAC) for 2010 - South Africa _ 7000 RHD AND 8000 RHD Service Manual.pdf
S08361 - DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — DuraStar, TerraStar, TranStar, and WorkStar Built May 2010 and Later.pdf
S12022 - Radiator _ Cooling System (Aug 2010) Service Manual.pdf
S09016 - 2010 Hood Grille Fenders Bumper WorkStar, TranStar Service Manual.pdf
S02014 - Carraro Axle Repair Manual (Feb 2009) Service Manual.pdf
S16054 - SERVICE MANUAL CAB MANUALModel DuraStar Vehicle.pdf
S04038 - EC-17 Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Technical Manual.pdf
S08285 - 4200, 4300, 4400 Models Built October 16, 2000 to December 31, 2001 Electrical Circuit Diagrams (Jan 2001).pdf
0000680131 - DuraStar Radiator _ Cooling System (Euro V Latin American Market ) Service Manual.pdf
S04051 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual.pdf
S09002 - Hood, Grille, and Fenders - 2000, 4000, 8000 (Supersedes CTS-5269) (Feb 1999) Service Manual.pdf
S16038 - CAB_ 7300, 7400, 7500, 7600, 7700, 8500, 8600, TranStar, and WorkStar Models Service Manual.pdf
S12036 - Radiator_Cooling System 2010 Service Manual.pdf
S09007 - Hood, Grille, Fenders and Bumper - 7000 (Oct 2002) Service Manual.pdf
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Manual.pdf
S11004 - Spicer 14 Inch (350 mm) Solo Clutch Supersedes CTS-5256 (March 1996) Service Manual.pdf
S09014 - Hood Grille Fenders Bumper Service Manual (Dec 2011).pdf
S04050 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual.pdf
S11014 - Hydraulic Clutch Service Manual (2010) Service Manual.pdf
S14019 - LIFT AXLE SYSTEMS (7400, 7500 7600 Models) Service Manual.pdf
S02012 - Meritor Medium Duty Front Drive Steer Axle (Dec 2001) Service Manual.pdf
S08357 - 2011 DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE Model 4400.pdf
S040393 - Lucas Varity _ TRW Hydraulic Antilock Brake System (Dec 2003) Technical Manual.pdf
4328434 - New Truck Processing Technical Manual.pdf
S04016K - Caliper Disc Brakes, Supersedes CTS-5009K (March 1996) Service Manual.pdf
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual.pdf
S04045 - Meritor _ WABCO Hydraulic ABS for Medium-Duty Trucks, Buses and Motor Home Chassis (June 2000) Technical Manual.pdf
S08155X - Instruments (New Data Link Driven Instrument Cluster), Supersedes CTS-5228 (Oct 1999) Technical Manual.pdf
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual.pdf
S09018 - 2011 Hood Grille Fenders Bumper Service Manual.pdf
S12038 - 2011 Cooling System Service Manual.pdf
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual.pdf
S16016 - Air Conditioning - Heater System_ 2000, 4000, and 8000 - 12_06_1994 and After Formerly (CTS-5227) Service Manual.pdf
S04055 - MCAC 465 Air Compressor (Dec 2010) Service Manual.pdf
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual.pdf
S09003 - Hood, Grille, and Fenders (March 2001) Service Manual.pdf
S09003 - 2001 Hood Grille Fender Bumper Service Manual.pdf
S04053 - ECE-13 Brake System (2010) Service Manual.pdf
S12010 - Radiator, Removal and Replacement (April 2003) Service Manual.pdf
S05021 - Steering Wheel and Steering Column Assembly (July 2012) Service Manual.pdf
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual.pdf
S08034X - Instruments, Supersedes CTS-5088K (Oct 1999) Service Manual.pdf
S04004 - Air Compressor_ Bendix 2150, Supersedes CTS-5058 (March 1996) Service Manual.pdf
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual.pdf
S16027 - SERVICE CAB 4100, 4200, 4300, 4400 SERVICE MANUAL .pdf
S04033 - Antilock Brakes_Traction Control_ Bendix - Troubleshooting, Supersedes CTS-5250 (June 1996) Service Manual.pdf
S12008 - Radiator, Removal and Replacement (2012) Service Manual.pdf
S13037 - OMSI PFT-PCV_3000 Split Shaft PTO Service Manual.pdf
s04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual.pdf
S04018W - Reconditioning Rotors, Supersedes CTS-5086W (June 1998) Service Manual.pdf
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual.pdf
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual.pdf
S04011 - Air Compressor_ Midland Models EL-1300 and EL-1600, Supersedes CTS-5146 (March 1996) Service Manual.pdf
S05022 - Steering Wheel _ Column Assembly _ Power Steering Reservoir (Jan 2011) Brazilian Market Service Manual.pdf
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual.pdf
S04010 - Air Compressor_ Bendix TU-FLO 501, Supersedes CTS-5145 (March 1996) Service Manual.pdf
S08308 - Diamond Logic PowerPack 3 Dynamic Power System Service _ Troubleshooting Guide (Feb 2006) Service Manual.pdf
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual.pdf
S04020X - DCM and DDM Drum Type Parking Brake, Supersedes CTS-5135TA (July 1997) Service Manual.pdf
S04017Y - Hydro-Max Brake Booster and Master Cylinder, Supersedes CTS-5018K (Dec 2000) Service Manual.pdf
S16017X - Air Conditioning Compressor and Clutch, Two Cylinder Reciprocating Type - After 01_01_1993 (R-134A) (Formerly CTS-5241) Service Manual.pdf
S08333 - 4300 Eaton Hybrid Drive System Built November 2006 through February 2007 Electrical Circuit Diagrams.pdf
S05013 - Steering Column Assembly, Standard and Tilt, Supersedes CTS-5168 (April 1996) Service Manual.pdf
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual.pdf
S08327 - 2007-2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual.pdf
S11002 - Spicer 13-Inch (310 mm) and 14-Inch (350 mm) Angle-Ring Single Plate Push-Type Clutch Supersedes CTS-5057 Service Manual.pdf
S04044 - Bosch Parking Brake_ Manual or Power Brake (Oct 2008) Service Manual.pdf
S05025 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual.pdf
s12005 - Radiator Shutters, Supersedes CTS-5084 (March 1996) Service Manual.pdf
S05016 - Steering Wheel Removal and Installation (Sept 2010) Service Manual.pdf
S11006R - Clutch Control Linkage Supersedes CTS-5053R (Oct 2002) Service Manual.pdf
S05012 - Steering Column Assembly, Tilt_Telescoping Supersedes CTS-5167 (May 1996) Service Manual.pdf
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual.pdf
S10020 - USPS International 4400 Master Index (June 2005) Service Manual.pdf
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes (June 2005) Service Manual.pdf
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual.pdf

MAIN SECTIONS
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10 Service Manual....1
  toc....3
    Summary of Changes....3
      1. Description....9
        1.1. Theory of Operation....15
          Aftertreatment regeneration burns soot to ash when excess soot buildup occurs. For regeneration to occur, the Engine Control Module (ECM) must detect a DPF restriction by monitoring temperature and pressure sensors.....15
        1.2. Switchback / Horizontal....16
        1.3. Vertical / Vertical....17
        1.4. In-Line....18
      2. General Service Information....19
        2.1. Exhaust Aftertreatment System Modifications....20
        2.2. Gaskets and Fasteners....21
        2.3. Diesel Particulate Filter (DPF) Indexing....21
        2.4. DPF and DOC Cleaning....21
        2.5. DPF General Inspection....22
          DPF Inspection Points....23
        2.6. DOC General Inspection....26
          DOC Inspection Points....26
        2.7. DPF / DOC Thread Repair....30
          12 MM Thread Replacement....30
          14 MM Thread Replacement....34
        2.8. DOC and DPF Reuse Guidelines....38
          General Information....38
          Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted....39
          Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged....40
          Diesel Particulate Filter (DPF) Inlet / Outlet – New....41
          Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1)....42
          Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2)....43
          Diesel Particulate Filter (DPF) Inlet – Clean....44
          Diesel Particulate Filter (DPF) Inlet – Gouged....45
          Diesel Particulate Filter (DPF) Inlet – Ash....46
          Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings....47
          Diesel Particulate Filter (DPF) Outlet – Soot Stains....48
          Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process....49
          Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains ....50
          Diesel Particulate Filter (DPF) Outlet – Face Cracked....51
          Diesel Particulate Filter (DPF) Outlet – Coolant Staining....52
          Diesel Particulate Filter (DPF) Outlet – Melted....53
        2.9. Decomposition Reactor Tube Cleaning....54
        2.10. Diesel Exhaust Fluid (DEF) Dosing Valve cleaning....55
        2.11. DEF Supply Module Filter Inspection....57
        2.12. Diesel Exhaust Fluid (DEF) System Contamination....59
        2.13. DEF System Decontamination Procedure....62
        2.14. Diesel Exhaust Fluid (DEF) Refractometer Tool....63
        Using the DEF Refractometer....63
        DEF Refractometer Maintenance....65
        2.15. Diesel Exhaust Fluid (DEF) Dosing System Reuse Guidelines....66
        2.16. Diesel Exhaust Fluid (DEF) Tank Draining....69
      3. Switchback / Horizontal....70
        3.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....70
          Switchback / Horizontal – Removal....70
          Switchback / Horizontal – Installation....72
          Diesel Exhaust Fluid (DEF) Dosing Valve – Removal....73
          Diesel Exhaust Fluid (DEF) Dosing Valve – Installation....74
          Decomposition Reactor Tube – Removal....75
          Decomposition Reactor Tube – Installation....76
          Aftertreatment Assembly Mounting Bracket – Removal....77
          Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly Mounting Bracket – Installation....78
          Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal....79
          Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation....79
          Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal....81
          Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation....81
          Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal  (If Equipped)....82
          Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If Equipped)....82
          Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped)....83
          Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped)....83
          Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal....84
          Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation....84
           (DPF) Temperature Sensors and Module – Removal....86
          Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation....86
          Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal....88
          Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation....89
          Diesel Particulate Filter (DPF) High Pressure Tube – Removal....90
          Diesel Particulate Filter (DPF) High Pressure Tube – Installation....90
          Diesel Particulate Filter (DPF) Low Pressure Tube – Removal....91
          Diesel Particulate Filter (DPF) Low Pressure Tube – Installation....91
      4. Vertical / Vertical ....92
        4.1. Navistar® N13 Engine....92
          Vertical / Vertical....92
          Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal....93
          Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Installation....93
          Power Distribution Module (PDM) – Removal....94
          Power Distribution Module (PDM) – Installation....94
          Aftertreatment Control Module (ACM) – Removal....95
          Aftertreatment Control Module (ACM) – Installation....95
      5. In–Line....96
        5.1. Cummins ISB6.7 or Navistar® N9 and N10 Engines....96
          In-Line....96
      6. Diesel Exhaust Fluid (DEF) System....97
        6.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....97
          Diesel Exhaust Fluid (DEF) Tank – Removal....97
          Diesel Exhaust Fluid (DEF) Tank – Installation....100
          Power Distribution Module (PDM) – Removal....101
          Power Distribution Module (PDM) – Installation....101
          Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal....102
          Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation....105
          Diesel Exhaust Fluid (DEF) Tank Lines – Removal....106
          Diesel Exhaust Fluid (DEF) Tank Lines – Installation....108
          Diesel Exhaust Fluid (DEF) Supply Module – Removal....109
          Diesel Exhaust Fluid (DEF) Supply Module – Installation....110
          Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal....111
          Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation....111
          Aftertreatment Control Module (ACM) – Removal....112
          Aftertreatment Control Module (ACM) – Installation....113
          Diesel Exhaust Fluid (DEF) Tank Bracket – Removal....114
          Diesel Exhaust Fluid (DEF) Tank Bracket – Installation....115
          Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal....116
          Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation....117
          Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal....118
          Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation....119
          Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal....120
          Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation....122
          Diesel Exhaust Fluid (DEF) System....123
      7. Acronym List....124
  tables....20
    Table 2Minimum Clearance Between Exhaust System Components and Other Chassis Components.....20
    Table 32Acronym List.....124
    Table 33Torque Chart.....125
0000001844 - Radiator, Cooling System Cooling System Service Manual 2013....126
  toc....128
    Summary of Changes....128
      1. Description....134
        1.1. Deaeration Tank....135
        1.2. Fan Shroud....136
        1.3. A/C Condenser....136
        1.4. Radiator....136
        1.5. Charge Air Cooler....136
        1.6. Low-Temperature Radiator....136
        1.7. Transmission Oil Cooler....136
        1.8. Fuel Cooler....136
      2. Removal and Installation....137
        2.1. Cooling Package Cleaning Procedures....138
          Cleaning Cooling Package (MaxxForce® 9, 10, and DT Engines)....138
          Cleaning Cooling Package (Navistar® 11 and 13 Engines)....139
        2.2. Coolant Drain, Pressure Test, and Fill Procedures....142
          Coolant Drain Procedure (Recommended)....144
          Pressure Test Procedure (Recommended)....146
          Coolant Fill Procedure (Recommended)....147
          Coolant Drain Procedure (Optional)....149
          Coolant Fill Procedure (MaxxForce® DT, 9, and 10 Engines) (Optional)....150
          Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....151
        2.3. Grille....154
          Grille (Standard) – Removal....154
          Grille (Standard) – Installation....154
          Grille (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....155
          Grille (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....155
          Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....156
          Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....156
        2.4. Splash Panel....157
          Splash Panel (Standard) – Removal....157
          Splash Panel (Standard) – Installation....158
          Splash Panel (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....158
          Splash Panel (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....159
          Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....159
          Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....160
        2.5. Deaeration Tank....160
          Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....160
          Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....162
          Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....162
          Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....164
          Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....164
          Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....166
        2.6. A/C Condenser....167
          A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....167
          A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....168
          A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....169
          A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....170
          A/C Condenser (Navistar® 11 and 13 Engines) – Removal....171
          A/C Condenser (Navistar® 11 and 13 Engines) – Installation....172
        2.7. Fan Shroud....173
          Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....173
          Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....176
          Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal ....176
          Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....177
          Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....178
          Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....180
          Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....180
          Upper Fan Shroud  (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....183
          Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....184
          Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....186
        2.8. Radiator Fan....187
          Radiator Fan (Standard) – Removal....187
          Radiator Fan (Standard) – Installation....187
          Radiator Fan (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal ....188
          Radiator Fan (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....189
          Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....189
          Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....190
        2.9. Radiator Hose....191
          Heat Shrink Clamp – Removal....191
          Heat Shrink Clamp – Installation....192
          Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....194
          Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....195
          Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....196
          Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....198
          Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....199
          Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....200
          Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....200
          Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....203
        2.10. Charge Air Cooler....204
          Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....204
          Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....207
          Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....207
          Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....207
          Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....208
          Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....211
          Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....212
          Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....214
          Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....214
          Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....216
          Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....217
          Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....218
        2.11. Low-Temperature Radiator....219
          Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....219
          Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....221
          Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....222
          Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....222
          Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....223
          Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....225
        2.12. Radiator Core....227
          Radiator Core (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....227
          Radiator Core (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....232
          Radiator Core (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal ....233
          Radiator Core (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation ....241
          Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....242
          Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....244
          Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....245
          Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....248
        2.13. Transmission Oil Cooler....249
          Transmission Oil Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....249
          Transmission Oil Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....250
          Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....251
          Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....252
          Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....252
          Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....253
        2.14. Fuel Cooler....254
          Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....254
          Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....254
  tables....256
    Table 2Torque Chart....256
0000001844 WorkStar Radiator _ Cooling System (Supersedes S12026) Service Manual....260
  toc....262
    Summary of Changes....262
      1. Description....270
        1.1. Surge Tank (If Equipped)....272
        1.2. Deaeration Tank....272
        1.3. Fan Shroud....272
        1.4. Fan Drive....272
        1.5. A / C Condenser....272
        1.6. Radiator....272
        1.7. Charge Air Cooler....272
        1.8. Cross-Member....272
        1.9. Low-Temperature Radiator....273
        1.10. Low Temperature Radiator (LTR) Thermostat....273
        1.11. Fuel Cooler....273
        1.12. Transmission Oil Cooler....273
      2. Removal and Installation....274
        2.1. Coolant Drain, Pressure Test, and Fill Procedures....275
          2.1.1. Coolant Drain Procedure (Recommended)....277
          2.1.2. Pressure Test Procedure (Recommended)....280
          2.1.3. Coolant Fill Procedure (Recommended)....284
          2.1.4. Coolant Gravity Drain Procedure (Optional)....288
          2.1.5. Coolant Fill Procedure (MaxxForce® DT, 9, and 10 Engines) (Optional)....289
          2.1.6. Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....290
          2.1.7. Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....293
        2.2. Grille....297
          2.2.1. Grille (Standard) – Removal....297
          2.2.2. Grille (Standard) – Installation....298
          2.2.3. Grille (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....298
          2.2.4. Grille (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....299
          2.2.5. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....299
          2.2.6. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....300
        2.3. Splash Panel....301
          2.3.1. Splash Panel (Standard) – Removal....301
          2.3.2. Splash Panel (Standard) – Installation....301
          2.3.3. Splash Panel (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....302
          2.3.4. Splash Panel (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....302
          2.3.5. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....303
          2.3.6. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....304
        2.4. Surge Tank (if equipped)....305
          2.4.1. Surge Tank (with Cummins® ISB6.7 Engine) – Removal....305
          2.4.2. Surge Tank (with Cummins® ISB6.7 Engine) – Installation....306
        2.5. Deaeration Tank....307
          2.5.1. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....307
          2.5.2. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....308
          2.5.3. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....308
          2.5.4. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....310
          2.5.5. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....310
          2.5.6. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....312
          2.5.7. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Removal ....313
          2.5.8. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Installation....316
        2.6. A/C Condenser....317
          2.6.1. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....317
          2.6.2. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....318
          2.6.3. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....319
          2.6.4. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....320
          2.6.5. A/C Condenser (Navistar® 11 and 13 Engines) – Removal....321
          2.6.6. A/C Condenser (Navistar® 11 and 13 Engines) – Installation....322
          2.6.7. A/C Condenser (ISB6.7) Engine – Removal....322
          2.6.8. A / C Condenser (ISB6.7 Engine) – Installation....324
        2.7. Fan Belts....325
          2.7.1. Fan Belt with A / C (Cummins® ISB6.7 Engine) - Removal ....325
          2.7.2. Fan Belt with A / C (Cummins® ISB6.7 Engine) – Installation ....326
        2.8. Fan Shroud....327
          2.8.1. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....327
          2.8.2. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....330
          2.8.3. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal ....330
          2.8.4. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....331
          2.8.5. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....332
          2.8.6. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....334
          2.8.7. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....334
          2.8.8. Upper Fan Shroud  (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....337
          2.8.9. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....338
          2.8.10. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....340
          2.8.11. Fan Shroud (Cummins® ISB6.7 Engine) 7 similar - Removal....341
          2.8.12. Fan Shroud - Installation....341
        2.9. Fan and Fan Drive Assembly....342
          2.9.1. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Removal....342
          2.9.2. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Installation....343
          2.9.3. Fan Removal – (12THZ and 12THT Horton DA) (optional)....344
          2.9.4. Fan Installation – (12THZ and 12THT Horton DA) (optional)....345
          2.9.5. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....346
          2.9.6. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....348
          2.9.7. 12THT Horton (DMA) Serviceable Fan Drive – Removal....349
          2.9.8. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....356
          2.9.9. 12THT Pulley Bearing – Removal....357
          2.9.10. 12THT Pulley Bearing – Installation....357
          2.9.11. 12THT Fan Drive Friction Liner– Removal....358
          2.9.12. 12THT Fan Drive Friction Liner – Installation....363
          2.9.13. 12THT Clutch Pack Seal Face – Removal....364
          2.9.14. 12THT Clutch Pack Seal Face – Installation....364
          2.9.15. 12THT Air Cartridge – Removal....365
          2.9.16. 12THT Air Cartridge – Installation....367
          2.9.17. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Removal....370
          2.9.18. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Installation....373
        2.10. Radiator Fan....374
          2.10.1. Radiator Fan (Standard) – Removal....374
          2.10.2. Radiator Fan (Standard) – Installation....375
          2.10.3. Radiator Fan (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal ....376
          2.10.4. Radiator Fan (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....377
          2.10.5. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....378
          2.10.6. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....379
        2.11. Radiator Hose....379
          2.11.1. Heat Shrink Clamp – Removal....379
          2.11.2. Heat Shrink Clamp – Installation....381
          2.11.3. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....384
          2.11.4. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....386
          2.11.5. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....387
          2.11.6. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....389
          2.11.7. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....390
          2.11.8. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....391
          2.11.9. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....392
          2.11.10. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....394
        2.12. Coolant Package....395
        Overview....395
          2.12.1. Coolant Package – Removal....395
          2.12.2. Coolant Package – Installation....402
        2.13. Charge Air Cooler....404
          2.13.1. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....404
          2.13.2. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....406
          2.13.3. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....406
          2.13.4. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....406
          2.13.5. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....407
          2.13.6. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....411
          2.13.7. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....412
          2.13.8. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....413
          2.13.9. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....413
          2.13.10. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....415
          2.13.11. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....416
          2.13.12. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....417
        2.14. Low-Temperature Radiator....418
          2.14.1. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....418
          2.14.2. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....420
          2.14.3. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....421
          2.14.4. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....421
          2.14.5. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....422
          2.14.6. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....425
        2.15. Low Temperature Radiator (LTR) Thermostat....426
          2.15.1. Low Temperature Radiator (LTR) Thermostat – Removal....426
          2.15.2. Low Temperature Radiator (LTR) Thermostat – Installation....427
        2.16. Radiator Core....428
          2.16.1. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....428
          2.16.2. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....433
          2.16.3. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal ....434
          2.16.4. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation ....442
          2.16.5. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....443
          2.16.6. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....445
          2.16.7. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....446
          2.16.8. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....449
        2.17. Transmission Oil Cooler....450
          2.17.1. Transmission Oil Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....450
          2.17.2. Transmission Oil Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....451
          2.17.3. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....452
          2.17.4. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....453
          2.17.5. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....453
          2.17.6. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....454
        2.18. Fuel Cooler....455
          2.18.1. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....455
          2.18.2. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....456
        2.19. Low Temperature Radiator Hoses....457
          2.19.1. Low Temperature Radiator Hoses – Removal....457
          2.19.2. Low Temperature Radiator (LTR) Thermostat Hose – Installation....461
      3. Cooling Package Cleaning Procedures....462
        3.1. Cooling Package Cleaning Procedures....462
          3.1.1. Cleaning Cooling Package (MaxxForce® DT, 9, and 10 Engines)....463
          3.1.2. Cleaning Cooling Package (Navistar® 11 and 13 Engines)....463
      4. Inspection Procedures....466
        4.1. Deaeration Tank and Cap Inspection Procedures....466
          4.1.1. Deaeration Tank....466
          4.1.2. Deaeration Tank Cap Vacuum Relief Check....468
        4.2. Fan Drive Pulley and Pulley Groove Inspection Procedures....469
          4.2.1. Pulley Crack Inspection....469
          4.2.2. Pulley Nick Inspection....470
        4.3. 12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....471
          4.3.1. Fan Drive Movement....471
        4.4. 12THT Horton Drivemaster Advantage Fan Drive Inspection Procedures....472
          4.4.1. Fan Drive Movement....472
          4.4.2. Clutch Pack Face Seal....474
          4.4.3. Cartridge Assembly Seal and Spring....475
          4.4.4. Friction Liner Measurement....476
          4.4.5. Fan Drive Bearing Measurement and Inspection....477
        4.5. 12TTD Borg – Warner 842B Visctronics Inspection Procedure....478
          4.5.1. Fan Drive Movement....478
        4.6. Fuel Cooler Valve (FCV) Inspection Procedure....479
          4.6.1. Fuel Cooler Valve (FCV) Filter Screen – Removal....479
          4.6.2. Fuel Cooler Valve (FCV) Filter Screen – Installation....480
      5. 12THT and 12THZ Horton DriveMaster Advantage (DMA) Fan Drive System Diagnostics....481
        5.1. Start Diagnostics here: 12THT and 12THZ Horton DriveMaster Advantage (DMA) System Operational Checks....481
        Overview....481
        Tools Required....481
        Operational Checks – Start Fan Drive Diagnostics Here.....481
        Visual Air Leak Check....481
        5.2. Symptom 1: Fan Always On....484
        5.3. Symptom 2: Fan Always Off....503
        5.4. Symptom 3: Cycles Too Frequently....511
        5.5. Symptom 4: Excessive Noise From Fan Drive....513
      6. 12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics....516
        6.1. Start Diagnostics here: 12TTD Borg-Warner 842B Visctronic Fan Drive....516
        Overview....516
        Tools Required....516
        Operational Checks – Start Fan Drive Diagnostics Here....516
        6.2. Symptom 1: Fan Always ON....518
        6.3. Symptom 2: Fan Always OFF....524
        6.4. Symptom 3: Cycles Too Frequently....542
        6.5. Symptom 4: Excessive Noise From Fan Drive....545
      7. 12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....548
        7.1. Start Diagnostics Here: 12TSY Borg-Warner SA85 Fan Drive Assembly....548
        Overview....548
        Tools Required....548
      8. Abbreviations and Acronyms....550
      9. Terminology....551
  tables....554
    Table 88Torque Chart....554
0000002322 - DuraStar and TerraStar Cab Service Manual (Supersedes S16026)....558
  toc....560
    Summary of Changes....560
      1. DESCRIPTION....572
        1.1. Standard Cab, Extended Cab and Crew Cab....572
        1.2. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION....573
        1.3. ELECTRIC WINDSHIELD WIPERS....574
        1.4. WINDSHIELD WASHER....575
      2. OPERATION....578
        2.1. Electric Windshield Wipers....578
        2.2. WINDSHIELD WASHER....578
      3. MAINTENANCE....579
        3.1. Windshield Washer....579
      4. REMOVE....580
        4.1. ONE PIECE ENCAPSULATED WINDSHIELD....580
          Remove One Piece Encapsulated Windshield on Standard Cab, Extended Cab and Crew Cab for all Models....580
        4.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY....586
          Remove Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....586
        4.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY....589
          Remove Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....589
        4.4. HOOD SEAL....597
          Remove Hood Seal on Standard Cab, Extended Cab and Crew Cab for All Models....597
        4.5. SUNSHADE....598
          Remove Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models....598
        4.6. SUN VISOR AND CLIP....598
          Remove Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models....598
        4.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER....600
          Remove Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models....601
          Remove Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models....603
        4.8. INSTRUMENT PANEL....605
          Remove Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models....605
        4.9. CAB DOORS....609
          Remove Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models....609
          Remove Rear Cab Door on Crew Cab for All Models....613
        4.10. Cab Door Hinge....618
          Remove Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....618
          Remove Rear Cab Door Hinge on Crew Cab for all Models....619
        4.11. CAB DOOR STRIKER PIN....621
          Remove Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for All Models....621
          Remove Rear Cab Door Striker Pin on Crew Cab for all Models....622
        4.12. CAB DOOR CHECK BRACKET....623
          Remove Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models....623
          Remove Crew Cab rear Door Check Bracket on Crew Cab for all Models....624
        4.13. CAB DOOR CHECK LINK....624
          Remove Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models....624
          Remove Rear Door Check Link on Crew Cab for all Models....625
        4.14. CAB DOOR TRIM PANEL....627
          Remove Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....627
          Remove Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....629
          Remove Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for all Models....631
          Remove Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for all Models....633
        4.15. CAB DOOR INNER DOOR PANEL WATER SHIELD....635
          Remove Front Cab Door Inner Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for all Models....635
          Remove Rear Cab Door Inner Panel Water Shield on Crew Cab for all Models....637
        4.16. CAB DOOR WINDOW SLIDE BLOCK....638
          Remove Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models....638
          Remove Rear Cab Door Window Slide Block on Crew Cab for all Models....639
        4.17. CAB DOOR GLASS....641
          Remove Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models....641
          Remove Rear Cab Door Glass on Crew Cab for all Models....645
        4.18. MODULAR DOOR HARDWARE ASSEMBLY....649
          Remove Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....649
          Remove Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models....653
        4.19. CAB DOOR VENT WINDOW....656
          Remove Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models....656
        4.20. CAB DOOR VENT WINDOW HINGE....657
          Remove Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....657
        4.21. CAB DOOR VENT WINDOW SEAL....659
          Remove Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models....659
        4.22. CAB DOOR LOCK CYLINDER....659
          Remove Cab Door Lock Cylinder on Front Cab Door of Standard Cab or Extended Cab Models and on Front and Rear Cab Doors of Crew Cab Models....659
        4.23. CAB DOOR WINDOW ELECTRIC MOTOR....661
          Remove Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for all Models....661
          Remove Rear Cab Door Window Electric Motor on Crew Cab for all Models....662
        4.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY....663
          Remove Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....663
          Remove Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models....667
        4.25. OUTER CAB DOOR HANDLE....668
          Remove Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....668
          Remove Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models....672
        4.26. CAB DOOR LATCH....673
          Remove Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models....673
          Remove Rear Cab Door Latch on Crew Cab for all Models....675
        4.27. INNER CAB DOOR HANDLE....676
          Remove Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....676
          Remove Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models....678
        4.28. CAB DOOR WINDOW RUN CHANNELS....679
          Remove Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for all Models....679
          Remove Rear Cab Door Window Run Channels on Crew Cab for all Models....682
        4.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH....683
          Remove Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and Crew Cab for all Models....683
          Remove Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models....684
        4.30. CAB DOOR ELECTRIC MIRROR SWITCH....685
          Remove Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all Models....685
        4.31. SEATS....686
          Remove Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models....686
          Remove Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models....688
          Remove Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....690
          Remove Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....690
          Remove Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models....690
        4.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER....692
          Remove Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab and Crew Cab for all Models....692
        4.33. EXTENDED CAB BUNK/STORAGE UNIT....693
          Remove Bunk/Storage Unit on Extended Cab for all Models....693
        4.34. SIDE AND CORNER INTERIOR TRIM PANEL....694
          Remove Side and Corner Interior Trim Panel on Standard Cab for all Models....694
          Remove Side and Corner Interior Trim Panel on Extended Cab for all Models....695
          Remove Side and Corner Interior Trim Panel on Crew Cab for all Models....696
        4.35. Extended Cab Rear Side Window....698
          Remove Rear Side Window on Extended Cab for all Models....698
          Remove Rear Side Window Latch from Rear Side Window on Extended Cab for all Models....700
        4.36. REAR INTERIOR TRIM PANEL....701
          Remove Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models....701
        4.37. HEADER CONSOLE PANEL....701
          Remove Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models....701
        4.38. HEADLINER TRIM PANEL....705
          Remove Headliner Trim Panel on Standard Cab for all Models....705
          Remove Front Headliner Trim Panel on Extended Cab for all Models....706
          Remove Rear Headliner Trim Panel on Extended Cab for all Models....708
          Remove Front Headliner Trim Panel on Crew Cab for all Models....708
          Remove Rear Headliner Trim Panel on Crew Cab for all Models....711
        4.39. Crew Cab B - Pillar Trim Panel....712
          Remove B - Pillar Trim Panel on Crew Cab for all Models....712
        4.40. Cab Door Opening Weather Seals....712
          Remove Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for all Models....712
          Remove Rear Cab Door Opening Weather Seals on Crew Cab for all Models....713
        4.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....714
          Remove Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....714
        4.42. CAB COWL TRAY....715
          Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September 2000....715
          Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September 2000....717
          Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002....719
        4.43. WINDSHIELD WIPER ASSEMBLY....721
          Remove Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....721
        4.44. ELECTRIC WINDSHIELD WIPER MOTOR....723
          Remove Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models....723
        4.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR....725
          Remove Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for all Models....725
        4.46. Engine Cover And Cup Holder....729
          Remove Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models....729
          Remove Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models....729
        4.47. CAB....732
          General Procedures for Cab Removal....732
          Remove Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....733
          Cab with Low Mount Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....734
          Cab with Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....736
          Remove Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab before January 2003....737
          Remove Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models before January 2003....737
          Remove Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....737
          Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003....738
          Cab with Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....739
          Remove Low Mount Rear Cab Air Suspension for all Crew Cab Models....740
          Remove Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models....740
          Remove Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....740
          Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....741
          Remove Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications....742
          Remove Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City Tractor Applications....743
      5. INSTALL....744
        5.1. ONE PIECE ENCAPSULATED WINDSHIELD....744
          Install One Piece Encapsulated Windshield using Two Part U216 Urethane Adhesive (adhesive A and curative B) on Standard Cab, Extended Cab and Crew Cab for all Models....744
          Install One Piece Encapsulated Windshield using One Part U400HV Urethane Adhesive on Standard Cab, Extended Cab and Crew Cab for all Models....760
        5.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY....765
          Install Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....765
        5.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY....780
          Install Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....780
        5.4. HOOD SEAL....799
          Install Hood Seal on Standard Cab, Extended Cab and Crew Cab for all Models....799
        5.5. SUNSHADE....799
          Install Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models....799
        5.6. SUN VISOR AND CLIP....800
          Install Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models....800
        5.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER....800
          Install Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models....800
          Install Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models....801
        5.8. INSTRUMENT PANEL....801
          Install Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models....801
        5.9. CAB DOORS....804
          Install Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models....804
          Install Rear Cab Door on Crew Cab for all Models....804
        5.10. CAB DOOR HINGE....806
          Install Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....806
          Install Rear Cab Door Hinge on Crew Cab for all Models....806
        5.11. CAB DOOR STRIKER PIN....807
          Install Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for all Models....807
          Install Rear Cab Door Striker Pin on Crew Cab for all Models....807
        5.12. CAB DOOR CHECK BRACKET....807
          Install Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models....807
          Install Crew Cab Rear Door Check Bracket on Crew Cab for all Models....807
        5.13. CAB DOOR CHECK LINK....808
          Install Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models....808
          Install Crew Cab Rear Door Check Link on Crew Cab for all Models....808
        5.14. CAB DOOR TRIM PANEL....808
          Install Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....808
          Install Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....809
          Install Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for all Models....809
          Install Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for all Models....810
        5.15. CAB DOOR INNER DOOR PANEL WATER SHIELD....811
          Install Front Cab Door Inner Door Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for all Models....811
          Install Rear Cab Door Inner Door Panel Water Shield on Crew Cab for all Models....811
        5.16. CAB DOOR WINDOW SLIDE BLOCK....811
          Install Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models....811
          Install Rear Cab Door Window Slide Block on Crew Cab for all Models....813
        5.17. CAB DOOR GLASS....814
          Install Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models....814
          Install Rear Cab Door Glass on Crew Cab for all Models....818
        5.18. MODULAR DOOR HARDWARE ASSEMBLY....822
          Install Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....822
          Install Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models....823
        5.19. CAB DOOR VENT WINDOW....825
          Install Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models....825
        5.20. CAB DOOR VENT WINDOW HINGE....825
          Install Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....825
        5.21. CAB DOOR VENT WINDOW SEAL....825
          Install Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models....825
        5.22. CAB DOOR LOCK CYLINDER....826
          Install Cab Door Lock Cylinder on Front Cab Door on Standard Cab, Extended Cab and Crew Cab Models and Rear Cab Doors on Crew Cab Models....826
        5.23. CAB DOOR WINDOW ELECTRIC MOTOR....826
          Install Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for all Models....826
          Install Rear Cab Door Window Electric Motor on Crew Cab for all Models....827
        5.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY....827
          Install Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....827
          Install Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models....829
        5.25. OUTER CAB DOOR HANDLE....831
          Install Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....831
          Install Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models....832
        5.26. CAB DOOR LATCH....834
          Install Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models....834
          Install Rear Cab Door Latch on Crew Cab for all Models....835
        5.27. INNER CAB DOOR HANDLE....835
          Install Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....835
          Install Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models....836
        5.28. CAB DOOR WINDOW RUN CHANNELS....838
          Install Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for all Models....838
          Install Rear Cab Door Window Run Channels on Crew Cab for all Models....839
        5.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH....840
          Install Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and Crew Cab for all Models....840
          Install Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models....840
        5.30. CAB DOOR ELECTRIC MIRROR SWITCH....840
          Install Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all Models....840
        5.31. SEATS....841
          Install Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models....841
          Install Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models....841
          Install Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....841
          Install Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....842
          Install Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models....842
        5.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER....842
          Install Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab and Crew Cab for all Models....842
        5.33. EXTENDED CAB BUNK/STORAGE UNIT....843
          Install Bunk/Storage Unit on Extended Cab for all Models....843
        5.34. SIDE AND CORNER INTERIOR TRIM PANEL....843
          Install Side and Corner Interior Trim Panel on Standard Cab for all Models....843
          Install Side and Corner Interior Trim Panel on Extended Cab for all Models....844
          Install Side and Corner Interior Trim Panel on Crew Cab for all Models....844
        5.35. Extended Cab Rear Side Window....845
          Install Rear Side Window Latch onto Rear Side Window on Extended Cab for all Models....845
          Install Rear Side Window on Extended Cab for all Models....845
        5.36. REAR INTERIOR TRIM PANEL....847
          Install Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models....847
        5.37. HEADER CONSOLE PANEL....847
          Install Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models....847
        5.38. HEADLINER TRIM PANEL....848
          Install Headliner Trim Panel on Standard Cab for all Models....848
          Install Front Headliner Trim Panel on Extended Cab for all Models....849
          Install Rear Headliner Trim Panel on Extended Cab for all Models....849
          Install Front Headliner Trim Panel on Crew Cab for all Models....850
          Install Rear Headliner Trim Panel on Crew Cab for all Models....850
        5.39. Crew Cab B - Pillar trim panel....851
          Install B - Pillar Trim Panel on Crew Cab for all Models....851
        5.40. Cab Door Opening Weather Seals....852
          Install Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for all Models....852
          Install Rear Cab Door Opening Weather Seals on Crew Cab for all Models....852
        5.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....853
          Install Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....853
        5.42. CAB COWL TRAY....853
          Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September 2000....853
          Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September 2000....854
          Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002....855
        5.43. WINDSHIELD WIPER ASSEMBLY....855
          Install Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....855
        5.44. ELECTRIC WINDSHIELD WIPER MOTOR....856
          Install Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models....856
        5.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR....857
          Install Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for all Models....857
        5.46. Engine Cover And Cup Holder....857
          Install Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models....857
          Install Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models....858
        5.47. CAB....859
          Cab Squaring....859
          Install Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....859
          Install Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models Before January 2003....859
          Install Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models Before January 2003....860
          Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....860
          Install Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....861
          Install Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models....861
          Install Low Mount Rear Cab Air Suspension for all Crew Cab Models....861
          Cab with Low Mount Front Cab Mounting for all Crew Cab Models and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....861
          Install Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....862
          Install Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City Tractor Applications....862
          Install Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications....862
          Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....863
          General Procedures for Cab Installation....863
      6. TROUBLESHOOTING....865
        6.1. Electric Windshield Wiper Motor....865
        6.2. WASHER PUMP MOTOR....866
      7. LUBRICATION....867
        7.1. 4000 Miles (6000 Km) Or Monthly....867
        7.2. AS REQUIRED....867
      8. ADJUSTMENTS....868
        8.1. Cab Door....868
        8.2. HINGE AT CAB HINGE PILLAR....868
        8.3. STRIKER PIN AT LOCK PILLAR....869
        8.4. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....871
        8.5. CAB AIR SUSPENSION....872
      9. FORMS....875
        9.1. Bonded Windshield Replacement Report....875
      10. Torque....877
        10.1. Torque Chart....877
  tables....865
    Table 2Electric Windshield Wiper Motor....865
    Table 3Washer Pump Motor....866
    Table 4Torque Chart....877
0000002324 - SERVICE MANUAL CAB TranStar, WorkStar....884
  toc....886
    Summary of Changes....886
      1. DESCRIPTION....892
        1.1. Standard Cab and extended cab....892
        1.2. Cab Interior Trim Panels....892
        1.3. VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS....893
        1.4. WINDSHIELD....894
        1.5. ELECTRIC WINDSHIELD WIPERS....895
        1.6. WINDSHIELD WASHER....895
        1.7. IGNITION SWITCH CYLINDER....896
        1.8. Rear CAB AIR SUSPENSION system....897
      2. REMOVAL AND INSTALLATION....898
        2.1. Windshield....899
          Windshield - Removal....899
          Windshield - Installation....903
        2.2. Rear Window Glass....914
          Rear Window Glass (Unobstructed Access) – Removal....914
          Rear Window Glass (Unobstructed Access) – Installation....916
          Rear Window Glass (Obstructed Access) – Removal....926
          Rear Window Glass (Obstructed Access) – Installation....931
        2.3. Rear Side Window....946
          Rear Side Window – Removal....946
          Latch – Removal....947
          Latch – Installation....947
          Rear Side Window – Installation....948
        2.4. Hood Seal....950
          Hood Seal – Removal....950
          Hood Seal – Installation ....950
        2.5. Cab Cowl Tray....951
          Cab Cowl Tray – Removal....951
          Cab Cowl Tray – Installation....951
        2.6. Windshield Wiper Arm and Blade Assembly....952
          Windshield Wiper Arm and Blade Assembly – Removal....952
          Windshield Wiper Arm and Blade Assembly – Installation....953
        2.7. Windshield Wiper Assembly....953
          Windshield Wiper Assembly – Removal....953
          Windshield Wiper Assembly – Installation....954
        2.8. Windshield Washer Bottle With Pump Motor....955
          WorkStar® Windshield Washer Bottle With Pump Motor – Removal....955
          WorkStar® Windshield Washer Bottle With Pump Motor – Installation....956
          TranStar® Windshield Washer Bottle With Pump Motor – Removal....957
          TranStar® Windshield Washer Bottle With Pump Motor – Installation  ....958
        2.9. Windshield Washer Pump Motor....959
          Windshield Washer Pump Motor – Removal....959
          Windshield Washer Pump Motor – Installation....960
        2.10. Electric Windshield Wiper Motor....960
          Electric Windshield Wiper Motor – Removal....960
          Electric Windshield Wiper Motor – Installation....961
        2.11. Cab Doors....962
          Cab Doors – Removal....962
          Cab Doors – Installation....965
        2.12. Door Hinge....966
          Door Hinge – Removal....966
          Door Hinge – Installation....967
        2.13. Door Striker Pin....967
          Door Striker Pin – Removal....967
          Door Striker Pin – Installation....968
        2.14. Door Check Bracket....968
          Door Check Bracket – Removal....968
          Door Check Bracket – Installation....969
        2.15. Door Check Link....969
          Door Check Link – Removal....969
          Door Check Link – Installation....970
        2.16. Door Trim Panel....971
          Door Trim Panel – Removal....971
          Door Trim Panel – Installation....972
        2.17. Door Vapor Barrier....973
          Door Vapor Barrier – Removal....973
          Door Vapor Barrier – Installation....973
        2.18. Window Slide Block....974
          Window Slide Block – Removal....974
          Window Slide Block – Installation....975
        2.19. Door Glass....975
          Door Glass – Removal....975
          Door Glass – Installation....977
        2.20. Modular Door Hardware Assembly....978
          Modular Door Hardware Assembly – Removal....978
          Modular Door Hardware Assembly – Installation....981
        2.21. Vent Window, Latch, And Seal....983
          Vent Window, Latch, And Seal – Removal....983
          Vent Window, Latch, And Seal – Installation....984
        2.22. Door Lock Cylinder....985
          Door Lock Cylinder – Removal....985
          Door Lock Cylinder – Installation....986
        2.23. Window Electric Motor....987
          Window Electric Motor – Removal....987
          Window Electric Motor – Installation....987
        2.24. Regulator Arm Assembly....988
          Regulator Arm Assembly – Removal....988
          Regulator Arm Assembly – Installation....992
        2.25. Outer Door Handle....993
          Outer Door Handle – Removal....993
          Outer Door Handle – Installation....995
        2.26. Door Latch....996
          Door Latch – Removal....996
          Door Latch – Installation....997
        2.27. Inner Door Handle....997
          Inner Door Handle – Removal....997
          Inner Door Handle – Installation....998
        2.28. Window Run Channels....999
          Window Run Channels – Removal....999
          Window Run Channels – Installation....1001
        2.29. Electric Window And Door Lock Switch....1002
          Electric Window And Door Lock Switch – Removal....1002
          Electric Window And Door Lock Switch – Installation....1003
        2.30. Electric Mirror Switch....1003
          Electric Mirror Switch – Removal....1003
          Electric Mirror Switch – Installation....1004
        2.31. Weather Seals....1004
          Weather Seals – Removal....1004
          Weather Seals – Installation....1004
        2.32. Scuff Plate and Seat Belt Retractor Cover....1005
          Scuff Plate and Seat Belt Retractor Cover – Removal....1005
          Scuff Plate and Seat Belt Retractor Cover – Installation....1005
        2.33. Sunshade....1006
           Sunshade – Removal....1006
          Sunshade – Installation....1006
        2.34. Sun Visor and Clip....1007
          Sun Visor and Clip – Removal....1007
          Sun Visor and Clip – Installation....1007
        2.35. Ignition Switch And Ignition Switch Cylinder....1008
          Ignition Switch – Removal....1008
          Ignition Switch – Installation....1009
          Ignition Switch Cylinder – Removal....1010
          Ignition Switch Cylinder – Installation....1011
        2.36. INSTRUMENT Panel....1012
          Gauge Cluster – Removal....1012
          Gauge Cluster – Installation....1013
          Instrument Panel – Removal....1013
          Instrument Panel – Installation....1016
        2.37. Front Seats....1018
          Front Seats – Removal....1018
          Front Seats – Installation....1019
        2.38. Rear Bench Seat....1020
          Rear Bench Seat – Removal....1020
          Rear Bench Seat – Installation....1020
        2.39. Corner and Side Interior Trim Panel....1021
          Corner and Side Interior Trim Panel – Removal....1021
          Corner and Side Interior Trim Panel – Installation....1021
        2.40. Rear Interior Trim Panel....1022
          Rear Interior Trim Panel – Removal....1022
          Rear Interior Trim Panel – Installation....1022
        2.41. Header Console Panel....1023
          Header Console Panel – Removal....1023
          Header Console Panel – Installation....1027
        2.42. Headliner Trim Panel (Standard Cab)....1027
          Headliner Trim Panel (Standard Cab) – Removal....1027
          Headliner Trim Panel (Standard Cab) – Installation....1029
        2.43. Headliner Trim Panel (Extended Cab)....1029
          Headliner Trim Panel (Extended Cab) Front – Removal....1029
          Headliner Trim Panel (Extended Cab) Front – Installation....1031
          Headliner Trim Panel (Extended Cab) Rear – Removal....1032
          Headliner Trim Panel (Extended Cab) Rear – Installation....1033
        2.44. Engine Cover And Cup Holder....1034
          Cup Holder and Ashtray – Removal....1034
          Cup Holder and Ashtray – Installation....1034
          Engine Cover – Removal....1035
          Engine Cover – Installation....1035
        2.45. Cab....1035
          Initial Procedures Before Cab Removal....1035
          Cab – Removal....1038
          Cab – Installation....1039
          Final Procedures After Cab Installation....1040
        2.46. Rear Cab Air Suspension Assembly....1041
           Rear Cab Air Suspension Assembly – Removal....1041
           Rear Cab Air Suspension Assembly – Installation....1042
        2.47. Front Cab Mounting Bushings....1043
          Front Cab Mounting Bushings – Removal....1043
          Front Cab Mounting Bushings – Installation....1044
        2.48. Rear Cab Air Suspension System....1045
          Height Control Valve – Removal....1045
          Height Control Valve – Installation....1046
          Shock Absorber – Removal....1047
          Shock Absorber – Installation....1048
          Suspension Air Spring (Bag) – Removal....1048
          Suspension Air Spring (Bag) – Installation....1050
          Lateral Control Rod – Removal....1050
          Lateral Control Rod – Installation....1051
          Jounce Bumper – Removal....1052
          Jounce Bumper – Installation....1052
      3. TROUBLESHOOTING....1053
        3.1. ELECTRIC WINDSHIELD WIPER MOTOR....1053
        3.2. WASHER PUMP MOTOR....1054
        3.3. Rear CAB AIR SUSPENSION SYSTEM....1054
      4. LUBRICATION....1055
        4.1. 4,000 MILES (6,000 km) OR MONTHLY....1055
        4.2. AS REQUIRED....1055
      5. ADJUSTMENTS....1056
        5.1. CAB SQUARING....1056
        5.2. CAB DOOR....1057
        5.3. Door HINGE....1057
        5.4. STRIKER PIN....1058
        5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....1059
        5.6. Rear Cab Air Suspension....1060
          Ride Height....1060
  tables....1062
    Table 5Torque....1062
0000002601 - 3200, RXT, DuraStar, TranStar, TranStar Natural Gas, WorkStar Series Built May 17, 2010 and Later Electrical Circuit Diagrams (Supersedes S08343)....1064
0000002601 - 4000 Series (Oct 2014) Wiring Diagrams....2101
0000002842 - 3200, DuraStar, TranStar, WorkStar, and RXT Models Built March, 2008 to May 16, 2010 Electrical Circuit Diagrams (Supersedes S08337) ....2821
0000002842 - 4000 Series (March 2008 to May 2010) Wiring Diagrams....3229
0000003046 - Radiator_Cooling System DuraStar Cooling System Service Manual....3629
  toc....3631
    Summary of Changes....3631
    Table of Contents....3633
      1. DESCRIPTION....3635
        1.1. DEAERATION TANK....3636
        1.2. FAN SHROUD....3636
        1.3. FAN DRIVE....3636
        1.4. A/C CONDENSER....3636
        1.5. RADIATOR/Charge Air Cooler ASSEMBLY....3636
        1.6. Cross-Member....3636
        1.7. Low Temperature Radiator (LTR)....3636
        1.8. Low Temperature Radiator (ltr) Thermostat....3636
        1.9. TRANSMISSION OIL COOLER....3636
      2. Removal and Installation....3637
        2.1. Coolant Drain, Pressure Test, and Fill procedures....3638
          Coolant Drain Procedure (Recommended)....3640
          Pressure Test Procedure (Recommended)....3643
          Coolant Fill Procedure (Recommended)....3644
          Coolant Drain Procedure (Optional)....3646
          Coolant Fill Procedure (Optional Navistar® Engines)....3647
          Coolant Fill Procedure (Optional Cummins® ISB Engine)....3649
        2.2. Splash panel....3651
          Splash Panel – Removal....3651
          Splash Panel – Installation....3651
        2.3. DEAERATION TANK....3652
          Deaeration Tank (Radiators with Single Mega Bracket) - Removal....3652
          Deaeration Tank (Radiators with Single Mega Bracket) - Installation....3653
          Deaeration Tank (Radiators with Dual Mega Bracket) – Removal....3654
          Deaeration Tank (Radiators with Dual Mega Bracket) – Installation....3655
        2.4. A/C CONDENSER....3656
          A/C Condenser - Removal....3656
          A/C Condenser - Installation....3657
        2.5. Radiator Fan and Fan Drive Assembly....3658
          Horton Drivemaster (optional) - Removal....3658
          Horton Drivemaster (optional) - Installation....3659
          Viscous Fan and Two Speed Fan Drive - Removal....3659
          Viscous Fan and Fan Drive - Installation....3661
        2.6. FAN SHROUD....3662
          Fan Shroud - Removal....3662
          Fan Shroud - Installation....3664
        2.7. Low Temperature Radiator....3666
          Low Temperature Radiator - Removal....3666
          Low Temperature Radiator - Installation....3667
        2.8. RADIATOR HOSE....3668
          Heat Shrink Clamp - Removal....3668
          Heat Shrink Clamp - Installation....3669
          Radiator Hoses - Removal....3671
          Radiator Hoses - Installation....3672
        2.9. LTR Thermostat....3673
          LTR Thermostat – Removal....3673
          LTR Thermostat – Installation....3674
        2.10. Coolant Package....3675
          Coolant Package - Removal....3675
          Coolant Package - Installation....3681
        2.11. RADIATOR CORE/CAC ASSEMBLY....3683
          Radiator Core/CAC Assembly - Removal....3683
          Radiator Core/CAC Assembly - Installation....3685
  tables....3686
    Table 2Torque Chart....3686
0000003922 - 4000 Series (Nov 2010) Wiring Diagrams....3688
0000003922 - DuraStar, WorkStar, TranStar Series Models Built From November 22, 2010 Electrical Circuit Diagrams  (Supersedes S08353) (Latin America _ Mexico)....4170
0000017581 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Series Built March 11, 2004 to September 30, 2005 Electrical Circuit Diagrams  (Supersedes S082854)....4662
  toc....4664
    Table of Contents....4664
      INSTRUCTIONS AND CHARTS (Chapter 1)....4670
        2.1. Circuit Number Identification and Location Chart, p. 1....4670
        2.2. Circuit Number Identification and Location Chart, p. 2....4671
        2.3. Circuit Number Identification and Location Chart, p. 3....4672
        2.4. Circuit Number Identification and Location Chart, p. 4....4673
        2.5. Circuit Number Identification and Location Chart, p. 5....4674
        2.6. NAVPAK/ECM I6 Engine Controller Connector Pin Number Identi....4675
        2.7. Circuit Diagram Instructions, p. 7....4676
        2.8. Circuit Diagram Instructions, p. 8....4677
        2.9. Schematic Symbol Chart, p. 9....4678
        2.10. Relay Functions, p. 10....4679
        2.11. Lamp Bulb Chart, p. 11....4680
        2.12. International V8 and I6 ECM Controller Connectors Pin Numb....4681
      12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....4682
        3.1. Accessory, p. 1....4682
        3.2. Battery Feeds, Cab, p. 2....4683
        3.3. Battery, p. 3....4684
        3.4. 1708 Data Link Chassis, p. 4....4685
        3.5. Switch Data Link, p. 5....4686
        3.6. Drivetrain 1939 Data Link (Cab), p. 6....4687
        3.7. Drivetrain 1939 Data Link (Chassis), p. 7....4688
        3.8. Grounds Chassis, p. 8....4689
        3.9. Grounds Chassis, p. 9....4690
        3.10. Grounds IP, p. 10....4691
        3.11. Grounds IP, p. 11....4692
        3.12. Ignition Cab, p. 12....4693
        3.13. Ignition Cab, p. 13....4694
        3.14. Ignition Feeds, Chassis, p. 14....4695
        3.15. Start, p. 15....4696
      CAB ACCESSORIES (Chapter 3)....4697
        4.1. Cigar Lighter and Power Feeds, p. 1....4697
        4.2. CB Power, p. 2....4698
        4.3. Compass and Temperature Display, p. 3....4699
        4.4. Front Doors Windows and Locks (Power), p. 4....4700
        4.5. Crew Doors Windows and Locks (Power), p. 5....4701
        4.6. Horn, Dual Electric, p. 6....4702
        4.7. Mirrors (Heated, Lighted and Power), p. 7....4703
        4.8. Radio (Entertainment), Speakers, p. 8....4704
        4.9. Windshield Wiper and Washer Pump, p. 9....4705
        4.10. 2–Way Radio, p. 10....4706
        4.11. Switch Pack, Optional Gauge Pack, p. 11....4707
        4.12. Lighted Air Shield, p. 12....4708
        4.13. Roof Aux. Load, p. 13....4709
        4.14. Satellite Communication Qualcomm-MCT and IMCT Systems, p. ....4710
        4.15. Self Contained Air Seat, p. 15....4711
        4.16. Digital Clock PTC, p. 16....4712
        4.17. Transmission Allison LCT Column Shifter, p. 17....4713
        4.18. Heated Seats for 7700 Models Only, p. 18....4714
        4.19. Backup Camera, p. 19....4715
        4.20. XATA Computer, p. 20....4716
        4.21. Keyless Ignition System, p. 21....4717
      12V CHARGING + CRANKING SYSTEM (Chapter 4)....4718
        5.1. I6 EGR Engines, p. 1....4718
        5.2. V8 AVNT Engines, p. 2....4719
        5.3. Caterpillar, Cummins ISM Engines, p. 3....4720
        5.4. I6 HEUI Engines, p. 4....4721
        5.5. Caterpillar Engines, Cummins ISM and with Eaton Ultrashift/....4722
        5.6. I6 EGR Engines with Air Start, p. 6....4723
      FANS AND ENGINE ACCESSORIES (Chapter 5)....4724
        6.1. Fan Wiring, p. 1....4724
        6.2. Ether Start, p. 2....4725
        6.3. Snow Valve, p. 3....4726
        6.4. Fan Wiring, Caterpillar and Cummins, p. 4....4727
      ELECTRONIC ENGINES (Chapter 6)....4728
        7.1. Electronic Engine Controls, I6–EGR Engines, p. 1....4728
        7.2. Electronic Engine Controls, I6-EGR Engine Cruise Control an....4729
        7.3. Electronic Engine Controls, (V8–AVNT) Engines, p. 3....4730
        7.4. Electronic Engine Controls, V8–AVNT Engine Cruise Control a....4731
        7.5. Caterpillar C10, C11, C12, and C13 Engines, p. 5....4732
        7.6. Cummins ISM Engine, p. 6....4733
        7.7. I6 HEUI Engine, p. 7....4734
        7.8. I6 HEUI Engine Cruise Control and Body Builder Connections ....4735
      GAUGES WITH AND WITHOUT INTEGRAL WARNING LIGHT (Chapter 7)....4736
        8.1. IP/Gauge List, p. 1....4736
        8.2. Warning Light List, p. 2....4737
        8.3. Warning Lights Controlled by Engine, Transmission, ABS Cont....4738
        8.4. Engine Oil Pressure and Temp, Speedometer, Tach, Voltmeter ....4739
        8.5. IP/Gauges and Warning Lights — Gauge Cluster, p. 5....4740
        8.6. Air Pressure Input Circuit, p. 6....4741
        8.7. Axle Temperature, FWD Rear and Rear Axles, Gauge Input Circ....4742
        8.8. Fuel Gauge Input Circuit (Single Tank) Differential Lock Wa....4743
        8.9. Gauges and Warning Lights — Fuel Filter Restriction and Wat....4744
        8.10. Gauges and Warning Lights — Park Brake Light and Transmiss....4745
        8.11. Gauges and Warning Lights — Ammeter, p. 11....4746
        8.12. Engine Oil Temperature Gauge With Caterpillar, p. 12....4747
        8.13. Front Axle Engagement Lamp, p. 13....4748
      LIGHTS (Chapter 8)....4749
        9.1. Back Up Lights, p. 1....4749
        9.2. Light Systems — Clearance, Marker, Park, Tail, Turn and Sto....4750
        9.3. Light Systems — Clearance, Marker, Park, Tail, Turn and Sto....4751
        9.4. Light Systems — Turn Signal and Stop Switches, p. 4....4752
        9.5. Dome Light, Map Light, p. 5....4753
        9.6. Dome Light, Map Light (Cont.), p. 6....4754
        9.7. Fog Light and Work Light, p. 7....4755
        9.8. Headlights, p. 8....4756
        9.9. Aux. Headlights, Aux. Park, Aux. Turn, p. 9....4757
        9.10. Panel Lights, p. 10....4758
      CHASSIS ACCESSORIES (Chapter 9)....4759
        10.1. Air Dryer and Heated Drain Valve, p. 1....4759
        10.2. Antilock Brake System (ABS), Air, p. 2....4760
        10.3. Antilock Brake System (ABS), Air, Traction Control, p. 3....4761
        10.4. Antilock Brake System (ABS), Hydraulic, p. 4....4762
        10.5. Antilock Brake System (ABS), Hydraulic (Cont.), p. 5....4763
        10.6. Antilock Brake System (ABS), Hydraulic (Cont.), p. 6....4764
        10.7. Two Speed Axle Switch With Manual Transmission and I6 HEUI....4765
        10.8. Brake System, Hydraulic, p. 8....4766
        10.9. Fuel Transfer Pump, p. 9....4767
        10.10. Back of Cab Body Builder and Trailer Stop, Tail, Marker, ....4768
        10.11. Body Builder and Trailer Turns, Center Pin ABS, Center Pi....4769
        10.12. Body Builder and Trailer Socket Back of Cab Sockets, p. 1....4770
        10.13. Body Builder and Trailer Socket End of Frame (EOF) Socket....4771
        10.14. Air Solenoid 4–Way Pack, p. 14....4772
        10.15. Remote Power Units, Solenoid Packs, Remote Engine Speed C....4773
        10.16. HYD Power Park, p. 16....4774
        10.17. Air Suspension, p. 17....4775
        10.18. Aux. Trailer, Acc Controlled, p. 18....4776
        10.19. Aux. Trailer, Battery Controlled, p. 19....4777
        10.20. Lift Axles (Non-Steerable), p. 20....4778
        10.21. Lift Axles (Steerable), p. 21....4779
        10.22. Air Actuated Park Brake, p. 22....4780
        10.23. Antilock Brake System, WABCO Air, p. 23....4781
        10.24. Antilock Brake System, WABCO Air, p. 24....4782
        10.25. Lift Axles, With Non-Steerable for SS Models, p. 25....4783
        10.26. Fuel / Water Separator With 12VDC Fuel Preheater, p. 26....4784
        10.27. Electronic Trailer Brake Accommodation, p. 27....4785
        10.28. Lectrashift Accommodation, p. 28....4786
        10.29. Auxiliary 40 Amp Circuit, p. 29....4787
        10.30. Hourmeter, Customer Mounted PTO, p. 30....4788
        10.31. Remote Start/ Stop, p. 31....4789
        10.32. Lift Axle with 14RAR, p. 32....4790
        10.33. Lift Gate, p. 33....4791
        10.34. Lift Axle Multiplex, p. 34....4792
      TRANSMISSIONS (Chapter 10)....4793
        11.1. Allison LCT Transmission or Allison 1000, 2000, 2400, p. 1....4793
        11.2. Allison MD Transmission, p. 2....4794
        11.3. Allison MD Transmission (WTEC), p. 3....4795
        11.4. Allison MD Transmission (Cont.), p. 4....4796
        11.5. Transmission, WTEC MD W/Auto Neutral, p. 5....4797
        11.6. Eaton Autoshift Transmission, p. 6....4798
        11.7. Eaton Autoshift Transmission (Cont.), p. 7....4799
        11.8. Eaton Lightning Transmission, p. 8....4800
        11.9. Allison HD Transmission, p. 9....4801
        11.10. Allison HD Transmission, p. 10....4802
        11.11. Allison HD Transmission, p. 11....4803
        11.12. Allison HD Transmission With Auto Neutral, p. 12....4804
        11.13. Allison HD Transmission With Auto Neutral and with 0013WU....4805
        11.14. Allison LCT Transmission (Allison 1000, 2000, 2400) with ....4806
        11.15. Transmission Retarder Control Wiring with MD Xmsn, Hard W....4807
        11.16. Transmission Retarder Control Wiring with MD Xmsn, Hard W....4808
      AIR CONDITIONING (Chapter 11)....4809
        12.1. HVAC Systems, p. 1....4809
        12.2. Air Conditioning (Only), p. 2....4810
        12.3. Autotherm Systems, p. 3....4811
      CONNECTOR COMPOSITES (Chapter 12)....4812
        13.1. Connector Composites (10M), (71), (72), (345F), p. 1....4812
        13.2. Connector Composites (420F), (420M), (520), (521), (522), ....4813
        13.3. Connector Composites (1002), (1003), (1010), p. 3....4814
        13.4. Connector Composite (1011), p. 4....4815
        13.5. Connector Composite (1012), p. 5....4816
        13.6. Connector Composite (1013), p. 6....4817
        13.7. Connector Composite (1014), p. 7....4818
        13.8. Connector Composites (1018), (1019M), (1020M), (1021M), (1....4819
        13.9. Connector Composites (1027M, F), (1100), (1101A), (1101), ....4820
        13.10. Connector Composites (1104), (1106), (1200), (1210), p. 1....4821
        13.11. Connector Composites (1300), (1301), (1400), (1402), (141....4822
        13.12. Connector Composites (1553), (1554F), (1555), (1600), (16....4823
        13.13. Connector Composites (1652), (1657M), (1658), (1659), (18....4824
        13.14. Connector Composites (1804), (1807), (1808), (1809), (181....4825
        13.15. Connector Composites (1820), (1822), (1823), (1824), (182....4826
        13.16. Connector Composites (1918), (1935), (1920), (2000), (200....4827
        13.17. Connector Composites (2006M), (2007F), (2021F), (2021M), ....4828
        13.18. Connector Composites (2304M), (2305M), (2306M), (2307F), ....4829
        13.19. Connector Composites (2601M, F), (2602M, F), (3000M), (30....4830
        13.20. Connector Composites (3204M, F), (3209), (3210M), (3211M)....4831
        13.21. Connector Composite (4001), p. 21....4832
        13.22. Connector Composite (4002), p. 22....4833
        13.23. Connector Composite (4003), p. 23....4834
        13.24. Connector Composites (4004), (4007), (4008), p. 24....4835
        13.25. Connector Composite (4014), p. 25....4836
        13.26. Connector Composite (4014/1700), p. 26....4837
        13.27. Connector Composites (4015), (4017), (4018), (4019), (402....4838
        13.28. Connector Composites (4024), (4030), (4031), (4032), (403....4839
        13.29. Connector Composites (4070), (4071), (4087), (4098), (410....4840
        13.30. Connector Composite (4103), p. 30....4841
        13.31. Connector Composites (4105), (4111), (4120), (4301), p. 3....4842
        13.32. Connector Composites (4305), (4410), (4410B), (4410C), (4....4843
        13.33. Connector Composites (4411A), (4411B), (4412), (4415), (4....4844
        13.34. Connector Composite (4705), p. 34....4845
        13.35. Connector Composites (4810), (4712F), (4820), (4713F), (4....4846
        13.36. Connector Composites (4900), (4910), (4950), (4951), p. 3....4847
        13.37. Connector Composites (6007), (6011), p. 37....4848
        13.38. Connector Composites (6013M), (6014), p. 38....4849
        13.39. Connector Composites (6015), (6020), (6021), p. 39....4850
        13.40. Connector Composites (6200), (6316), (6323), (6332), (633....4851
        13.41. Connector Composites (6550), (6703), (6704), (6708), (710....4852
        13.42. Connector Composites (7200), (7202), (7203), p. 42....4853
        13.43. Connector Composites (7204), (7205), (7206), (7211), (72....4854
        13.44. Connector Composites (7214), (7300), (7301), p. 44....4855
        13.45. Connector Composites (7302), (7304), (7305), (7306), (750....4856
        13.46. Connector Composites (7603), (7604), (7605), (7606), (760....4857
        13.47. Connector Composites (7800), (7801M), (7803), (7900), (79....4858
        13.48. Connector Composites (7905), (7906), (8000), (8001), (810....4859
        13.49. Connector Composites (8201), (8301), (8310), (8311), (831....4860
        13.50. Connector Composites (8503), (8503A), (8505), (8506), (85....4861
        13.51. Connector Composites (8700), (8701), (8800), (8801), (880....4862
        13.52. Connector Composites (9001), (9002), (9100), (9101), (910....4863
        13.53. Connector Composites (9260), (9261), (9262), (9263), (926....4864
        13.54. Connector Composites (9405), (9501), (9502), (9503), (950....4865
        13.55. Connector Composites (9507), (9508), (9509), (9510), (951....4866
        13.56. Connector Composites (9516), (9517), (9518), (9519), p. 5....4867
        13.57. Connector Composite (9700), p. 57....4868
        13.58. Connector Composite (9700), p. 58....4869
        13.59. Connector Composites (9715), (9715A), (9715B), p. 59....4870
        13.60. Connector Composites (9716), (9716A), (9716B), p. 60....4871
        13.61. Connector Composites (9717A), (9717B), p. 61....4872
        13.62. Connector Composites (9718), (9719), (9720), (9733), (973....4873
        13.63. Connector Composites (9777), (9778), (9800), p. 63....4874
        13.64. Connector Composites (9870), (9871), (9811), (9812), (981....4875
        13.65. Connector Composites (9913B), (9914), (4100), (4109), (41....4876
0000018561 - DuraStar with Cummins Euro 5 ISB Engine Electrical Circuit Diagram Manual (for Latin America and Mexico)....4877
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Revision 1 (Supersedes 0000001601, 0000001843 & 0000002222) Service Manual....5063
  toc....5065
    Table of Contents....5065
      1. Description....5077
        1.1. Cooling Package Visual Inspection....5082
      2. Cooling Package Cleaning Procedures....5083
        2.1. Cleaning Cooling Package (MaxxForce® 9, and 10 Engines) ....5084
        2.2. Cleaning Cooling Package (Navistar® 11 and 13 Engines) ....5085
        2.3. Charge Air Cooler Cleaning Procedure....5088
        Overview....5088
        Tools Required....5089
        Service Parts....5089
          2.3.1. Charge Air Cooler Cleaning Procedure Setup....5089
          2.3.2. Off-chassis Pressure Test....5090
          2.3.3. Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation....5092
          2.3.4. Charge Air Cooler Cleaning Procedure....5094
          2.3.5. Flushing Procedure....5095
          2.3.6. Cleaning Management System (CMS) Removal Procedure....5096
      3. PayStar® and 9900....5098
        3.1. PayStar® and 9900 Description ....5104
          3.1.1. Deaeration Tank ....5104
          3.1.2. Fan Shroud ....5104
          3.1.3. A/C Condenser ....5104
          3.1.4. Transmission Oil Cooler ....5104
          3.1.5. Radiator ....5104
          3.1.6. Charge Air Cooler ....5104
          3.1.7. Low-Temperature Radiator ....5104
          3.1.8. Fan Drive....5105
        3.2. Coolant Drain and Pressure Test Procedures....5107
          3.2.1. Coolant Drain Procedure (Recommended)....5109
          3.2.2. Pressure Test (Recommended)....5111
          3.2.3. Coolant Fill Procedure (Recommended)....5113
          3.2.4. Coolant Gravity Drain Procedure (Optional)....5116
          3.2.5. Coolant Fill Procedure (Optional) Cummins® ISB6.7 Engine)....5117
          3.2.6. Coolant Fill Procedure – MaxxForce 11 Liter, 13 Liter, 15 Liter (Optional)....5119
          3.2.7. Coolant Fill Procedure – Cummins® ISX 15 Engines (Optional)....5122
        3.3. PayStar® and 9900 Removal and Installation....5124
          3.3.1. Splash Panel – Removal....5125
          3.3.2. Splash Panel – Installation....5125
          3.3.3. Grille – Removal....5126
          3.3.4. Grille Installation....5126
          3.3.5. Surge Tank (Cummins® ISB6.7 Engine) – Removal....5127
          3.3.6. Surge Tank (Cummins® ISB6.7 Engine) – Installation....5127
          3.3.7. Deaeration Tank – Removal....5129
          3.3.8. Deaeration Tank – Installation....5130
          3.3.9. A/C Condenser (N13 Engine) – Removal....5131
          3.3.10. A/C Condenser  (N13 Engine) – Installation....5132
          3.3.11. A/C Condenser (Cummins® ISX) – Removal....5132
          3.3.12. A/C Condenser (Cummins® ISX) – Installation....5133
          3.3.13. Upper Fan Shroud  (N13 Engine) – Removal....5134
          3.3.14. Upper Fan Shroud (N13) – Installation....5136
          3.3.15. Lower Fan Shroud (N13) – Removal ....5137
          3.3.16. Lower Fan Shroud (N13) – Installation....5140
          3.3.17. Fan Shroud (Two and Three Piece) Cummins® ISX15 Engines – Removal....5141
          3.3.18. Fan Shroud (Two Piece) Cummins® ISX15 Engines – Installation ....5144
          3.3.19. Fan Belt N13 – Removal....5145
          3.3.20. Fan Belt (N13) – Installation....5146
          3.3.21. Fan Belt (MaxxForce® 15 Engine) – Removal....5146
          3.3.22. Fan Belt (MaxxForce® 15) – Installation....5148
          3.3.23. Alternator Fan Belt (MaxxForce® 15) – Removal....5148
          3.3.24. Alternator Fan Belt (MaxxForce® 15) – Installation....5149
          3.3.25. Fan Belt (Cummins®ISX15) – Removal....5150
          3.3.26. Fan Belt (Cummins® ISX15) – Installation....5151
          3.3.27. Transmission Oil Cooler (Cross-member Mounted) – Removal....5152
          3.3.28. Transmission Oil Cooler (Cross-member mounted) – Installation....5153
          3.3.29. Transmission Oil Cooler (Front Mounted) – Removal....5154
          3.3.30. Transmission Oil Cooler (Front Mounted) – Installation....5154
          3.3.31. Radiator Hose Heat Shrink Clamp – Removal and Installation....5156
          Heat Shrink Clamp – Removal....5156
          Heat Shrink Clamp – Installation....5157
          3.3.32. Radiator Hose (N13) – Removal....5159
          3.3.33. Radiator Hose (N13) – Installation....5162
          3.3.34. Radiator Hose (Series 9900 with Cummins® ISX15) – Removal ....5163
          3.3.35. Radiator Hose (Series 9900 with Cummins® ISX15) – Installation....5166
          3.3.36. Front Charge Air Cooler (N13) – Removal....5167
          3.3.37. Front Charge Air Cooler (N13) – Installation....5168
          3.3.38. Rear Charge Air Cooler (N13) – Removal....5169
          3.3.39. Rear Charge Air Cooler (N13) – Installation....5169
          3.3.40. Charge Air Cooler (Cummins® ISX15) – Removal....5170
          3.3.41. Charge Air Cooler (Cummins®ISX15) – Installation....5171
          3.3.42. Low-Temperature Radiator – Removal....5172
          3.3.43. Low-Temperature Radiator – Installation....5174
          3.3.44. Radiator Assembly (N13) – Removal....5175
          3.3.45. Radiator Assembly (N13) – Installation ....5178
          3.3.46. Radiator Assembly (Cummins®ISX15) – Removal....5179
          3.3.47. Radiator Assembly (Cummins®ISX15) – Installation....5184
          3.3.48. Recirculation Seals  (MaxxForce® 11 or 13 L) – Removal....5187
          3.3.49. Recirculation Seals (MaxxForce® 11 or 13 L) – Installation....5188
          3.3.50. Recirculation Seals (MaxxForce® 15 L) – Removal ....5189
          3.3.51.  Recirculation Seals (MaxxForce® 15) –  Installation ....5192
          3.3.52. Radiator Core (MaxxForce® 11 L or 13 L) – Removal....5192
          3.3.53. Radiator Core (MaxxForce® 11 L or 13 L) – Installation....5194
          3.3.54. Radiator Core (MaxxForce® 15 L) – Removal....5194
          3.3.55. Radiator Core (MaxxForce® 15 L) – Installation....5196
          3.3.56. Radiator Core- Removal – (Cummins® ISX15) ....5197
          3.3.57. Radiator Core Installation – (Cummins® ISX15) ....5200
          3.3.58. Power Steering Oil Cooler (Cummins® ISX15) – Removal....5201
          3.3.59. Power Steering Oil Cooler (Cummins® ISX15) – Installation....5201
        3.4. PayStar® Inspection Procedures....5202
          3.4.1. Deaeration Tank Inspection Procedure....5202
          3.4.2. Deaeration Tank Cap Vacuum Relief Check....5203
          3.4.3. Fan Drive Pulley Crack Inspection....5204
          3.4.4. Fan Drive Pulley Nick Inspection....5204
          3.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....5205
          Fuel Cooler Valve (FCV) Filter Screen – Removal....5205
          Fuel Cooler Valve (FCV) Filter Screen – Installation....5206
        3.5. Torque Chart....5207
      4. ProStar®....5209
        4.1. ProStar®General Description....5215
          4.1.1. Deaeration Tank....5215
          4.1.2. Fan Shroud....5215
          4.1.3. A/C Condenser....5215
          4.1.4. Transmission Oil Cooler....5215
          4.1.5. Radiator....5215
          4.1.6. Charge Air Cooler....5215
          4.1.7. Low-Temperature Radiator....5215
          4.1.8. Fan Drive....5215
          4.1.9. Power Steering Oil Cooler....5216
        4.2. ProStar® Coolant Drain, Pressure Test, and Fill procedures ....5217
          4.2.1. Coolant Drain Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....5221
          4.2.2. Pressure Test Procedure – Navistar® 11, 13, 15, and Cummins® ISX15 (Recommended)....5223
          4.2.3. Coolant Fill Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....5224
          4.2.4. Coolant Drain Procedure – Navistar® 11, 13, 15, Cummins® ISX15 (Optional)....5227
          4.2.5. Coolant Fill Procedure – Navistar® 11, 13, 15 (Optional)....5228
          4.2.6. Coolant Fill Procedure – Cummins® ISX Engines (Optional)....5231
        4.3. ProStar ® Removal and Installation....5233
          4.3.1. Grille – Removal....5234
          4.3.2. Grille – Installation....5234
          4.3.3. Deaeration Tank Removal – Navistar® 11, 13, 15....5234
          4.3.4. Deaeration Tank – Installation Navistar® 11, 13, N13, 15....5235
          4.3.5. Deaeration Tank Removal – Cummins® ISX15....5236
          4.3.6. Deaeration Tank Installation – Cummins® ISX15....5237
          4.3.7. A/C Condenser Removal – MaxxForce® 11, 13 and N13....5238
          4.3.8. A/C Condenser Installation – MaxxForce® 11, 13 or N13 ....5241
          4.3.9. A/C Condenser Removal – Navistar® 15 L ....5242
          4.3.10. A/C Condenser Installation – Navistar® 15 L ....5243
          4.3.11. A/C Condenser Removal – Cummins® ISX15 ....5244
          4.3.12. A/C Condenser Installation – Cummins® ISX15....5245
          4.3.13. Fan Shroud Removal – MaxxForce® 11, 13, N13....5246
          4.3.14. Fan Shroud Installation – MaxxForce® 11, 13 L and N13....5252
          4.3.15. Fan Shroud Removal – (Three-Piece Upper) Navistar® 15 ....5252
          4.3.16.  Fan Shroud Installation – (Three-Piece Upper) Navistar® 15 ....5254
          4.3.17.  Fan Shroud Removal – (Three-Piece Lower) Navistar® 15 ....5255
          4.3.18.  Fan Shroud Installation – (Three-Piece Lower) Navistar® 15....5255
          4.3.19.  Fan Shroud (One-Piece) Removal – Navistar® 15....5256
          4.3.20.  Fan Shroud Installation – (One-Piece) Navistar® 15....5257
          4.3.21. Fan Shroud Removal – (Two-Piece) Cummins® ISX15....5258
          4.3.22. Fan Shroud Installation – (Two-Piece) Cummins® ISX15....5262
          4.3.23. Radiator Fan Removal – Navistar® 11, 13....5262
          4.3.24. Radiator Fan Installation – Navistar® 11, 13 ....5263
          4.3.25. Radiator Fan Removal (With Three-Piece Fan Shroud) – Navistar® 15....5263
          4.3.26.  Radiator Fan Installation (With Three-Piece Fan Shroud) – Navistar® 15....5264
          4.3.27.  Radiator Fan Removal (With One-Piece Fan Shroud) – Navistar® 15....5264
          4.3.28. Radiator Fan Installation (With One-Piece Fan Shroud) – Navistar® 15....5265
          4.3.29. Radiator Fan Removal – Cummins® ISX15....5266
          4.3.30. Radiator Fan Installation – Cummins® ISX15....5266
          4.3.31.  Fan Drive Removal – Navistar® 11, 13....5267
          4.3.32. Fan Drive Installation – Navistar® 11, 13....5269
          4.3.33. Fan Drive Removal – Navistar® 15....5269
          4.3.34.  Fan Drive Installation – Navistar® 15....5270
          4.3.35. Fan Drive Assembly Removal – Cummins® ISX15 (Horton)....5270
          4.3.36. Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ....5273
          4.3.37.  Fan Belt Removal – Navistar® 11, 13....5274
          4.3.38. Fan Belt Installation – Navistar® 11, 13....5275
          4.3.39. Fan Belt Removal – Navistar® 15 ....5275
          4.3.40. Fan Belt Installation – Navistar® 15....5277
          4.3.41. Alternator Fan Belt Removal – Navistar® 15 ....5277
          4.3.42. Alternator Fan Belt Installation – Navistar® 15 ....5279
          4.3.43. Fan Belt Removal – Cummins® ISX15 ....5279
          4.3.44. Fan Belt Installation – Cummins® ISX15....5281
          4.3.45. Radiator Hose Heat Shrink Clamp Removal and Installation....5281
          Heat Shrink Clamp Removal....5281
          Heat Shrink Clamp Installation....5282
          4.3.46. Radiator Hose Removal – Navistar® 11, 13 ....5286
          4.3.47.  Radiator Hose Installation – Navistar® 11, 13....5287
          4.3.48. Radiator Hose Removal – Navistar® 15 ....5288
          4.3.49.  Radiator Hose Installation – Navistar® 15....5289
          4.3.50. Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Removal – Navistar® N13....5290
          4.3.51.  Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Installation – Navistar® N13....5292
          4.3.52. Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Removal – Navistar® 15 ....5295
          4.3.53.  Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Installation – Navistar® 15....5297
          4.3.54. Radiator Hose Removal – Cummins® ISX15....5300
          4.3.55. Radiator Hose Installation – Cummins® ISX15 ....5302
          4.3.56. Recirculation Seals Removal – Navistar® 11, 13....5303
          4.3.57. Recirculation Seals Installation – Navistar® 11, 13 ....5304
          4.3.58. Recirculation Seals Removal – Navistar® 15 ....5304
          4.3.59.  Recirculation Seals Installation – Navistar® 15....5305
          4.3.60. Charge Air Cooler Removal – Navistar® 11, 13, 15....5306
          4.3.61. Charge Air Cooler Installation – Navistar® 11, 13, 15....5307
          4.3.62. Charge Air Cooler Removal – Cummins® ISX15....5307
          4.3.63. Charge Air Cooler Installation – Cummins® ISX15....5311
          4.3.64. Hood-Tilt Assist Cylinder – Removal....5312
          4.3.65. Hood-Tilt Assist Cylinder – Installation....5314
          4.3.66. Low-Temperature Radiator Removal – Navistar® 11, 13....5315
          4.3.67. Low-Temperature Radiator Installation – Navistar® 11, 13....5317
          4.3.68. Low-Temperature Radiator Removal – Navistar® 15....5318
          4.3.69. Low-Temperature Radiator Installation – Navistar® 15....5322
          4.3.70. Radiator Assembly Removal – Navistar® 11, 13....5323
          4.3.71. Radiator Assembly Installation – Navistar® 11, 13....5324
          4.3.72. Radiator Assembly Removal – Navistar® 15....5326
          4.3.73. Radiator Assembly Installation – Navistar® 15....5328
          4.3.74. Radiator Assembly Removal – Cummins® ISX15....5329
          4.3.75. Radiator Assembly Installation – Cummins® ISX15....5335
          4.3.76. Radiator Core Removal – Navistar® 11, 13....5337
          4.3.77. Radiator Core Installation – Navistar® 11, 13....5340
          4.3.78. Radiator Core Removal – Navistar® 15....5341
          4.3.79. Radiator Core Installation – Navistar® 15....5343
          4.3.80. Radiator Core- Removal – Cummins® ISX15 ....5344
          4.3.81. Radiator Core Installation – Cummins® ISX15 ....5348
          4.3.82. Power Steering Oil Cooler – Removal....5349
          4.3.83. Power Steering Oil Cooler – Installation....5351
          4.3.84. Transmission Oil Cooler Removal (Cummins® ISX15 ONLY)....5351
          4.3.85. Transmission Oil Cooler – Installation....5352
        4.4. ProStar® Inspection Procedures....5354
          4.4.1. Deaeration Tank Inspection Procedure....5354
          4.4.2. Deaeration Tank Cap Vacuum Relief Check....5355
          4.4.3. Fan Drive Pulley Crack Inspection....5356
          4.4.4. Fan Drive Pulley Nick Inspection....5356
          4.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....5357
          Fuel Cooler Valve (FCV) Filter Screen – Removal....5357
          Fuel Cooler Valve (FCV) Filter Screen – Installation....5358
        4.5. Torque Chart Navistar® Engines....5359
      5. TranStar®....5362
        5.1. TranStar® General Description....5367
          5.1.1. Deaeration Tank....5367
          5.1.2. Fan Shroud....5367
          5.1.3. A/C Condenser....5367
          5.1.4. Transmission Oil Cooler....5367
          5.1.5. Radiator....5367
          5.1.6. Charge Air Cooler....5367
          5.1.7. Low-Temperature Radiator....5367
          5.1.8. Fan Drive....5367
        5.2. TranStar® Coolant Drain, Pressure Test, and Fill procedures....5368
          5.2.1. Coolant Drain, Pressure Test, and Fill procedures (Recommended)....5371
          5.2.2. Pressure Test Procedure (Recommended)....5373
          5.2.3. Coolant Fill Procedure (Recommended)....5376
          5.2.4. Coolant Drain Procedure (Optional)....5379
        5.3. TranStar® Removal and Installation....5380
          5.3.1. Grille – Removal....5381
          5.3.2. Grille – Installation....5381
          5.3.3. Deaeration Tank – Removal....5381
          5.3.4. Deaeration Tank – Installation....5382
          5.3.5. A/C Condenser – Removal....5384
          5.3.6. A/C Condenser – Installation....5386
          5.3.7. Fan Shroud – Removal....5387
          5.3.8. Fan Shroud – Installation....5390
          5.3.9. Radiator Fan – Removal....5390
          5.3.10. Radiator Fan – Installation....5391
          5.3.11. Fan Clutch – Removal....5392
          5.3.12. Fan Clutch – Installation....5393
          5.3.13. Fan Belt – Removal....5394
          5.3.14. Fan Belt – Installation....5396
          5.3.15. Heat Shrink Clamp Removal and Installation....5396
          Heat Shrink Clamp Removal....5396
          Heat Shrink Clamp Installation....5397
          5.3.16. Radiator Hose – Removal....5400
          5.3.17. Radiator Hose – Installation....5404
          5.3.18. Charge Air Cooler – Removal....5405
          5.3.19. Charge Air Cooler – Installation....5407
          5.3.20. Low-Temperature Radiator – Removal....5408
          5.3.21. Low-Temperature Radiator – Installation....5409
          5.3.22. Radiator Assembly – Removal....5410
          5.3.23. Radiator Assembly – Installation....5412
          5.3.24. Radiator Core – Removal....5413
          5.3.25. Radiator Core – Installation....5415
          5.3.26. Transmission Oil Cooler (Crossmember mounted) – Removal....5416
          5.3.27. Transmission Oil Cooler (Crossmember mounted) – Installation....5416
        5.4. TranStar® Inspection Procedures....5418
          5.4.1. Deaeration Tank Inspection Procedure....5418
          5.4.2. Deaeration Tank Cap Vacuum Relief Check....5419
          5.4.3. Fan Drive Pulley Crack Inspection....5420
          5.4.4. Fan Drive Pulley Nick Inspection....5420
          5.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....5421
          Fuel Cooler Valve (FCV) Filter Screen – Removal....5421
          Fuel Cooler Valve (FCV) Filter Screen – Installation....5422
        5.5. Torque Chart....5423
      6. WorkStar®....5424
        6.1. WorkStar® and 9900 Description....5430
          6.1.1. Surge Tank (If Equipped) ....5430
          6.1.2. Deaeration Tank....5430
          6.1.3. Fan Shroud....5430
          6.1.4. Fan Drive....5430
          6.1.5. A/C Condenser....5430
          6.1.6. Radiator....5430
          6.1.7. Charge Air Cooler....5430
          6.1.8. Cross-Member....5430
          6.1.9. Low-Temperature Radiator....5431
          6.1.10. Low Temperature Radiator (LTR) Thermostat....5431
          6.1.11. Fuel Cooler....5431
          6.1.12. Transmission Oil Cooler....5431
        6.2. WorkStar® Coolant Drain, Pressure Test, and Fill procedures....5432
          6.2.1. Coolant Drain Procedure (Recommended)....5435
          6.2.2. Pressure Test Procedure (Recommended)....5437
          6.2.3. Coolant Fill Procedure (Recommended)....5440
          6.2.4. Coolant Gravity Drain Procedure (Optional)....5443
          6.2.5. Coolant Fill Procedure (MaxxForce® 9, and 10 Engines) (Optional)....5444
          6.2.6. Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....5446
          6.2.7. Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....5448
        6.3. WorkStar® Removal and Installation....5451
          6.3.1. Grille (Standard) – Removal....5452
          6.3.2. Grille (Standard) – Installation....5452
          6.3.3. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5452
          6.3.4. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5453
          6.3.5. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5453
          6.3.6. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5454
          6.3.7. Splash Panel (Standard) – Removal....5454
          6.3.8. Splash Panel (Standard) – Installation....5455
          6.3.9. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5455
          6.3.10. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5456
          6.3.11. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5456
          6.3.12. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5457
          6.3.13. Surge Tank (with Cummins® ISB6.7 Engine) – Removal....5457
          6.3.14. Surge Tank (with Cummins® ISB6.7 Engine) – Installation....5458
          6.3.15. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5458
          6.3.16. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5459
          6.3.17. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5460
          6.3.18. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5461
          6.3.19. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....5461
          6.3.20. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....5462
          6.3.21. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Removal ....5463
          6.3.22. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Installation....5465
          6.3.23. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5465
          6.3.24. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5466
          6.3.25. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5467
          6.3.26. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5468
          6.3.27. A/C Condenser (Navistar® 11 and 13 Engines) – Removal....5468
          6.3.28. A/C Condenser (Navistar® 11 and 13 Engines) – Installation....5469
          6.3.29. A/C Condenser (ISB6.7) Engine – Removal....5470
          6.3.30. A/C Condenser (ISB6.7 Engine) – Installation....5470
          6.3.31. Fan Belt with A/C (Cummins® ISB6.7 Engine) - Removal ....5471
          6.3.32. Fan Belt with A/C (Cummins® ISB6.7 Engine) – Installation ....5471
          6.3.33. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5473
          6.3.34. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5475
          6.3.35. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....5476
          6.3.36. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5477
          6.3.37. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....5477
          6.3.38. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....5479
          6.3.39. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5480
          6.3.40. Upper Fan Shroud  (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5482
          6.3.41. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5482
          6.3.42. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....5484
          6.3.43. Fan Shroud (Cummins® ISB6.7 Engine) 7 similar - Removal....5484
          6.3.44. Fan Shroud - Installation....5485
          6.3.45. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Removal....5485
          6.3.46. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Installation....5486
          6.3.47. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Removal....5486
          6.3.48. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Installation....5488
          6.3.49. Radiator Fan (Standard) – Removal....5489
          6.3.50. Radiator Fan (Standard) – Installation....5490
          6.3.51. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....5490
          6.3.52. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5491
          6.3.53. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5492
          6.3.54. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5492
          6.3.55. Heat Shrink Clamp Removal and Installation....5493
          Heat Shrink Clamp Removal....5493
          Heat Shrink Clamp Installation....5494
          6.3.56. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5496
          6.3.57. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5498
          6.3.58. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5498
          6.3.59. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5501
          6.3.60. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....5502
          6.3.61. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....5504
          6.3.62. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5504
          6.3.63. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5508
          6.3.64. Coolant Package – Removal....5509
          Overview....5509
          6.3.65. Coolant Package – Installation....5513
          6.3.66. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5515
          6.3.67. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5516
          6.3.68. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5517
          6.3.69. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5517
          6.3.70. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....5518
          6.3.71. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....5521
          6.3.72. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5522
          6.3.73. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5523
          6.3.74. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....5524
          6.3.75. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....5526
          6.3.76. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5526
          6.3.77. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5527
          6.3.78. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5528
          6.3.79. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5530
          6.3.80. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5530
          6.3.81. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5531
          6.3.82. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....5531
          6.3.83. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....5534
          6.3.84. Low Temperature Radiator (LTR) Thermostat – Removal....5535
          6.3.85. Low Temperature Radiator (LTR) Thermostat – Installation....5536
          6.3.86. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5538
          6.3.87. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5542
          6.3.88. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....5544
          6.3.89. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation ....5550
          6.3.90. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....5553
          6.3.91. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....5555
          6.3.92. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5556
          6.3.93. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5558
          6.3.94. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5559
          6.3.95. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5560
          6.3.96. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....5561
          6.3.97. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....5562
          6.3.98. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5562
          6.3.99. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5563
          6.3.100. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5563
          6.3.101. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5564
          6.3.102. Low Temperature Radiator Hoses – Removal....5564
          6.3.103. Low Temperature Radiator (LTR) Thermostat Hose – Installation....5566
        6.4. WorkStar® Inspection Procedures....5568
          6.4.1. Deaeration Tank Inspection Procedure....5568
          6.4.2. Deaeration Tank Cap Vacuum Relief Check....5569
          6.4.3. Fan Drive Pulley Crack Inspection....5570
          6.4.4. Fan Drive Pulley Nick Inspection....5570
          6.4.5. 12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....5571
          6.4.6. 12TTD Borg – Warner 842B Visctronics Inspection Procedure....5572
          6.4.7. Fuel Cooler Valve (FCV) Inspection Procedure....5572
          Fuel Cooler Valve (FCV) Filter Screen – Removal....5572
          Fuel Cooler Valve (FCV) Filter Screen – Installation....5574
        6.5. Torque Chart....5575
      7. 12THT Horton DriveMaster Fan Drive System....5579
        7.1. 12THT Horton Drivemaster Fan Drive System Removal and Installation....5579
          7.1.1. 12THT Radiator Fan (N13) – Removal....5579
          7.1.2. 12THT Radiator Fan (N13) – Installation....5579
          7.1.3. 12THT Radiator Fan (Cummins® ISX15) – Removal....5580
          7.1.4. 12THT Radiator Fan Cummins® ISX15 – Installation....5580
          7.1.5. Fan Removal – (12THZ and 12THT Horton DA) (optional)....5581
          7.1.6. Fan Installation – (12THZ and 12THT Horton DA) (optional)....5581
          7.1.7. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....5582
          7.1.8. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....5583
          7.1.9. 12THT Horton (DMA) Serviceable Fan Drive – Removal....5583
          7.1.10. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....5587
          7.1.11. 12THT Pulley Bearing – Removal....5588
          7.1.12. 12THT Pulley Bearing – Installation....5588
          7.1.13. 12THT Fan Drive Friction Liner– Removal....5589
          7.1.14. 12THT Fan Drive Friction Liner – Installation....5591
          7.1.15. 12THT Clutch Pack Seal Face – Removal....5592
          7.1.16. 12THT Clutch Pack Seal Face – Installation....5592
          7.1.17. 12THT Air Cartridge – Removal....5592
          7.1.18. 12THT Air Cartridge – Installation....5593
        7.2. 12THT Horton Drivemaster Fan Drive System Inspection Procedures....5595
          7.2.1. Fan Drive Movement / Clutch Pack Bearing Check....5595
          7.2.2. Clutch Pack Face Seal....5596
          7.2.3. Cartridge Assembly Seal and Spring....5597
          7.2.4. Friction Liner Measurement....5598
          7.2.5. Fan Drive Bearing Measurement and Inspection....5599
        7.3. 12THT Horton Drivemaster Fan Drive System Diagnostics....5600
          7.3.1. 12THT Horton DriveMaster Fan Drive Operational Checks....5600
          Overview....5600
          Tools Required....5600
          Operational Checks – Start Fan Drive Diagnostics Here.....5600
          Visual Air Leak Check....5600
          7.3.2. Symptom 1: Fan Always On....5603
          7.3.3. Symptom 2: Fan Always Off....5619
          7.3.4. Symptom 3: Cycles Too Frequently....5625
          7.3.5. Symptom 4: Excessive Noise From Fan Drive....5627
      8. 12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics ....5629
        8.1. Start Diagnostics here: 12TTD Borg-Warner 842B Visctronic Fan Drive....5629
        Overview....5629
        Tools Required....5629
        Operational Checks – Start Fan Drive Diagnostics Here....5629
        8.2. Symptom 1: Fan Always ON....5631
        8.3. Symptom 2: Fan Always OFF....5637
        8.4. Symptom 3: Cycles Too Frequently....5654
        8.5. Symptom 4: Excessive Noise From Fan Drive....5657
      9. 12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....5659
        9.1. Start Diagnostics Here: 12TSY Borg-Warner SA85 Fan Drive Assembly....5659
        Overview....5659
        Tools Required....5659
      10. 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly....5661
        10.1. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly Removal and Installation....5661
        Tools Required....5661
          10.1.1. 12TKY Borg-Warner Fan Drive Clutch Lining – Removal....5661
          10.1.2. 12TKY Borg-Warner Fan Drive Clutch Lining – Installation....5661
          10.1.3. 12TKY Borg-Warner Fan Drive and Hub Assembly – Removal....5662
          10.1.4. 12TKY Borg-Warner Fan Drive and Hub Assembly – Installation....5662
        10.2. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Inspection....5664
          10.2.1. 12TKY Borg-Warner Fan Drive Clutch Friction Lining Inspection....5664
        10.3. Start Diagnostics here: 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Diagnostics....5665
        Overview....5665
        Tools Required....5665
        Operational Checks – Start Fan Drive Diagnostics here.....5665
        10.4. Symptom 1: Fan Always On....5667
        10.5. Symptom 2: Fan Always Off....5668
        10.6. Symptom 3: Fan Cycles Too Frequently....5669
        10.7. Clutch Will Not Engage....5669
        10.8. Clutch Will Not Disengage....5670
        10.9. Air Leak In Drive....5671
        10.10. Symptom 4: Excessive Noise From Fan Drive....5672
      11. 12THX Horton Stratis V-Master-Ultra Viscous Fan Drive Assembly System....5675
        11.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly Removal and Installation....5675
          11.1.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Removal....5675
          11.1.2. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Installation....5676
        11.2. 12THX Horton Stratis Viscous Fan Drive Assembly System Diagnostics....5677
          11.2.1. 12THX Horton Stratis Viscous Fan Drive Assembly Diagnostics – Operations Checks....5677
          Overview....5677
          Tools Required....5677
          Operational Checks – Start Fan Drive Diagnostics here.....5677
          Visual Air Leak Check....5677
        11.3. 12THX Horton Stratis Fan Drive Inspection, Pin Point Test, and ServiceMaxx™ Engine Fan Test....5680
          11.3.1. Fan Drive Inspection....5680
          11.3.2. Fan Drive Pin Point Test....5681
        11.4. ServiceMaxx Engine Fan Test™....5681
        11.5. Engine Fan Test Results....5684
          11.5.1. Engine Fan Test Overview....5684
          11.5.2. Properly Working Fan Hub Assembly....5684
        11.6. Fan Engages Prematurely....5685
        11.7. Symptom 1: Fan Always On....5685
        11.8. Symptom 2: Fan Always Off....5686
        11.9. Symptom 3: Fan Cycles Too Frequently....5687
        11.10. Symptom 4: Excessive Noise From Fan Drive....5688
      12. Abbreviations and Acronyms....5690
      13. Terminology....5691
  tables....5207
    Table 7Torque Chart....5207
    Table 13Torque Chart Navistar® Engines....5359
    Table 14Torque Chart Cummins® ISX15 Engine....5361
    Table 20Torque Chart....5423
    Table 28Torque Chart....5575
0000680131 - DuraStar Radiator _ Cooling System (Euro V Latin American Market ) Service Manual....5694
  toc....5696
    Table of Contents....5696
      1. DESCRIPTION....5698
        1.1. DEAERATION TANK....5699
        1.2. A/C CONDENSER....5699
        1.3. FAN AND FAN DRIVE....5699
        1.4. FAN SHROUD....5699
        1.5. RADIATOR / CHARGE AIR COOLER ASSEMBLY....5699
      2. Removal and Installation....5700
        2.1. COOLING PACKAGE CLEANING PROCEDURE....5701
        2.2. COOLANT DRAIN, PRESSURE TEST, AND FILL PROCEDURES....5704
          2.2.1. Coolant Drain Procedure (Recommended)....5706
          2.2.2. Pressure Test Procedure (Recommended)....5710
          2.2.3. Coolant Fill Procedure (Recommended)....5712
          2.2.4. Coolant Drain Procedure (Optional)....5714
          2.2.5. Coolant Fill Procedure (Optional)....5715
        2.3. SPLASH PANEL....5717
          2.3.1. Splash Panel – Removal....5717
          2.3.2. Splash Panel – Installation....5717
        2.4. DEAERATION TANK....5718
          2.4.1. Deaeration Tank – Removal....5718
          2.4.2. Deaeration Tank – Installation....5719
        2.5. A/C CONDENSER....5720
          2.5.1. A/C Condenser – Removal....5720
          2.5.2. A/C Condenser – Installation....5721
        2.6. FAN AND ACCESSORY BELTS....5722
          2.6.1. Fan and Accessory Belts – Removal....5722
          2.6.2. Fan and Accessory Belts – Installation....5723
        2.7. FAN AND FAN DRIVE....5724
          2.7.1. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....5724
          2.7.2. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....5725
          2.7.3. 12THT Horton (DMA) Serviceable Fan Drive – Removal....5725
          2.7.4. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....5729
          2.7.5. 12THT Pulley Bearing – Removal....5730
          2.7.6. 12THT Pulley Bearing – Installation....5730
          2.7.7. 12THT Fan Drive Friction Liner– Removal....5730
          2.7.8. 12THT Fan Drive Friction Liner – Installation....5733
          2.7.9. 12THT Clutch Pack Seal Face – Removal....5734
          2.7.10. 12THT Clutch Pack Seal Face – Installation....5734
          2.7.11. 12THT Air Cartridge – Removal....5734
          2.7.12. 12THT Air Cartridge – Installation....5735
        2.8. FAN SHROUD....5737
          2.8.1. Fan Shroud – Removal....5737
          2.8.2. Fan Shroud – Installation....5737
        2.9. RADIATOR HOSES....5738
          2.9.1. Radiator Hoses – Removal....5738
          2.9.2. Radiator Hoses – Installation....5739
        2.10. RECIRCULATION SEALS....5740
          2.10.1. Recirculation Seals – Removal....5740
          2.10.2. Recirculation Seals – Installation....5740
        2.11. COOLING PACKAGE....5741
          2.11.1. Cooling Package – Removal....5741
          2.11.2. Cooling Package – Installation....5745
        2.12. RADIATOR / CHARGE AIR COOLER....5746
          2.12.1. Radiator / Charge Air Cooler – Removal....5746
          2.12.2. Radiator / Charge Air Cooler – Installation....5747
      3. 12THT Horton Drivemaster Fan Drive System Inspection Procedures....5748
        3.1. Fan Drive Movement / Clutch Pack and Pulley Bearing Check....5748
        3.2. Clutch Pack Face Seal....5749
        3.3. Cartridge Assembly Seal and Spring....5750
        3.4. Friction Liner Measurement....5751
        3.5. Fan Drive Bearing Measurement and Inspection....5752
      4. 12THT Horton Drivemaster Fan Drive System Diagnostics....5753
      Overview....5753
        4.1. 12THT Horton DriveMaster Fan Drive Operational Checks....5754
        4.2. Symptom 1: Fan Always On....5755
        4.3. Symptom 2: Fan Always Off....5756
        4.4. Symptom 3: Cycles Too Frequently....5757
        4.5. Symptom 4: Excessive Noise From Fan Drive....5757
      5. Abbreviations and Acronyms....5761
      6. Terminology....5762
  tables....5764
    Table 13Torque Chart....5764
0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 13....5765
  toc....5767
    Table of Contents....5767
    Safety Terminology....5770
    Safety Instructions....5770
    Work Area....5770
    Safety Equipment....5770
    Protective Measures....5770
    Vehicle....5770
    Engine....5771
    Fire Prevention....5771
    Batteries....5771
    Compressed Air....5771
    Tools....5771
    Fluids Under Pressure....5772
    Fuel....5772
    Removal of Tools, Parts, and Equipment....5772
      Frame....5773
      Front Axle....5777
      Front Suspension....5781
      Brakes....5785
        1. Air Brakes - Foundation....5787
          Service Brakes....5787
          Overview....5787
            Brake Chambers....5788
            Removal....5788
            Overview....5788
            Special Tools....5788
            Equipment Conditions....5788
            Removal Procedure....5788
            Follow-On Procedure....5790
            Installation....5791
            Overview....5791
            Special Tools....5791
            Equipment Conditions....5791
            Installation Procedure....5791
            Follow-On Procedure....5793
            Adjustment....5794
            Overview....5794
            Special Tools....5794
            Equipment Conditions....5794
            Adjustment Procedure (Preferred)....5794
            Adjustment Procedure (Alternate)....5795
            Follow-On Procedure....5798
            Foot Valve....5799
            Removal....5799
            Overview....5799
            Special Tools....5799
            Equipment Conditions....5799
            Removal Procedure....5800
            Follow-On Procedure....5800
            Installation....5801
            Overview....5801
            Special Tools....5801
            Torque Specifications....5801
            Equipment Conditions....5801
            Installation Procedure....5802
            Follow-On Procedure....5802
            Rod Stroke Sensor....5803
            Removal....5803
            Overview....5803
            Special Tools....5803
            Equipment Conditions....5803
            Removal Procedure....5804
            Follow-On Procedure....5806
            Installation....5807
            Overview....5807
            Special Tools....5807
            Equipment Conditions....5807
            Installation Procedure....5807
            Follow-On Procedure....5808
          Park (Spring) Brakes....5809
            Spring Brake Modulator Valve....5809
            Overview....5809
          Slack Adjusters....5810
            Front Axle....5810
            Overview....5810
            Clevis Types....5812
            Rear Axle....5818
            Overview....5818
            Clevis Types....5820
            Inspection....5825
            Overview....5825
            Special Tools....5825
            Equipment Conditions....5825
            Minor Inspection Procedure....5825
            Major Inspection Procedure....5825
            Follow-On Procedure....5827
            Removal....5828
            Overview....5828
            Special Tools....5828
            Equipment Conditions....5828
            Removal Procedure....5828
            Follow-On Procedure....5829
            Installation....5830
            Overview....5830
            Special Tools....5830
            Equipment Conditions....5830
            Installation Procedure....5830
            Follow-On Procedure....5836
            Disassembly....5837
            Overview....5837
            Special Tools....5837
            Equipment Conditions....5837
            Disassembly Procedure....5837
            Follow-On Procedure....5843
            Assembly....5844
            Overview....5844
            Special Tools....5844
            Equipment Conditions....5844
            Assembly Procedure....5844
            Follow-On Procedure....5851
            Cleaning....5852
            Overview....5852
            Special Tools....5852
            Equipment Conditions....5852
            Cleaning Metal Parts with Polished Surfaces....5853
            Cleaning Non-Metal Parts....5853
            Follow-On Procedure....5853
        2. Air Brakes - Bendix....5854
          ABS / ATC / ESC....5854
          Overview....5854
          ABS....5857
          ATC....5858
          ESC....5860
            ABS Module....5862
            Removal....5862
            Overview....5862
            Special Tools....5862
            Equipment Conditions....5862
            Removal Procedure....5862
            Follow-On Procedure....5862
            Installation....5863
            Overview....5863
            Special Tools....5863
            Torque Specifications....5863
            Equipment Conditions....5863
            Installation Procedure....5863
            Follow-On Procedure....5863
            Modulator Valve....5864
            Removal....5864
            Overview....5864
            Special Tools....5864
            Equipment Conditions....5864
            Removal Procedure....5865
            Follow-On Procedure....5865
            Installation....5866
            Overview....5866
            Special Tools....5866
            Torque Specifications....5866
            Equipment Conditions....5866
            Installation Procedure....5867
            Follow-On Procedure....5867
            Steering Angle Sensor....5868
            Removal....5868
            Overview....5868
            Special Tools....5868
            Equipment Conditions....5868
            Removal Procedure....5868
            Follow-On Procedure....5870
            Installation....5871
            Overview....5871
            Special Tools....5871
            Equipment Conditions....5871
            Installation Procedure....5871
            Follow-On Procedure....5873
            Traction Relay Valve....5874
            Front Removal....5874
            Overview....5874
            Special Tools....5874
            Equipment Conditions....5874
            Removal Procedure....5875
            Follow-On Procedure....5875
            Front Installation....5876
            Overview....5876
            Special Tools....5876
            Torque Specifications....5876
            Equipment Conditions....5876
            Installation Procedure....5877
            Follow-On Procedure....5877
            Rear Removal....5878
            Overview....5878
            Special Tools....5878
            Equipment Conditions....5878
            Removal Procedure....5879
            Follow-On Procedure....5879
            Rear Installation....5880
            Overview....5880
            Special Tools....5880
            Torque Specifications....5880
            Equipment Conditions....5880
            Installation Procedure....5881
            Follow-On Procedure....5881
            Wheel Speed Sensor....5882
            Removal....5882
            Overview....5882
            Special Tools....5882
            Equipment Conditions....5882
            Removal Procedure....5883
            Follow-On Procedure....5883
            Installation....5884
            Overview....5884
            Special Tools....5884
            Torque Specifications....5884
            Equipment Conditions....5884
            Installation Procedure....5885
            Follow-On Procedure....5885
            Yaw Rate Sensor....5886
            Removal....5886
            Overview....5886
            Special Tools....5886
            Equipment Conditions....5886
            Removal Procedure....5887
            Follow-On Procedure....5887
            Installation....5888
            Overview....5888
            Special Tools....5888
            Equipment Conditions....5888
            Installation Procedure....5889
            Follow-On Procedure....5889
        3. Hydraulic Brakes - Foundation....5890
          Disc Brakes....5890
          Overview....5890
            Front Brake Caliper....5892
            Removal....5892
            Overview....5892
            Special Tools....5892
            Equipment Condition....5892
            Procedure....5893
            Follow-On Procedure....5897
            Installation....5898
            Overview....5898
            Special Tools....5898
            Equipment Condition....5899
            Procedure....5899
            Follow-On Procedure....5902
            Rear Brake Caliper....5903
            Removal....5903
            Overview....5903
            Special Tools....5903
            Equipment Condition....5903
            Procedure....5904
            Follow-On Procedure....5908
            Installation....5909
            Overview....5909
            Special Tools....5909
            Equipment Condition....5910
            Procedure....5910
            Follow-On Procedure....5913
          Park Brakes....5914
          Tech Tips....5915
            Park Brake Cable Adjustment....5916
            Overview....5916
            Special Tools....5917
            Equipment Conditions....5917
            Adjustment Procedure....5917
            Follow-On Procedure....5919
            Park Brake System Inspection....5920
            Overview....5920
            Special Tools....5920
            Equipment Conditions....5920
            Inspection Procedure....5920
            Follow-On Procedure....5921
            Park Brake Shoe Adjustment....5922
            Overview....5922
            Special Tools....5922
            Equipment Conditions....5922
            Adjustment Procedure (Drum OFF)....5923
            Adjustment Procedure (Drum ON)....5924
            Follow-On Procedure....5924
        4. Hydraulic Brakes - Wabco....5925
          SmartTrac ABS / ATC with Hydro-Max....5925
          Overview....5925
          ABS....5927
          ATC....5927
            ABS Unit....5930
            Removal....5930
            Overview....5930
            Special Tools....5930
            Equipment Conditions....5930
            Procedure....5931
            Follow-On Procedure....5934
            Installation....5935
            Overview....5935
            Special Tools....5935
            Equipment Conditions....5935
            Procedure....5936
            Follow-On Procedure....5939
            Wheel Speed Sensor....5940
            Removal....5940
            Overview....5940
            Special Tools....5940
            Equipment Conditions....5940
            Procedure....5941
            Follow-On Procedure....5941
            Installation....5942
            Overview....5942
            Special Tools....5942
            Torque Specifications....5942
            Equipment Conditions....5942
            Procedure....5943
            Follow-On Procedure....5943
            Brake Bleeding....5944
            Overview....5944
            Special Tools....5944
            Equipment Conditions....5944
            Procedure....5944
            Follow-On Procedure....5945
            Manual Brake Bleeding....5946
            Overview....5946
            Special Tools....5946
            Equipment Conditions....5946
            Procedure....5947
            Follow-On Procedure....5948
          Full Power ABS / ATC....5949
          Overview....5949
          Standard Features....5949
          Optional Features....5949
          System Layout....5952
          System Components....5953
          Master Cylinder and Reservoir....5953
          Normal Operation (Brakes Not Applied)....5954
          Service Brakes (Normal Braking)....5956
          Normal Operation (Brakes Applied)....5957
          Anti-lock Brake System (ABS)....5958
          ABS Decrease Pressure Stage....5959
          ABS Hold Stage....5960
          ABS Increase Pressure Stage....5961
          Automatic Traction Control (ATC) System (Optional)....5962
          ATC Inactive (ATC Circuit Operation with No ATC Event Occurring)....5962
          ATC Active (ATC Circuit Operation while Experiencing an ATC Event)....5964
          Tire Size Range....5966
          Tech Tips....5966
            Safety Precautions....5967
            General Warnings / Cautions for Servicing the Full Power Brake System....5967
            Asbestos Fibers Warning....5971
            Hazard Summary....5971
            Recommended Work Practices....5971
            Regulatory Guidance....5972
            Non-Asbestos Fibers Warning....5973
            Hazard Summary....5973
            Recommended Work Practices....5973
            Regulatory Guidance....5974
            Pressure Bleeding Procedure....5975
            Overview....5975
            Special Tools....5975
            Equipment Conditions....5976
            Master Cylinder Bleeding Procedure....5977
            Brake Caliper Bleeding Procedure....5980
            Follow-On Procedure....5982
            ABS Electronic Control Unit (ECU)....5983
            Removal....5983
            Overview....5983
            Special Tools....5983
            Equipment Conditions....5983
            Removal Procedure....5984
            Follow-On Procedure....5986
            Installation....5987
            Overview....5987
            Special Tools....5987
            Equipment Conditions....5987
            Installation Procedure....5988
            Follow-On Procedure....5989
            Accumulator....5990
            Removal....5990
            Overview....5990
            Special Tools....5990
            Equipment Conditions....5990
            Removal Procedure....5992
            Follow-On Procedure....5993
            Installation....5994
            Overview....5994
            Special Tools....5994
            Equipment Conditions....5994
            Installation Procedure....5996
            Follow-On Procedure....5997
            Disposal....5998
            Overview....5998
            Special Tools....5998
            Equipment Conditions....5998
            Disposal Procedure....5998
            Follow-On Procedure....5999
            Brake Light Switch (Mounted on MC)....6000
            Removal....6000
            Overview....6000
            Special Tools....6000
            Equipment Conditions....6000
            Removal Procedure....6000
            Follow-On Procedure....6001
            Installation....6002
            Overview....6002
            Special Tools....6002
            Equipment Conditions....6002
            Installation Procedure....6002
            Follow-On Procedure....6002
            Brake Lines (General)....6003
            Removal....6003
            Overview....6003
            Special Tools....6003
            Equipment Conditions....6003
            Removal Procedure....6004
            Follow-On Procedure....6005
             Installation....6006
            Overview....6006
            Special Tools....6006
            Equipment Conditions....6006
            Installation Procedure....6007
            Follow-On Procedure....6007
            Hydraulic Compact Unit (HCU)....6008
            Removal....6008
            Overview....6008
            Special Tools....6008
            Equipment Conditions....6008
            Removal Procedure....6010
            Follow-On Procedure....6014
            Installation....6015
            Overview....6015
            Special Tools....6015
            Equipment Conditions....6015
            Installation Procedure....6017
            Follow-On Procedure....6019
            HCU Reservoir....6020
            Removal....6020
            Overview....6020
            Special Tools....6020
            Equipment Conditions....6020
            Removal Procedure....6020
            Follow-On Procedure....6021
            Installation....6022
            Overview....6022
            Special Tools....6022
            Equipment Conditions....6022
            Installation Procedure....6023
            Follow-On Procedure....6023
            HCU Pumps....6024
            Primary HCU Pump Removal....6024
            Overview....6024
            Special Tools....6024
            Equipment Conditions....6024
            Removal Procedure....6025
            Follow-On Procedure....6027
            Primary HCU Pump Installation....6028
            Overview....6028
            Special Tools....6028
            Equipment Conditions....6028
            Installation Procedure....6030
            Follow-On Procedure....6030
            Secondary HCU Pump Removal....6031
            Overview....6031
            Special Tools....6031
            Equipment Conditions....6031
            Removal Procedure....6032
            Follow-On Procedure....6036
            Secondary HCU Pump Installation....6037
            Overview....6037
            Special Tools....6037
            Equipment Conditions....6037
            Installation Procedure....6039
            Follow-On Procedure....6042
            Fluid Level Switch (Mounted on MC Reservoir)....6044
            Removal....6044
            Overview....6044
            Special Tools....6044
            Equipment Conditions....6044
            Removal Procedure....6044
            Follow-On Procedure....6044
            Installation....6045
            Overview....6045
            Special Tools....6045
            Torque Specifications....6045
            Equipment Conditions....6045
            Installation Procedure....6045
            Follow-On Procedure....6045
            Low Pressure Hose....6046
            Removal....6046
            Overview....6046
            Special Tools....6046
            Equipment Conditions....6046
            Removal Procedure....6047
            Follow-On Procedure....6051
            Installation....6052
            Overview....6052
            Special Tools....6052
            Torque Specifications....6052
            Equipment Conditions....6052
            Installation Procedure....6053
            Follow-On Procedure....6053
            Master Cylinder (MC)....6054
            Removal....6054
            Overview....6054
            Special Tools....6054
            Equipment Conditions....6054
            Removal Procedure....6054
            Follow-On Procedure....6060
            Installation....6061
            Overview....6061
            Special Tools....6061
            Equipment Conditions....6061
            Installation Procedure....6062
            Follow-On Procedure....6065
            Master Cylinder Reservoir....6066
            Removal....6066
            Overview....6066
            Special Tools....6066
            Equipment Conditions....6066
            Removal Procedure....6066
            Follow-On Procedure....6069
            Installation....6070
            Overview....6070
            Special Tools....6070
            Equipment Conditions....6070
            Installation Procedure....6071
            Follow-On Procedure....6072
            Relay Valve Assembly....6073
            Removal....6073
            Overview....6073
            Special Tools....6073
            Equipment Conditions....6073
            Removal Procedure....6074
            Follow-On Procedure....6078
            Installation....6079
            Overview....6079
            Special Tools....6079
            Equipment Conditions....6079
            Installation Procedure....6081
            Follow-On Procedure....6084
            Wheel Speed Sensor....6085
            Removal....6085
            Overview....6085
            Special Tools....6085
            Equipment Conditions....6085
            Removal Procedure....6086
            Follow-On Procedure....6086
            Installation....6087
            Overview....6087
            Special Tools....6087
            Torque Specifications....6087
            Equipment Conditions....6087
            Installation Procedure....6088
            Follow-On Procedure....6089
      Steering....6091
        1. Steering Wheel and Steering Column Assembly....6093
          Description....6093
            Steering Wheel....6093
            Clock Spring....6093
            Steering Column....6094
          Remove and Install Procedures....6095
          Equipment Conditions....6095
            Steering Wheel....6096
            Overview....6096
            Removal....6097
            Installation....6099
            Clock Spring....6101
            Removal....6101
            Installation....6104
            Steering Column....6106
            Overview....6106
            Removal....6106
            Installation....6107
          Checks and Adjustments....6109
            Steering Wheel....6109
            Check....6109
            Adjust....6109
          Torque....6110
        2. Power Steering Gear: Sheppard M-Series....6111
          Identification....6111
          Operation....6114
          OIL FLOW THROUGH THE GEAR....6115
          Steering System Diagnostics....6117
            Diagnostic Overview....6117
            Define the Concern....6117
            Perform Visual Inspection....6117
            Inspect Mechanical Components....6117
            Hydraulic Diagnosis....6117
            Oil Flow and Pressure Recommendations....6120
            Common Complaints....6120
          Troubleshooting....6123
            Symptoms Table....6123
            Re-phasing Column....6126
            Troubleshooting Checklist....6127
          Preventative Maintenance....6128
            Fluid and Filter Change....6128
            Input Shaft Seal Replacement — Disassembly....6130
            Input Shaft Seal Replacement — Assembly....6134
          Bleeding....6137
            Single Gear System....6137
            Dual Steering Gears....6139
          Set Relief Plungers....6142
          Pitman Arm....6143
            Remove....6143
            Install....6145
          Steering Gear Disassembly....6152
          Sub-assembly Repair....6167
          M-SERIES - OPTIONAL INTEGRAL RELIEF VALVE....6167
          Clean....6169
          Inspect....6170
          Parts Discolored (Blue)....6170
          Broken Housing....6170
          Housing or Piston Scoring....6170
          Sector Shaft Roller (Bearing Wear)....6170
          Actuating Shaft....6171
          Thrust Bearings....6171
          Actuating Shaft Thread Wear....6171
          Piston Rings Cut, Pinched, Sheered or Worn....6171
          Reassemble....6172
          Dual Steering System....6188
            Description....6188
            Operation....6188
            Integral Slave Gear....6191
          Adjustments....6193
            Final....6193
            Axle Stop....6193
          Specifications....6194
          Torque....6194
          Special Tools....6195
          Glossary of Terms and Definitions....6195
        3. Power Steering Gear with Hydro-Max® Brake System....6198
        Overview....6198
          Cummins ISB with TRW....6199
          Cummins ISB with Sheppard....6199
          N9 with TRW....6199
          Power Steering Fluid Flow Test....6200
          Overview....6200
          Special Tools....6200
          Equipment Conditions....6200
          Procedure....6201
          Follow-On Procedure....6202
      Drivelines....6203
      Exhaust....6207
        1. Exhaust System....6209
          Single Can Aftertreatment - DuraStar....6209
            Overview....6209
          Single Can Aftertreatment - WorkStar....6211
            Overview....6211
      Electrical / Software....6215
        1. Diagnostic Trouble Code (DTC) List....6225
        2. Electronic Service Tools (EST)....6229
          Diamond Logic® Builder....6229
          Overview....6229
            Selecting an Interface Cable....6231
            Overview....6231
            Special Tools....6231
            Equipment Conditions....6231
            Selection Procedure....6231
            Follow-On Procedure....6232
            Connecting to a Vehicle....6233
            Overview....6233
            Special Tools....6233
            Equipment Conditions....6233
            Connection Procedure....6233
            Follow-On Procedure....6234
            Activating Diagnostic Mode....6235
            Overview....6235
            Special Tools....6235
            Equipment Conditions....6235
            Activation Procedure....6235
            Follow-On Procedure....6236
            Starting a Session....6237
            Overview....6237
            Special Tools....6237
            Equipment Conditions....6237
            Starting Procedure....6237
            Follow-On Procedure....6238
            Viewing Fault Codes....6239
            Overview....6239
            Special Tools....6239
            Equipment Conditions....6239
            Viewing Procedure....6239
            Follow-On Procedure....6239
            Clearing Fault Codes....6240
            Overview....6240
            Special Tools....6240
            Equipment Conditions....6240
            Clearing Procedure....6240
            Follow-On Procedure....6240
            Modifying Signals Tab....6241
            Overview....6241
            Special Tools....6241
            Equipment Conditions....6241
            Modify Watched Signal Columns....6241
            Modify Watched Signals....6242
            Follow-On Procedure....6242
            Programming Modules....6243
            Overview....6243
            Special Tools....6243
            Equipment Conditions....6243
            Programming Procedure....6244
            Follow-On Procedure....6247
            Input Not Recognized by Body Control Module....6248
            Overview....6248
            Special Tools....6248
            Equipment Conditions....6248
            Troubleshooting Procedure....6248
            Follow-On Procedure....6249
            Output Not Commanded by Body Control Module....6250
            Overview....6250
            Special Tools....6250
            Equipment Conditions....6250
            Troubleshooting Procedure....6250
            Follow-On Procedure....6251
        3. General Electrical Repair....6252
          Electrical Connector Cleaning....6252
          Overview....6252
          Special Tools....6252
          Specifications....6252
          Equipment Conditions....6252
          Cleaning Procedure....6252
          Follow-On Procedure....6252
        4. 12 Volt Electrical System....6253
          Battery Box - DuraStar....6253
            Overview....6253
          Battery Box - WorksStar....6254
            Overview....6254
          Battery Box....6255
          Overview....6255
            Battery Disconnect....6258
            Special Tools....6258
            Torque Specifications....6258
            Equipment Conditions....6258
            Disconnect Procedure....6259
            Follow-On Procedure....6259
            Battery Reconnect....6260
            Special Tools....6260
            Torque Specifications....6260
            Equipment Conditions....6260
            Reconnect Procedure....6261
            Follow-On Procedure....6261
            Battery Terminal Cleaning....6262
            Overview....6262
            Special Tools....6262
            Equipment Conditions....6262
            Cleaning Procedure....6263
            Follow-On Procedure....6263
          Battery Disconnect Switch....6264
          Overview....6264
          Brake Switch....6265
          Overview....6265
            SPN 597 FMI 0 – Brake Switch reading above normal range....6268
            Overview....6268
            Associated Faults....6268
            Fault Facts....6268
            Tools Required....6268
            Possible Causes....6268
            SPN 597 FMI 1 – Brake Switch reading below normal range....6271
            Overview....6271
            Associated Faults....6271
            Fault Facts....6271
            Possible Causes....6271
          CAN Systems....6273
          Overview....6273
          Faults....6273
          Short....6273
          Terminating Resistor Failure....6273
          Backbone Open....6273
          Node Open....6274
            Tests....6275
            Module Communication Test....6275
            Overview....6275
            Tools Required....6275
            Equipment Condition....6275
            Test Setup....6275
            Test Procedure....6276
            Follow-On Procedure....6276
          Remote Start / Stop....6277
          Overview....6277
            500K....6279
            Overview....6279
            Operational Checkout Procedure....6280
            Overview....6280
            Not Operating....6281
            Fault Overview....6281
            Fault Facts....6281
            Possible Causes....6281
            Pin-Point Test - Remote Start / Stop Not Operating with 500K....6288
            Tools Required....6288
            250K....6289
            Overview....6289
            Operational Checkout Procedure....6291
          Charging and Starting System....6292
            Operational Checkout Procedure....6293
            Electrical System Operational Checkout Procedure....6293
            Starting System....6294
            System Overview....6294
            Battery Pack....6294
            Starter....6294
            Control....6294
            No Click No Crank....6295
            Overview....6295
            Possible Causes....6295
            Click No Crank....6297
            Overview....6297
            Possible Causes....6297
            Low Cranking Speed....6299
            Overview....6299
            Possible Causes....6299
            250K Input Diagnostics....6300
            Overview....6300
            Navistar Starter Input Diagnostics....6301
            Navistar Starter Input Pinpoint Tests....6304
            Cummins Starter Input Diagnostics....6310
            Cummins Starter Input Pinpoint Tests....6314
            500K Input Diagnostics....6317
            Overview....6317
            Key Switch and Grid Control....6317
            Crank Inhibit....6317
            GridCtrl_CrankInhibit....6317
            Crank_Inhibit_Reason....6317
            Lower_Clutch_Signal....6318
            Neutral_Status_TCM....6318
            Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal)....6318
            Hood_Switch....6318
            500K Input Operational Checkout Procedure....6320
            Overview....6320
            Charging System....6324
            Overview....6324
            Battery Pack....6324
            Alternator....6324
            Red Battery Warning Light....6325
            Overview....6325
            Possible Causes....6325
            Repeated Jump Starts....6327
            Overview....6327
            Possible Causes....6327
            Battery Gauge Reading High....6329
            Overview....6329
            Possible Causes....6329
            Battery Gauge Reading Low / Fluctuating....6330
            Overview....6330
            Possible Causes....6330
            Tests....6332
            Individual Battery Test....6332
            Overview....6332
            Special Tools....6332
            Equipment Condition....6332
            Test Setup....6332
            Test Procedure....6333
            Expected Outcome....6335
            Follow-On Procedure....6335
            Electrical System Test....6336
            Overview....6336
            Special Tools....6336
            Equipment Condition....6337
            Test Setup....6337
            Battery Pack Test Procedure....6339
            Starter System Test Procedure....6342
            Charging System Test Procedure....6344
            Expected Outcome....6347
            Follow-On Procedure....6347
            Cable Drop Test....6348
            Overview....6348
            Special Tools....6348
            Equipment Condition....6348
            Test Setup....6348
            Test Procedure....6348
            Expected Outcome....6351
            Follow-On Procedure....6351
            Parasitic Draw Test....6352
            Overview....6352
            Tools Required....6352
            Equipment Condition....6352
            Test Setup....6352
            Test Procedure....6352
            Expected Outcome....6355
            Follow-On Procedure....6355
            Manual Engine Bar Test....6356
            Overview....6356
            Tools Required....6356
            Equipment Condition....6356
            Test Setup....6356
            Test Procedure....6356
            Expected Outcome....6356
            Follow-On Procedure....6356
            Starter Control Circuit Test....6357
            Overview....6357
            Spacial Tools....6357
            Equipment Condition....6357
            Test Setup....6357
            Test Procedure....6357
            Expected Outcome....6358
            Follow-On Procedure....6358
            Inspections....6359
            Ring Gear Inspection....6359
            Overview....6359
            Special Tools....6359
            Equipment Condition....6359
            Inspection Procedure....6359
            Expected Outcome....6360
            Follow-On Procedure....6361
            Electrical System Inspection....6362
            Overview....6362
            Special Tools....6362
            Equipment Condition....6362
            Inspection Procedure....6362
            Expected Outcome....6363
            Follow-On Procedure....6363
        5. Accessories....6364
          Air Dryer and Heated Drain Valve....6364
          Overview....6364
            Diagnostics....6364
          Air Horn....6366
          Overview....6366
            Operational Checkout Procedure....6367
            Air Horn Test....6368
          Air Solenoid....6369
          Overview....6369
            Operational Checkout Procedure....6379
            Air Solenoid Diagnosis....6380
          Auxiliary Power Source....6381
          Overview....6381
            Diagnostics....6381
          Axle Load Monitor....6383
          Overview....6383
          User Programmable Parameters....6383
          Diagnostic Trouble Codes (DTC)....6385
            Diagnostics....6387
            Body Controller Signals....6389
            Body Controller Functions....6390
            To activate the axle load monitor feature, the following conditions must be true:....6390
          C.B. Power Radio....6391
          Overview....6391
            Diagnostics....6391
          Cigar Lighter and Power Feed ....6393
          Overview....6393
            Diagnostics....6393
          Cruise Control....6396
          Overview....6396
            Operational Checkout Procedure....6398
            Cruise Control Switch Tests....6399
          Customer Installed Lift Gate Power Source....6401
          Overview....6401
          User Programmable Parameters....6401
            Diagnostics....6403
          Differential Lock, Air Controlled....6404
          Overview....6404
          User Programmable Parameters....6405
            Diagnostics....6407
          Electric Horn....6410
          Overview....6410
            Operational Checkout Procedure....6411
            Electric Horn Test....6412
          Fifth Wheel Slide, Air Controlled....6413
          Overview....6413
          User Programmable Parameters....6413
            Diagnostics....6414
          Fuel Transfer Pump....6416
          Overview....6416
          User Programmable Parameters....6416
            Diagnostics....6419
          Heated Mirrors....6423
          Overview....6423
          Feature Codes....6424
          Diagnostic Trouble Codes....6426
            Diagnostics....6427
          Heated Seats....6429
          Overview....6429
            Diagnostics....6429
          Load Shedding....6430
          Overview....6430
          Latching Relay Diagnostics....6430
          Power Divider Lock, Air Controlled....6432
          Overview....6432
          User Programmable Parameters....6432
            Diagnostics....6434
          Power Take Off (PTO)....6435
          Overview....6435
            Operational Checkout Procedure....6460
            PTO Test....6462
          Power Windows and Locks....6463
          Overview....6463
            Operational Checkout Procedure....6466
            Power Windows....6467
            Overview....6467
            Operational Checkout Procedure....6469
            Power Window Test....6470
            Power Door Locks....6471
            Overview....6471
            Operational Checkout Procedure....6473
            Power Door Lock Tests....6474
          Power Mirrors....6475
          Overview....6475
            Diagnostics....6476
          Radio and Speakers....6479
          Overview....6479
            Diagnostics....6479
          Remote Power Module....6481
          Overview....6481
          RPM Addressing....6481
            Operational Checkout Procedure....6486
            RPM Diagnostics....6487
          Roof Auxiliary and Air Shield Light....6488
          Overview....6488
            Roof Auxiliary Load....6489
            Overview....6489
            Operational Checkout Procedure....6489
            Roof Auxiliary Load Test....6490
            Lighted Air Shield....6491
            Overview....6491
            Lighted Air Shield Preliminary Check....6491
            Lighted Air Shield Test....6492
          Seat Belt and Seat Sensor....6493
          Overview....6493
          Feature Codes....6493
          User programmable parameters....6493
            Diagnostics....6494
          Self Contained Air Seat....6495
          Overview....6495
            Diagnostics....6495
          Suspension Dump....6496
          Overview....6496
          User Programmable Parameters....6496
            Diagnostics....6499
          Theft Deterrent System....6501
          Overview....6501
            Operational Checkout Procedure....6503
            Theft Deterrent System Not Responding....6504
            Fault Overview....6504
            Fault Facts....6504
            Possible Causes....6504
          Two-speed Axle Switch....6507
          Overview....6507
            Diagnostics....6507
          Two-way Radio....6508
          Overview....6508
            Diagnostics....6508
          Water In Fuel Monitor Test....6509
          Overview....6509
            Diagnostics....6509
          Wheelchair Lift Interlock....6511
          Overview....6511
          Activate Wheelchair Lift Solenoid....6511
          Activate Audible Alarm....6512
          Diagnostic Trouble Codes....6514
            Operational Checkout Procedure....6515
        6. Aftertreatment....6518
          Overview....6518
          Operation....6518
          Aftertreatment Definitions....6519
          Soot Accumulation Level Indications....6519
          Feature Related Text Messages in the Gauge Cluster....6521
          Feature Codes....6521
          Diagnostic Trouble Codes....6523
          Body Controller Signals....6526
          Body Controller Functions....6528
          Parked Regeneration....6529
          Inhibit Regeneration....6530
          Parked Regeneration Switch Indicator....6531
          Inhibit Regeneration Switch Indicator....6532
          DPF Status Warning Lamp....6533
          HEST Warning Lamp....6534
          Audible Alarm....6535
          Aftertreatment Troubleshooting....6536
            Parked Regeneration Switch Test....6536
            Parked Regeneration Switch Indicator Test....6537
            Inhibit Regeneration Switch Test....6537
            Inhibit Regeneration Switch Indicator Test....6538
            DPF Status Warning Lamp Test....6538
            HEST Warning Lamp Test....6538
            Lamp Check....6538
            Lost Communication and Warning Lamp Diagnostics....6539
        7. Brakes and Traction Control System....6540
          Bendix Air Brake System....6540
            Anti-Lock Brake System (ABS)....6540
            Overview....6540
            Inputs....6543
            Outputs....6544
            Operational Checkout Procedure....6546
            Overview....6546
            ABS Module Loss of Communication....6547
            Overview....6547
            Fault Facts....6547
            Tools Required....6547
            Possible Causes....6547
            Automatic Traction Control (ATC) System....6550
            Overview....6550
            Inputs....6552
            Outputs....6552
            Electronic Stability Control (ESC) System....6554
            Overview....6554
            Inputs....6556
            Outputs....6557
          Wabco Hydraulic Brake System....6560
            SmartTrac Anti-Lock Brake System (ABS)....6560
            Overview....6560
            Operational Checkout Procedure....6568
            Overview....6568
            Low Brake Fluid Level Diagnostics....6571
            Overview....6571
            Associated Faults....6571
            Fault Facts....6571
            Special Tools....6571
            Possible Causes....6571
            ABS Diagnostics....6574
            Overview....6574
            Associated Faults....6575
            Fault Facts....6575
            Special Tools....6575
            Possible Causes....6575
            SPN 1044 FMI 3 Hydraulic Pump Motor – Above Normal....6582
            Overview....6582
            Associated Faults....6582
            Fault Facts....6582
            Special Tools....6582
            Possible Causes....6582
            SPN 1044 FMI 4 Hydraulic Pump Motor – Below Normal....6586
            Overview....6586
            Associated Faults....6586
            Fault Facts....6586
            Special Tools....6586
            Possible Causes....6586
            SPN 1044 FMI 5 Hydraulic Pump Motor – Open....6592
            Overview....6592
            Associated Faults....6592
            Fault Facts....6592
            Special Tools....6592
            Possible Causes....6592
            SPN 2584 FMI 3 Hydraulic Brake Pressure Warning State Circuit 1 – Above Normal....6596
            Overview....6596
            Associated Faults....6596
            Fault Facts....6596
            Special Tools....6596
            Possible Causes....6596
            SPN 2584 FMI 4 Hydraulic Brake Pressure Warning State Circuit 1 – Below Normal....6603
            Overview....6603
            Associated Faults....6603
            Fault Facts....6603
            Special Tools....6603
            Possible Causes....6603
            SPN 2584 FMI 5 Hydraulic Brake Pressure Warning State Circuit 1 – Open....6610
            Overview....6610
            Associated Faults....6610
            Fault Facts....6610
            Special Tools....6610
            Possible Causes....6610
            SPN 2931 FMI 1 Hydraulic Brake Fluid Level Switch — Below Normal....6616
            Overview....6616
            Associated Faults....6616
            Fault Facts....6616
            Possible Causes....6617
            SPN 520941 FMI 5 Hydro-Max Control output of BC – Open....6618
            Overview....6618
            Associated Faults....6618
            Fault Facts....6618
            Special Tools....6618
            Possible Causes....6618
            SPN 520941 FMI 6 Hydro-Max Control output of BC – Shorted to Ground / Over Current....6629
            Overview....6629
            Associated Faults....6629
            Fault Facts....6629
            Special Tools....6629
            Possible Causes....6629
            Hydraulic Brake System Inspection....6633
            Overview....6633
            Special Tools....6633
            Equipment Condition....6633
            Test Setup....6633
            Test Procedure....6634
            Expected Outcome....6634
            Automatic Traction Control System with SmartTrac....6635
            Overview....6635
            Full Power Anti-Lock Brake System (ABS)....6638
            Overview....6638
            Standard Features....6638
            System Layout....6641
            System Components....6642
            Hydraulic Compact Unit (HCU)....6643
            Electronic Control Unit (ECU)....6648
            Wheel Speed Sensors....6649
            Service Brakes (Normal Braking)....6651
            Normal Operation (Brakes Applied)....6652
            Normal Braking with Electronic Brakeforce Distribution....6653
            Anti-lock Brake System (ABS)....6653
            ABS Decrease Pressure Stage....6656
            ABS Hold Stage....6658
            ABS Increase Pressure Stage....6660
            Warning Indicators....6660
            Service Procedures....6661
            Fault Detection....6662
            TOOLBOX™ Software....6663
            Diagnostic Trouble Codes....6663
            Observing Signals with the EZ-Tech® Service Tool....6663
            Definitions....6664
            Tech Tips....6664
            Troubleshooting Tables....6665
            General Information Regarding the Driver Interface....6665
            Troubleshooting Table (System Reaction)....6665
            Multiple Failures Table....6666
            Special System Conditions....6666
            Repair Instructions....6666
            ABS and ATC Wiring Inspection....6681
            Overview....6681
            Special Tools....6681
            Equipment Conditions....6681
            Inspection Procedure....6681
            Follow-On Procedure....6681
            Wheel Speed Sensor Output Voltage Test....6682
            Overview....6682
            Special Tools....6682
            Equipment Conditions....6682
            Test Setup....6682
            Test Procedure....6682
            Front Axle....6682
            Rear Axle....6682
            Follow-On Procedure....6683
            Wheel Speed Sensor Resistance....6684
            Overview....6684
            Special Tools....6684
            Equipment Conditions....6684
            Test Setup....6684
            Test Procedure....6684
            Follow-On Procedure....6684
            Automatic Traction Control System with Full Power Brakes....6685
            Overview....6685
            TRAC CTRL Indicator....6685
            Traction Control Mud/Snow Switch....6686
            ATC Inactive (ATC Circuit Operation with No ATC Event Occurring)....6688
            ATC Active (ATC Circuit Operation while Experiencing an ATC Event)....6690
            Warning Indicators....6690
            Service Procedures....6692
            Fault Detection....6693
            TOOLBOX™ Software....6694
            Diagnostic Trouble Codes....6694
            Observing Signals with the EZ-Tech® Service Tool....6694
            Definitions....6694
            Tech Tips....6695
          Parking Brake....6696
          Overview....6696
          Park Brake Indicator....6697
            Park Brake Switch Diagnostics....6698
            Overview....6698
            Associated Faults....6698
            Fault Facts....6698
            Special Tools....6698
            Possible Causes....6698
        8. Collision Mitigation Systems....6702
          Bendix® Wingman® Advanced™....6702
          Overview....6702
          Adaptive Cruise Control (ACC)....6705
          Alerts....6705
          Collision Mitigation Braking....6705
          Tech Tips....6707
            Operational Checkout Procedure....6708
            Overview....6708
            Special Tools....6708
            Driver Interface Unit....6710
            Electrical Test....6710
            Overview....6710
            Special Tools....6710
            Equipment Conditions....6710
            Test Setup....6710
            Follow-On Procedure....6712
            Removal....6713
            Overview....6713
            Special Tools....6713
            Equipment Conditions....6713
            Removal Procedure....6713
            Follow-On Procedure....6713
            Installation....6714
            Overview....6714
            Special Tools....6714
            Torque Specifications....6714
            Equipment Conditions....6714
            Installation Procedure....6714
            Follow-On Procedure....6714
            Radar Sensor....6715
            Electrical Test....6715
            Overview....6715
            Special Tools....6715
            Equipment Conditions....6715
            Test Setup....6715
            Follow-On Procedure....6717
            Removal....6718
            Overview....6718
            Special Tools....6718
            Equipment Conditions....6718
            Removal Procedure....6718
            Follow-On Procedure....6719
            Installation....6720
            Overview....6720
            Special Tools....6720
            Torque Specifications....6720
            Equipment Conditions....6720
            Installation Procedure....6720
            Follow-On Procedure....6721
            Adjustment....6722
            Overview....6722
            Special Tools....6722
            Equipment Conditions....6722
            Lateral Adjustment Procedure....6722
            Vertical Adjustment Procedure....6724
            Follow-On Procedure....6726
          Bendix® Wingman® Fusion™....6727
          Overview....6727
          The following features are included with Bendix Wingman Fusion:....6728
          Adaptive Cruise Control (ACC)....6729
          Alerts....6729
          Collision Mitigation Braking....6729
          SafetyDirect Capability....6730
          Stationary Vehicle Braking (SVB)....6730
          Tech Tips....6731
            Operational Checkout Procedure....6732
            Overview....6732
            Special Tools....6732
            Camera Bracket....6735
            Removal....6735
            Overview....6735
            Special Tools....6735
            Equipment Conditions....6735
            Removal Procedure....6736
            Follow-On Procedure....6736
            Installation....6737
            Overview....6737
            Special Tools....6737
            Equipment Conditions....6737
            Installation Procedure....6738
            Follow-On Procedure....6739
            Camera Sensor....6740
            Electrical Test....6740
            Overview....6740
            Special Tools....6740
            Equipment Conditions....6740
            Test Setup....6740
            Follow-On Procedure....6742
            Removal....6743
            Overview....6743
            Special Tools....6743
            Equipment Conditions....6743
            Removal Procedure....6743
            Follow-On Procedure....6744
            Installation....6745
            Overview....6745
            Special Tools....6745
            Torque Specifications....6745
            Equipment Conditions....6745
            Installation Procedure....6745
            Follow-On Procedure....6746
            SafetyDirect® Module....6747
            Electrical Test....6747
            Overview....6747
            Special Tools....6747
            Equipment Conditions....6747
            Test Setup....6747
            Follow-On Procedure....6749
            Removal....6750
            Overview....6750
            Special Tools....6750
            Equipment Conditions....6750
            Removal Procedure....6750
            Follow-On Procedure....6750
            Installation....6751
            Overview....6751
            Special Tools....6751
            Torque Specifications....6751
            Equipment Conditions....6751
            Installation Procedure....6751
            Follow-On Procedure....6751
        9. Engine....6752
          Cummins - DuraStar....6752
            Overview....6752
          Cummins - WorkStar....6754
            Overview....6754
          Cummins Diagnostics....6756
            Table Of Contents....6756
            Fault Code Diagnostics....6757
            Fault Code List....6757
            SPN 111 FMI 1 (Cummins FC 235) - Coolant Level - Data Valid But Below Normal Operating Range - Most Severe Level....6759
            Fault Overview....6759
            Associated Faults....6759
            Fault Facts....6759
            Conditions For Clearing The Fault Codes....6759
            Possible Causes....6759
            SPN 111 FMI 3 (Cummins FC 195) - Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source....6771
            Fault Overview....6771
            Associated Faults....6771
            Fault Facts....6771
            Conditions For Clearing The Fault Codes....6771
            Possible Causes....6771
            SPN 111 FMI 4 (Cummins FC 196) - Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source....6783
            Fault Overview....6783
            Associated Faults....6783
            Fault Facts....6783
            Conditions For Clearing The Fault Codes....6783
            Possible Causes....6783
            SPN 111 FMI 17 (Cummins FC 2448) - Coolant Level - Data Valid But Below Normal Operating Range - Least Severe Level....6795
            Fault Overview....6795
            Associated Faults....6795
            Fault Facts....6795
            Conditions For Clearing The Fault Codes....6795
            Possible Causes....6795
            SPN 111 FMI 18 (Cummins FC 197) - Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level....6807
            Fault Overview....6807
            Associated Faults....6807
            Fault Facts....6807
            Conditions For Clearing The Fault Codes....6807
            Possible Causes....6807
            SPN 1569 FMI 15 (Cummins FC 6255) - Engine Protection Torque Derate - Data Valid But Above Normal Operating Range - Least Severe Level....6819
            Fault Overview....6819
            Associated Faults....6819
            Fault Facts....6819
            Conditions For Clearing The Fault Codes....6819
            Possible Causes....6819
            SPN 1569 FMI 31 (Cummins FC 3714) - Engine Protection Torque Derate - Condition Exists....6820
            Fault Overview....6820
            Conditions For Clearing The Fault Codes....6820
            Associated Faults....6820
            Fault Facts....6820
            Possible Causes....6820
            SPN 1761 FMI 1 (Cummins FC 1673) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Most Severe Level....6821
            Fault Overview....6821
            Associated Faults....6821
            Fault Facts....6821
            Conditions For Clearing The Fault Codes....6821
            Possible Causes....6821
            SPN 1761 FMI 3 (Cummins FC 1669) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Above Normal or Shorted to High Source....6822
            Fault Overview....6822
            Associated Faults....6822
            Fault Facts....6822
            Conditions For Clearing The Fault Codes....6822
            Possible Causes....6822
            SPN 1761 FMI 4 (Cummins FC 1668) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Below Normal or Shorted to Low Source....6823
            Fault Overview....6823
            Associated Faults....6823
            Fault Facts....6823
            Conditions For Clearing The Fault Codes....6823
            Possible Causes....6823
            SPN 1761 FMI 9 (Cummins FC 4677) Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Abnormal Update Rate ....6824
            Fault Overview....6824
            Associated Faults....6824
            Fault Facts....6824
            Conditions For Clearing The Fault Codes....6824
            Possible Cause....6824
            SPN 1761 FMI 10 (Cummins FC 4769) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal Rate of Change....6829
            Fault Overview....6829
            Associated Faults....6829
            Fault Facts....6829
            Conditions For Clearing The Fault Codes....6829
            Possible Causes....6829
            SPN 1761 FMI 11 (Cummins FC 4739) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Root Cause Not Known....6832
            Fault Overview....6832
            Associated Faults....6832
            Fault Facts....6832
            Conditions For Clearing The Fault Codes....6832
            Possible Causes....6832
            SPN 1761 FMI 13 (Cummins FC 4732) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of Calibration....6833
            Fault Overview....6833
            Associated Faults....6833
            Fault Facts....6833
            Conditions For Clearing The Fault Codes....6833
            Possible Causes....6833
            SPN 1761 FMI 17 (Cummins FC 3497) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Least Severe Level....6835
            Fault Overview....6835
            Associated Faults....6835
            Fault Facts....6835
            Conditions For Clearing The Fault Codes....6835
            Possible Causes....6835
            SPN 1761 FMI 18 (Cummins FC 3498) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range -Moderately Severe Level ....6836
            Fault Overview....6836
            Associated Faults....6836
            Fault Facts....6836
            Conditions For Clearing The Fault Codes....6836
            Possible Causes....6836
            SPN 3031 FMI 2 (Cummins FC 1679) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic, Intermittent, or Incorrect....6837
            Fault Overview....6837
            Associated Faults....6837
            Fault Facts....6837
            Conditions For Clearing The Fault Codes....6837
            Possible Causes....6837
            SPN 3031 FMI 3 (Cummins FC 1678) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Above Normal or Shorted to High Source ....6839
            Fault Overview....6839
            Associated Faults....6839
            Fault Facts....6839
            Conditions For Clearing The Fault Codes....6839
            Possible Causes....6839
            SPN 3031 FMI 4 (Cummins FC 1677) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Below Normal or Shorted to Low Source....6841
            Fault Overview....6841
            Associated Faults....6841
            Fault Facts....6841
            Conditions For Clearing The Fault Codes....6841
            Possible Causes....6841
            SPN 3031 FMI 9 (Cummins FC 4572) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal Update Rate....6843
            Fault Overview....6843
            Associated Faults....6843
            Fault Facts....6843
            Conditions For Clearing The Fault Codes....6843
            Possible Cause....6843
            SPN 3031 FMI 11 (Cummins FC 4737) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause Not Known....6849
            Fault Overview....6849
            Associated Faults....6849
            Fault Facts....6849
            Conditions For Clearing The Fault Codes....6849
            Possible Causes....6849
            SPN 3031 FMI 13 (Cummins FC 4731) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out of Calibration....6850
            Fault Overview....6850
            Associated Faults....6850
            Fault Facts....6850
            Conditions For Clearing The Fault Codes....6850
            Possible Causes....6850
            SPN 3364 FMI 2 (Cummins FC 3878) - Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or Incorrect....6852
            Fault Overview....6852
            Associated Faults....6852
            Fault Facts....6852
            Conditions For Clearing The Fault Codes....6852
            Possible Causes....6852
            SPN 3364 FMI 3 (Cummins FC 1686) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Above Normal or Shorted to High Source....6853
            Fault Overview....6853
            Associated Faults....6853
            Fault Facts....6853
            Conditions For Clearing The Fault Codes....6853
            Possible Cause....6853
            SPN 3364 FMI 4 - (Cummins 1685) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Below Normal or Shorted to Low Source....6855
            Fault Overview....6855
            Associated Faults....6855
            Fault Facts....6855
            Conditions For Clearing The Fault Codes....6855
            Possible Cause....6855
            SPN 3364 FMI 9 (Cummins FC 3868) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate....6857
            Fault Overview....6857
            Associated Faults....6857
            Fault Facts....6857
            Conditions For Clearing The Fault Codes....6857
            Possible Cause....6857
            SPN 3364 FMI 10 (Cummins FC 4277) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate of Change ....6862
            Fault Overview....6862
            Associated Faults....6862
            Fault Facts....6862
            Conditions For Clearing The Fault Codes....6862
            Possible Causes....6862
            SPN 3364 FMI 11 (Cummins FC 1715) - Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known....6865
            Fault Overview....6865
            Associated Faults....6865
            Fault Facts....6865
            Conditions For Clearing The Fault Codes....6865
            Possible Causes....6865
            SPN 3364 FMI 13 (Cummins FC 1714) - Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration....6866
            Fault Overview....6866
            Associated Faults....6866
            Fault Facts....6866
            Conditions For Clearing The Fault Codes....6866
            Possible Causes....6866
            SPN 3364 FMI 15 (Cummins FC 4842) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal Operating Range - Least Severe Level....6868
            Fault Overview....6868
            Associated Faults....6868
            Fault Facts....6868
            Conditions For Clearing The Fault Codes....6868
            Possible Causes....6868
            SPN 3364 FMI 18 (Cummins FC 3867) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal Operating Range - Moderately Severe Level....6870
            Fault Overview....6870
            Associated Faults....6870
            Fault Facts....6870
            Conditions For Clearing The Fault Codes....6870
            Possible Causes....6870
            SPN 3521 FMI 11 (Cummins FC 4768) - Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known....6872
            Fault Overview....6872
            Associated Faults....6872
            Fault Facts....6872
            Conditions For Clearing The Fault Codes....6872
            Possible Causes....6872
            SPN 3521 FMI 16 (Cummins FC 6765) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above Normal Operating Range - Moderately Severe Level....6873
            Fault Overview....6873
            Associated Faults....6873
            Fault Facts....6873
            Conditions For Clearing The Fault Codes....6873
            Possible Causes....6873
            SPN 3521 FMI 18 (Cummins FC 6766) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below Normal Operating Range - Moderately Severe Level....6875
            Fault Overview....6875
            Associated Faults....6875
            Fault Facts....6875
            Conditions For Clearing The Fault Codes....6875
            Possible Causes....6875
            SPN 3521 FMI 31 (Cummins FC 4235) - Aftertreatment 1 Diesel Exhaust Fluid Property- Condition Exists....6877
            Fault Overview....6877
            Associated Faults....6877
            Fault Facts....6877
            Conditions For Clearing The Fault Codes....6877
            Possible Causes....6877
            SPN 4096 FMI 31 (Cummins FC 3547) - Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition Exists....6879
            Fault Overview....6879
            Associated Faults....6879
            Fault Facts....6879
            Conditions For Clearing The Fault Codes....6879
            Possible Causes....6879
            SPN 5246 FMI 0 (Cummins FC 3712) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Most Severe Level....6880
            Fault Overview....6880
            Associated Faults....6880
            Fault Facts....6880
            Conditions For Clearing The Fault Codes....6880
            Possible Causes....6880
            SPN 5246 FMI 15 (Cummins FC 4134) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Least Severe Level....6881
            Fault Overview....6881
            Associated Faults....6881
            Fault Facts....6881
            Conditions For Clearing The Fault Codes....6881
            Possible Causes....6881
            SPN 5246 FMI 16 (Cummins FC 6254) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Moderately Severe Level....6882
            Fault Overview....6882
            Associated Faults....6882
            Fault Facts....6882
            Conditions For Clearing The Fault Codes....6882
            Possible Causes....6882
            Tests and Inspections....6883
            Overview....6883
            DEF Head Unit Coolant Line Routing Inspection....6884
            Overview....6884
            Tools Required....6884
            Equipment Condition....6884
            Inspection Procedure....6884
            Expected Outcome....6885
            DEF Quality Test....6886
            Overview....6886
            Tools Required....6886
            Equipment Condition....6886
            Test Procedure....6886
            Expected Outcome....6887
            DEFTHV Coolant Flow Test....6888
            Overview....6888
            Tools Required....6888
            Equipment Condition....6888
            Test Setup....6888
            Test Procedure....6888
            Expected Outcome....6888
        10. Engine Accessories....6889
          Engine Cooling Fan Control....6889
          Overview....6889
          Operation....6889
          Feature Codes....6890
          Diagnostic Trouble Codes....6891
          Operational Checkout....6892
          Body Controller Signals....6893
          Body Controller Functions....6895
          Fan Control — General Information....6895
          ON/OFF Fan Control....6895
          Low Air Pressure Engine Fan Override (0595BBB)....6896
          Variable Speed Fan Control (0595AYH)....6896
          Exhaust Brake....6899
          Overview....6899
          Operation....6899
          Feature Codes....6899
          Diagnostic Trouble Codes....6899
          Operational Checkout....6901
           Exhaust Brake Switch Test....6902
          Body Controller Signals....6903
          Body Controller Functions....6903
          To activate the exhaust brake feature, the following conditions must be true:....6903
          If the conditions to activate the feature (above) are true, then the following will occur:....6903
          Remote Engine Speed Control Module (RESCM)....6904
          Overview....6904
          Operation....6904
          Feature Codes....6905
          User Programmable Parameters....6905
          Diagnostic Trouble Codes....6906
          RESCM Preliminary Check....6911
          Body Controller Signals....6912
          Body Controller Functions....6914
          Snow Valve (engine intake) (big bore engines)....6915
          The snow valve (engine intake) feature turns a drum inside the air cleaner to divert engine air intake from outside of the vehicle to inside the engine compartment. This prevents heavy snow from clogging the air intake.....6915
            Operation....6915
            Feature Codes....6916
            User Programmable Parameters....6916
            Diagnostic Trouble Codes....6916
            Snow Valve Operational Checkout....6917
            Snow Valve Mechanical Checks....6918
            Snow Valve Switch Test....6919
            Snow Valve Module Checks....6920
            Body Controller Signals....6922
            Body Controller Functions....6922
            To activate the feature, the following conditions must be true:....6922
            If the conditions to activate the feature (above) are true, then the following will occur:....6922
            If any of the following conditions occur, then the feature will be deactivated.....6923
            If any of the conditions to deactivate the feature (above) are true, then the following will occur:....6923
          Snow Valve (engine intake) (non big bore engines)....6924
            Overview....6924
            Operation....6924
            Operational Checkout....6924
            Snow Valve Mechanical Checks....6925
             Snow Valve Module Checks....6925
            Feature Codes....6926
        11. Data Links....6927
          J1708 Datalink....6927
            J1708 Data Link (ATA)....6927
            J1708 Switch Pack Data Link....6928
            Overview....6928
            Switch Pack Electrical Tests....6930
            Overview....6930
            Special Tools....6930
            Equipment Condition....6930
            Test Setup....6930
            Test Procedure....6930
            Follow On Procedure....6932
        12. HVAC....6933
        Overview....6933
        Condenser....6934
        A/C compressor....6934
        HVAC controller....6935
        Air Distribution (General)....6936
        Air Distribution (Air Conditioning)....6938
        NORM A/C / Instrument Panel Vent (A)....6939
        MAX A/C (B)....6939
        Bi-Level A/C (C)....6939
        Heat and Ventilation Floor (D)....6939
        Bi-Level Defrost / Heat (E)....6939
        Defrost (F)....6939
        A/C Refrigerant Flow....6940
        Compression....6940
        Condensation....6941
        Expansion....6941
        Evaporation....6941
        General Operation of the HVAC Electrical System....6941
          Operational Checkout Procedure....6942
          Overview....6942
          Symptoms....6944
            A/C Blows Warm All the Time (Incorrect System Pressure)....6944
            Overview....6944
            Possible Causes....6944
            Compressor Does Not Cycle....6948
            Overview....6948
            Possible Causes....6948
            Operator Not Able to Control Air Flow Outlet....6951
            Overview....6951
          Diagnostics....6955
            Diagnostic Trouble Code (DTC) List....6955
            SPN 876 FMI 5 – Compressor Clutch Circuit ....6956
            Fault Overview....6956
            Associated Faults....6956
            Fault Facts....6956
            Possible Causes....6956
            SPN 1552 FMI 2 – A/C Control Head Temperature Mix DM1....6957
            Fault Overview....6957
            Associated Faults....6957
            Fault Facts....6957
            Possible Causes....6957
            Pin-Point Test SPN 1552 FMI 2....6958
            Tools Required....6958
            SPN 2609 FMI 16 – A/C High Pressure Protection....6959
            Fault Overview....6959
            Associated Faults....6959
            Fault Facts....6959
            Possible Causes....6959
            SPN 3981 FMI 2 – A/C Control Head Mode Fault DM1....6962
            Fault Overview....6962
            Associated Faults....6962
            Fault Facts....6962
            Possible Causes....6962
            Pin-Point Test SPN 3981 FMI 2....6963
            Tools Required....6963
            SPN 3984 FMI 2 – A/C Control Head Air Inlet DM1....6964
            Fault Overview....6964
            Associated Faults....6964
            Fault Facts....6964
            Possible Causes....6964
            Pin-Point Test SPN 3984 FMI 2....6965
            Tools Required....6965
            SPN 3985 FMI 9 – A/C Control Head Circuit Failed To Communicate With Body Controller....6966
            Fault Overview....6966
            Associated Faults....6966
            Fault Facts....6966
            Possible Causes....6966
            Pin-Point Test SPN 3985 FMI 9....6967
            Tools Required....6967
            SPN 520465 FMI 2 – A/C Control Head Multiple Motor Faults....6969
            Fault Overview....6969
            Associated Faults....6969
            Fault Facts....6969
            Possible Causes....6969
            Pin-Point Test SPN 520465 FMI 2....6971
            Tools Required....6971
          Tests....6974
            A/C Compressor Clutch Electrical Tests....6974
            Overview....6974
            Special Tools....6974
            Equipment Condition....6974
            Test Setup....6974
            Test Procedure....6974
            Expected Outcome....6977
            Follow-On Procedure....6977
            A/C Request Electrical Tests....6978
            Overview....6978
            Special Tools....6978
            Equipment Condition....6978
            Test Setup....6978
            Test Procedure....6978
            Expected Outcome....6979
            Follow-On Procedure....6979
            A/C System Functional Test....6980
            Overview....6980
            Special Tools....6980
            Equipment Condition....6980
            Test Setup....6980
            Test Procedure....6980
            Expected Outcome....6980
            Follow-On Procedure....6980
            A/C System Restriction Test....6981
            Overview....6981
            Special Tools....6981
            Equipment Condition....6981
            Test Setup....6981
            Test Procedure....6981
            Expected Outcome....6982
            Blend Door Tests....6983
            Overview....6983
            Special Tools....6983
            Equipment Condition....6983
            Test Setup....6983
            Test Procedure....6984
            Expected Outcome....6987
            Follow-On Procedure....6987
            Blower Motor Electrical Tests....6988
            Overview....6988
            Special Tools....6988
            Equipment Condition....6988
            Test Setup....6988
            Test Procedure....6988
            Expected Outcome....6991
            Follow-On Procedure....6991
            Body Controller Power and GND Tests....6992
            Overview....6992
            Special Tools....6992
            Equipment Condition....6992
            Test Setup....6992
            Test Procedure....6992
            Expected Outcome....6993
            Follow-On Procedure....6993
            Charge Quantity Measurement Test....6994
            Overview....6994
            Special Tools....6994
            Equipment Condition....6994
            Test Setup....6994
            Test Procedure....6994
            Compressor Clutch Signal Check....6995
            Overview....6995
            Special Tools....6995
            Equipment Condition....6995
            Test Setup....6995
            Test Procedure....6996
            Expected Outcome....6998
            Follow-On Procedure....6998
            Control Head Electrical Tests....6999
            Overview....6999
            Special Tools....6999
            Equipment Condition....6999
            Test Setup....6999
            Test Procedure....6999
            Expected Outcome....7001
            Follow On Procedure....7001
            Freeze Probe Electrical Tests....7002
            Overview....7002
            Special Tools....7002
            Equipment Condition....7002
            Test Setup....7002
            Test Procedure....7002
            Expected Outcome....7004
            Follow On Procedure....7004
            Heater Core Seal Leak Test....7005
            Overview....7005
            Special Tools....7005
            Equipment Condition....7005
            Test Setup....7005
            Test Procedure....7006
            Expected Outcome....7007
            Follow On Procedure....7007
            HVAC Actuator Calibration Procedure....7008
            Overview....7008
            Special Tools....7008
            Equipment Condition....7008
            Test Setup....7008
            Test Procedure....7008
            Expected Outcome....7008
            Leak Detection Test....7009
            Overview....7009
            Special Tools....7009
            Equipment Conditions....7009
            Refrigerant Present....7009
            No Refrigerant Present....7010
            No Refrigerant Present - High Pressure Nitrogen....7011
            Follow-On Procedure....7013
            Low-Pressure Switch Electrical Tests....7014
            Overview....7014
            Special Tools....7014
            Equipment Condition....7014
            Test Setup....7014
            Test Procedure....7014
            Expected Outcome....7016
            Follow On Procedure....7016
            Mode Door Tests....7017
            Overview....7017
            Special Tools....7017
            Equipment Condition....7017
            Test Setup....7017
            Test Procedure....7018
            Expected Outcome....7021
            Follow On Procedure....7021
            Pressure Transducer Electrical Tests....7022
            Overview....7022
            Special Tools....7022
            Equipment Condition....7022
            Three-wire Pressure Transducer Test Procedure....7022
            Expected Outcome....7024
            Pressure Transducer Functional Test....7025
            Overview....7025
            Special Tools....7025
            Equipment Condition....7025
            Test Setup....7025
            Pressure Test Procedure....7025
            Temperature Test Procedure....7025
            Expected Outcome....7026
            Recirculation Door Tests....7027
            Overview....7027
            Special Tools....7027
            Equipment Condition....7027
            Test Setup....7027
            Test Procedure....7028
            Expected Outcome....7031
            Follow On Procedure....7031
            Static Pressure Test....7032
            Overview....7032
            Special Tools....7032
            Equipment Condition....7032
            Test Setup....7032
            Test Procedure....7032
            Expected Outcome....7033
            Follow On Procedure....7033
            System Performance Test....7034
            Overview....7034
            Special Tools....7034
            Equipment Condition....7034
            Test Setup....7034
            Test Procedure....7034
            Expected Outcome....7035
            Follow-On Procedure....7035
          Inspections....7036
            A/C System Internal Damage Inspection....7036
            Overview....7036
            Special Tools....7036
            Equipment Condition....7036
            Inspection Procedure....7036
            Expected Outcome....7040
            A/C System Inspection....7041
            Overview....7041
            Special Tools....7041
            Equipment Condition....7041
            Inspection Procedure....7042
            Expected Outcome....7049
            HVAC Module Inspection....7050
            Overview....7050
            Special Tools....7050
            Equipment Condition....7050
            Test Setup....7050
            Inspection Procedure....7050
            Expected Outcome....7052
        13. Instrumentation and Gauges....7053
          Overview....7053
          Operational Checkout Procedure....7053
          Overview....7053
          Step-Based Diagnostics....7054
          Audible Alarm....7056
            One-time Five-short-beeps Alarm....7056
            Repetitive One-short-beep Alarm....7056
            One-time Ten-short-beeps Alarm ....7056
            One-time Three-long-beeps Alarm....7057
            Repetitive Short Duration Blips ....7057
          EGC Programming....7057
          Gauges....7058
            Air 1 Gauge....7058
            Overview....7058
            Possible Causes....7059
            Step Based Diagnostics....7059
            Pin-Point Tests — Air 1 Gauge....7062
            Tools Required....7063
            Air 2 Gauge....7071
            Overview....7071
            Possible Causes....7072
            Step Based Diagnostics....7072
            Pin-Point Tests — Air 2 Gauge....7075
            Tools Required....7076
            Auxiliary Gauge Switch Pack....7083
            Overview....7083
            In-Gauge Warning Lamps....7083
            Gauge Sweep....7083
            Lost Communication....7084
            Gauge Faults....7085
            Diagnostic Trouble Codes....7086
            Operational Checkout Procedure....7088
            Eaton Hybrid Auxiliary Gauge Pack....7089
            AGSP Power and Data Link Voltage Checks....7089
            Gauge Troubleshooting Procedure....7089
            Troubleshooting Specific Gauges....7091
            Forward-Rear Axle Temperature Gauge Troubleshooting....7091
            Rear-Rear Axle Temperature Gauge Troubleshooting....7093
            Air Application Gauge Troubleshooting....7095
            Ammeter Gauge Troubleshooting....7098
            Compass Display....7099
            Overview....7099
            Diagnostic Trouble Codes....7100
            DEF Level....7101
            Overview....7101
            Possible Causes....7101
            Step Based Diagnostics....7101
            Engine Coolant Temperature....7103
            Overview....7103
            Step Based Diagnostics....7103
            Engine Oil Pressure....7104
            Overview....7104
            Step Based Diagnostics....7104
            Engine Oil Temperature....7105
            Overview....7105
            Step Based Diagnostics....7105
            Engine Speed (Tachometer)....7106
            Overview....7106
            Step Based Diagnostics....7106
            Fuel Level....7107
            Overview....7107
            Possible Causes....7107
            Step Based Diagnostics....7108
            Outside Air Temperature....7113
            Overview....7113
            Step Based Diagnostics....7114
            Transmission Temperature....7116
            Overview....7116
            Possible Causes....7116
            Step-Based Diagnostics....7116
            Pin-Point Tests....7120
            Vehicle Speed (Speedometer)....7122
            Overview....7122
            Step Based Diagnostics....7122
            Voltage....7123
            Overview....7123
            Possible Causes....7123
            Step Based Diagnostics....7123
            Special Tools....7123
        14. Interior Lighting....7125
          Dome and Courtesy Lights....7125
          Overview....7125
            Operational Checkout Procedure....7126
            Dome and Courtesy Light Tests....7127
        15. Exterior Lighting....7129
          Back Up Lights....7129
          Overview....7129
            Operational Checkout Procedure....7130
            Back Up Lights Test....7131
          Brake Switch....7132
          Overview....7132
          Air Brake Switch....7133
          Hydro-Max Hydraulic Brake Switch....7135
          Full Power Hydraulic Brake Switch....7137
            Operational Checkout Procedure....7140
            Overview....7140
            Special Tools....7140
            Brake Switch Electrical & Circuit Test....7142
            Overview....7142
            Fault Facts....7142
            Special Tools....7142
            Possible Causes....7142
            SPN 597 FMI 0 – Brake Switch Reading Above Normal Range....7148
            Fault Overview....7148
            Associated Faults....7148
            Fault Facts....7148
            Special Tools....7148
            Possible Causes....7148
            SPN 597 FMI 1 – Brake Switch Reading Below Normal Range....7152
            Overview....7152
            Associated Faults....7152
            Fault Facts....7152
            Special Tools....7152
            Possible Causes....7152
            SPN 597 FMI 2 – Brake Switch Inputs Do Not Match....7154
            Fault Overview....7154
            Associated Faults....7154
            Fault Facts....7154
            Special Tools....7154
            Possible Causes....7154
            SPN 597 FMI 3 – Voltage Above Normal or Short to High Source....7155
            Fault Overview....7155
            Associated Faults....7155
            Fault Facts....7155
            Special Tools....7155
            Possible Causes....7155
            SPN 3541 FMI 6 – Current Above Normal or Grounded Circuit....7157
            Fault Overview....7157
            Associated Faults....7157
            Fault Facts....7157
            Special Tools....7157
            Possible Causes....7157
          Fog Lights....7159
          Overview....7159
            Operational Checkout Procedure....7161
            Overview....7161
            Fog Light Input Diagnostics....7164
            Fault Overview....7164
            Fault Facts....7164
            Possible Causes....7164
            Fog Light Output - Not Illuminating....7166
            Fault Overview....7166
            Fault Facts....7166
            Possible Causes....7166
            Pin-Point Test - Fog Light Output - Not Illuminating....7171
            Tools Required....7171
            Fog Light Output Diagnostics - Illuminating When Not Requested....7175
            Fault Overview....7175
            Fault Facts....7175
            Possible Causes....7175
            Pin-Point Test -Fog Light Output - Illuminating When Not Requested....7178
            Tools Required....7178
            SPN 2388 FMI 5 - Left Fog Light Open Circuit....7180
            Fault Overview....7180
            Associated Faults....7180
            Fault Facts....7180
            Possible Causes....7180
            Pin-Point Test - SPN 2388 FMI 5....7182
            Tools Required....7182
            SPN 2388 FMI 6 - Left Fog Light Short to GND....7184
            Fault Overview....7184
            Associated Faults....7184
            Fault Facts....7184
            Possible Causes....7184
            Pin-Point Test - SPN 2388 FMI 6....7186
            Tools Required....7186
            SPN 4008 FMI 5 - Right Fog Light Open Circuit....7188
            Fault Overview....7188
            Associated Faults....7188
            Fault Facts....7188
            Possible Causes....7188
            Pin-Point Test - SPN 4008 FMI 5....7190
            Tools Required....7190
            SPN 4008 FMI 6 - Right Fog Light Short to GND....7192
            Fault Overview....7192
            Associated Faults....7192
            Fault Facts....7192
            Possible Causes....7192
            Pin-Point Test - SPN 4008 FMI 6....7194
            Tools Required....7194
          Headlights and Daytime Running Lights....7196
          Overview....7196
            Operational Checkout Procedure....7198
            Overview....7198
            Low Beam Input Diagnostics....7203
            Fault Overview....7203
            Fault Facts....7203
            Possible Causes....7203
            Low Beam Output Diagnostics - Not illuminating....7205
            Fault Overview....7205
            Fault Facts....7205
            Possible Causes....7205
            Pin-Point Test - Low Beam Head Lamp Output - Not Illuminating....7210
            Tools Required....7210
            Low Beam Output Diagnostics - Illuminating When Not Requested....7214
            Fault Overview....7214
            Fault Facts....7214
            Possible Causes....7214
            Pin-Point Test - Low Beam Head Lamp Output - Illuminating When Not Requested....7217
            Tools Required....7217
            SPN 2653 FMI 5 - Left Low Beam Open Circuit....7219
            Fault Overview....7219
            Associated Faults....7219
            Fault Facts....7219
            Possible Causes....7219
            Pin-Point Test - SPN 2653 FMI 5....7221
            Tools Required....7221
            Pin-Point Test - SPN 2653 FMI 5....7222
            SPN 2653 FMI 6 - Left Low Beam Short to GND....7223
            Fault Overview....7223
            Associated Faults....7223
            Fault Facts....7223
            Possible Causes....7223
            Pin-Point Test - SPN 2653 FMI 6....7225
            Tools Required....7225
            SPN 2655 FMI 5 - Right Low Beam Open Circuit....7226
            Fault Overview....7226
            Associated Faults....7226
            Fault Facts....7226
            Possible Causes....7226
            Pin-Point Test - SPN 2655 FMI 5....7228
            Tools Required....7228
            SPN 2655 FMI 6 - Right Low Beam Short to GND....7229
            Fault Overview....7229
            Associated Faults....7229
            Fault Facts....7229
            Possible Causes....7229
            Pin-Point Test - SPN 2655 FMI 6....7231
            Tools Required....7231
            High Beam Input Diagnostics....7232
            Fault Overview....7232
            Fault Facts....7232
            Possible Causes....7232
            Pin-Point Test - High Beam Lamps Input....7235
            Tools Required....7235
            High Beam Output Diagnostics - Not Illuminating....7238
            Fault Overview....7238
            Fault Facts....7238
            Possible Causes....7238
            Pin-Point Test - High Beam Head Lamp Output - Not Illuminating....7243
            Tools Required....7243
            High Beam Output Diagnostics - Illuminating When Not Requested....7247
            Fault Overview....7247
            Fault Facts....7247
            Possible Causes....7247
            Pin-Point Test - High Beam Head Lamp Output - Illuminating When Not Requested....7250
            Tools Required....7250
            SPN 4011 FMI 5 - Left High Beam Open Circuit....7252
            Fault Overview....7252
            Associated Faults....7252
            Fault Facts....7252
            Possible Causes....7252
            Pin-Point Test - SPN 4011 FMI 5....7254
            Tools Required....7254
            SPN 4011 FMI 6 - Left High Beam Short to Ground....7255
            Fault Overview....7255
            Associated Faults....7255
            Fault Facts....7255
            Possible Causes....7255
            Pin-Point Test - SPN 4011 FMI 6....7257
            Tools Required....7257
            SPN 4012 FMI 5 - Right High beam Open Circuit....7258
            Fault Overview....7258
            Associated Faults....7258
            Fault Facts....7258
            Possible Causes....7258
            Pin-Point Test - SPN 4012 FMI 5....7260
            Tools Required....7260
            SPN 4012 FMI 6 - Right High Beam Short to Ground....7261
            Fault Overview....7261
            Associated Faults....7261
            Fault Facts....7261
            Possible Causes....7261
            Pin-Point Test - SPN 4012 FMI 6....7263
            Tools Required....7263
          Park and Marker Lights....7264
            Overview....7264
            Operational Checkout Procedure....7266
            Overview....7266
            Park Light Input Diagnostics....7270
            Fault Overview....7270
            Fault Facts....7270
            Possible Causes....7270
            Park Light Output - Not Illuminating....7272
            Fault Overview....7272
            Fault Facts....7272
            Possible Causes....7272
            Pin-Point Test - Park Light Output - Not Illuminating....7275
            Tools Required....7275
            Park Light Output Diagnostics - Illuminating When Not Requested....7277
            Fault Overview....7277
            Fault Facts....7277
            Possible Causes....7277
            Pin-Point Test - Park Light Output - Illuminating When Not Requested....7279
            Tools Required....7279
            SPN 2378 FMI 5 - Park Light UnderCurrent....7281
            Fault Overview....7281
            Associated Faults....7281
            Fault Facts....7281
            Possible Causes....7281
            Pin-Point Test - SPN 2378 FMI 5....7283
            Tools Required....7283
            SPN 2378 FMI 6 - Park Light OverCurrent....7285
            Fault Overview....7285
            Associated Faults....7285
            Fault Facts....7285
            Possible Causes....7285
            Pin-Point Test - SPN 2378 FMI 6....7287
            Tools Required....7287
            SPN 4024 FMI 2 - Marker Light Interrupt Switch Failure....7289
            Fault Overview....7289
            Associated Faults....7289
            Fault Facts....7289
            Possible Causes....7289
          Snow Plow Lights....7291
            Snow Plow Light System Overview....7291
            Operational Checkout Procedure....7293
            Overview....7293
            Snow Plow Light Input Diagnostics....7296
            Fault Overview....7296
            Fault Facts....7296
            Possible Causes....7296
            Snow Plow Light Output - Not Illuminating....7298
            Fault Overview....7298
            Fault Facts....7298
            Possible Causes....7298
            Pin-Point Test - Snow Plow Light Output - Not Illuminating....7302
            Tools Required....7302
            Snow Plow Low Beam Gen 4 Output - Not illuminating....7303
            Fault Overview....7303
            Fault Facts....7303
            Possible Causes....7303
            Pin-Point Test - Snow Plow Low Beam Gen 4 Output - Not illuminating....7306
            Tools Required....7306
            Snow Plow High Beam Gen 4 Output - Not illuminating....7307
            Fault Overview....7307
            Fault Facts....7307
            Possible Causes....7307
            Pin-Point Test - Snow Plow High Beam Gen 4 Output - Not illuminating....7310
            Tools Required....7310
          Stop, Turn, and Hazard Lights....7311
            Overview....7311
            Operational Checkout Procedure....7312
            Overview....7312
            Turn Signal, Hazard, and Front Turn Lamp Diagnostics....7320
            Overview....7320
            Hazard Input Diagnostics....7322
            Feature Code Overview....7322
            Fault Facts....7322
            Possible Causes....7322
            Pin-Point Test - Hazard Input Diagnostics....7325
            Tools Required....7325
            Turn Signal Input Diagnostics....7331
            Feature Code Overview....7331
            Fault Facts....7331
            Possible Causes....7331
            Pin-Point Test - Turn Signal Input Diagnostics....7334
            Tools Required....7334
            Front Turn Lamp Not Illuminating....7340
            Feature Code Overview....7340
            Fault Facts....7340
            Possible Causes....7340
            Pin-Point Test- Front Turn Lamp Output Not Illuminating....7344
            Tools Required....7344
            Front Turn Lamps Illuminating When Not Requested....7348
            Feature Code Overview....7348
            Fault Facts....7348
            Possible Causes....7348
            Pin-Point Test - Front Turn Lamps Illuminating When Not Requested....7350
            Tools Required....7350
            SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7352
            Fault Overview....7352
            Associated Faults....7352
            Fault Facts....7352
            Possible Causes....7352
            Pin-Point Test SPN 2368 FMI 5....7354
            Tools Required....7354
            SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7356
            Fault Overview....7356
            Associated Faults....7356
            Fault Facts....7356
            Possible Causes....7356
            Pin-Point Test SPN 2368 FMI 6....7358
            Tools Required....7358
            SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7360
            Fault Overview....7360
            Associated Faults....7360
            Fault Facts....7360
            Possible Causes....7360
            Pin-Point Test SPN 2370 FMI 5....7362
            Tools Required....7362
            SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7364
            Fault Overview....7364
            Associated Faults....7364
            Fault Facts....7364
            Possible Causes....7364
            Pin-Point Test SPN 2370 FMI 6....7366
            Tools Required....7366
            Combined Stop and Turn Lamps Diagnostics....7368
            Overview....7368
            Combined Stop and Turn Lamps - Rear Turn Lamp Not Illuminating....7370
            Feature Code Overview....7370
            Fault Facts....7370
            Possible Causes....7370
            Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7374
            Tools Required....7374
            Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7378
            Feature Code Overview....7378
            Fault Facts....7378
            Possible Causes....7378
            Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7380
            Tools Required....7380
            SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7382
            Fault Overview....7382
            Associated Fault....7382
            Fault Facts....7382
            Possible Causes....7382
            Pin-Point Test SPN 2372 FMI 5....7384
            Tools Required....7384
            SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7386
            Fault Overview....7386
            Associated Faults....7386
            Fault Facts....7386
            Possible Causes....7386
            Pin-Point Test SPN 2372 FMI 6....7388
            Tools Required....7388
            SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7390
            Fault Overview....7390
            Associated Faults....7390
            Fault Facts....7390
            Possible Causes....7390
            Pin-Point Test SPN 2374 FMI 5....7392
            Tools Required....7392
            SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7394
            Fault Overview....7394
            Associated Faults....7394
            Fault Facts....7394
            Possible Causes....7394
            Pin-Point Test SPN 2374 FMI 6....7396
            Tools Required....7396
            Separate Stop and Turn Lamps Diagnostics....7398
            Overview....7398
            Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7399
            Feature Code Overview....7399
            Fault Facts....7399
            Possible Causes....7399
            Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7403
            Tools Required....7403
            Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7407
            Feature Code Overview....7407
            Fault Facts....7407
            Possible Causes....7407
            Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7409
            Tools Required....7409
            Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....7411
            Feature Code Overview....7411
            Fault Facts....7411
            Possible Causes....7411
            Pin-Point Test - Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....7414
            Tools Required....7414
            Separate Stop and Turn Lamps- Stop Lamps Illuminating When Not Requested....7418
            Feature Code Overview....7418
            Fault Facts....7418
            Possible Causes....7418
            Pin-Point Test - Separate Stop and Turn Lamps- Rear Stop Lamps Illuminating When Not Requested....7420
            Tools Required....7420
          Trailer Lighting....7422
            Trailer Lighting Overview....7422
            Operational Checkout Procedure....7424
            Overview....7424
            Pin-Point Test - Trailer Lights Operational Checkout Procedure....7426
            Tools Required....7426
            Trailer Marker Lights - Not Illuminating....7430
            Fault Overview....7430
            Fault Facts....7430
            Possible Causes....7430
            Pin-Point Test - Trailer Marker Light Output - Not Illuminating....7433
            Tools Required....7433
            Trailer Tail Lights - Not Illuminating....7439
            Fault Overview....7439
            Fault Facts....7439
            Possible Causes....7439
            Pin-Point Test - Trailer Tail Light Output - Not Illuminating....7442
            Tools Required....7442
            Trailer Left Turn Lights - Not Illuminating....7448
            Fault Overview....7448
            Fault Facts....7448
            Possible Causes....7448
            Pin-Point Test - Trailer Left Turn Output - Not Illuminating....7451
            Tools Required....7451
            Trailer Right Turn Lights - Not Illuminating....7457
            Fault Overview....7457
            Fault Facts....7457
            Possible Causes....7457
            Pin-Point Test - Trailer Right Turn Output - Not Illuminating....7460
            Tools Required....7460
            Trailer Brake Lights - Not Illuminating....7466
            Fault Overview....7466
            Fault Facts....7466
            Possible Causes....7466
            Pin-Point Test - Trailer Brake Light Output - Not Illuminating....7469
            Tools Required....7469
            Trailer Auxiliary Power Circuit....7475
            Overview....7475
            Operational Checkout Procedure....7476
            Trailer Auxiliary Power Test....7477
            Electric Trailer Brakes....7478
            Overview....7478
            Operational Checkout Procedure....7479
            Electric Trailer Brake Test....7480
          Work Lights....7482
            Overview....7482
            Operation....7482
            Operational Checkout Procedure....7484
            Work Light Test....7485
        16. Transmission....7486
          Operation....7486
          Available Body Controller Configurations....7488
          User Programmable Parameters....7491
          Diagnostic Trouble Codes....7492
          Operational Checkout — All Transmissions....7494
          Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....7499
          LCT Column Shifter Interlock Checks....7500
          TCM Power, Ground and Data Link Circuit Checks....7501
          Shift Selector Power and Ground Circuit Checks....7502
          Body Controller Signals....7503
          Body Controller Functions....7504
            Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....7504
            PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....7504
          Auto Neutral....7505
            Auto Neutral Overview....7505
            Overview....7505
            Operational Checkout Procedure....7506
            Overview....7506
            Auto Neutral with Gen 2 Body Controller....7507
            Overview....7507
            Diagnostic Trouble Codes....7508
            Activate Auto Neutral....7510
            Error Operation....7511
            Operational Checkout Procedure....7512
            Auto Neutral Does Not Engage....7513
            Auto Neutral Does Not Disengage....7514
            Auto Neutral Warning Lamp Inoperative....7515
            Auto Neutral with Gen 4 Body Controller....7517
            Overview....7517
            Auto Neutral Not Working Gen 4 Body Controller....7518
            Fault Overview....7518
            Fault Facts....7518
            Possible Causes....7518
          Power Take OFF Programming with Eaton® Procision™ Transmission....7521
          Overview....7521
            Programming Procedure....7522
            Symptom(s)....7522
            Customer Observations or Concerns....7522
            Special Tools....7522
            Diagnostic Steps....7523
        17. Windshield Wiper System....7528
          Windshield Wiper Diagnostics....7528
            Overview....7528
            Wiper Operation....7528
            Park Operation....7528
            Washer Operation....7528
            Operational Checkout Procedure....7533
            Overview....7533
            Windshield Wiper Input 0 Not Working....7539
            Fault Overview....7539
            Fault Fact....7539
            Possible Causes....7539
            Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working....7542
            Tools Required....7542
            Windshield Wiper Input 1 Not Working....7546
            Feature Overview....7546
            Fault Fact....7546
            Possible Causes....7546
            Pin-Point Test - Windshield Wiper Input 1 Not Working....7548
            Tools Required....7548
            Windshield Wiper Input 2 Not Working....7552
            Feature Overview....7552
            Fault Fact....7552
            Possible Causes....7552
            Pin-Point Test - Windshield Wiper Input 2 Not Working....7555
            Tools Required....7555
            Windshield Wiper Low Speed Not Functioning....7559
            Feature Code Overview....7559
            Fault Facts....7559
            Possible Causes....7559
            Pin-Point Test - Windshield Wiper Low Speed Not Functioning....7564
            Tools Required....7564
            Windshield Wiper High Speed Not Functioning....7571
            Feature Code Overview....7571
            Fault Facts....7571
            Possible Causes....7571
            Pin-Point Test - Windshield Wiper High Speed Not Functioning....7576
            Tools Required....7576
            SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit....7584
            Fault Overview....7584
            Associated Faults....7584
            Fault Facts....7584
            Possible Causes....7584
            Pin-Point Test - SPN 2636 FMI 5....7586
            Tools Required....7586
            SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current....7588
            Fault Overview....7588
            Associated Faults....7588
            Fault Facts....7588
            Possible Causes....7588
            Pin-Point Test - SPN 2636 FMI 6....7589
            Tools Required....7589
            SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or High Resistance....7591
            Fault Overview....7591
            Associated Faults....7591
            Fault Facts....7591
            Possible Causes....7591
            Pin-Point Test - SPN 2637 FMI 5....7593
            Tools Required....7593
            SPN 2637 FMI 6 - Wiper High / Low Relay Over Current....7595
            Fault Overview....7595
            Associated Faults....7595
            Fault Facts....7595
            Possible Causes....7595
            Pin-Point Test - SPN 2637 FMI 6....7597
            Tools Required....7597
            SPN 4057 FMI 5 - Wiper Motor Under Current....7599
            Fault Overview....7599
            Associated Faults....7599
            Fault Facts....7599
            Possible Causes....7599
            Pin-Point Test - SPN 4057 FMI 5....7603
            Tools Required....7603
            SPN 4057 FMI 6 - Wiper Motor Over Current....7609
            Fault Overview....7609
            Associated Faults....7609
            Fault Facts....7609
            Possible Causes....7609
            Pin-Point Test - SPN 4057 FMI 6....7613
            Tools Required....7613
            Windshield Washer Pump is Not Working with Windshield Wipers....7617
            Feature Overview....7617
            Fault Fact....7617
            Possible Causes....7617
            Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....7620
            Tools Required....7620
            Windshield Wiper Not Working with Washer Pump....7625
            Feature Overview....7625
            Fault Fact....7625
            Possible Causes....7625
            Pin-Point Test - Windshield Wiper Not Working with Washer Pump....7627
            Tools Required....7627
            Windshield Wiper and Washer Pump Not Working....7629
            Feature Overview....7629
            Fault Fact....7629
            Possible Causes....7629
            Pin-Point Test - Windshield Wiper and Washer Pump Not Working....7632
            Tools Required....7632
          Windshield Washer Pump....7634
            Windshield Washer Pump is Not Working with Windshield Wipers....7634
            Feature Overview....7634
            Fault Fact....7634
            Possible Causes....7634
            Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....7638
            Tools Required....7638
            Windshield Wiper Not Working with Washer Pump....7643
            Feature Overview....7643
            Fault Fact....7643
            Possible Causes....7643
            Pin-Point Test - Windshield Wiper Not Working with Washer Pump....7645
            Tools Required....7645
            Windshield Wiper and Washer Pump Not Working....7647
            Feature Overview....7647
            Fault Fact....7647
            Possible Causes....7647
            Pin-Point Test - Windshield Wiper and Washer Pump Not Working....7650
            Tools Required....7650
      Front End....7653
        1. Hood, Grille, Fenders, and Bumper — 4100, 4200, 4300, 4400....7655
          Description....7655
            Bumper....7655
            Hood....7656
            Splash Panels....7656
            Mud Guards....7657
            Grille....7657
            Air Intakes....7658
            Fenders....7659
            Fender Extensions....7659
            Hood Seal....7660
          Remove and Install....7662
            4100 / 4200 / 4300 / 4400 Series Bumper....7662
            Remove....7662
            Install....7662
            4100 / 4200 / 4300 / 4400 Series Hood....7663
            Remove....7663
            Install....7667
            Splash Panels....7669
            Remove....7669
            Passenger Side....7670
            Driver Side....7670
            Install....7671
            Mud Guards....7672
            Remove....7672
            Install....7672
            Grille....7673
            Remove....7673
            Install....7674
            Air Intakes....7675
            Remove....7675
            Install....7675
            Fenders....7676
            Overview....7676
            Fender Lower Section — Remove....7677
            Valance — Remove....7677
            Fender Valance — Install....7677
            Headlights — Remove....7679
            Headlights — Install....7680
            Clearance Lights — Remove....7681
            Clearance Lights — Install....7681
            Upper Hood Latch — Remove....7682
            Upper Hood Latch — Install....7682
            Fender Extensions....7683
             Fender Extension — Remove....7683
            Fender Extension — Install....7685
            Hood Latch Lower Assembly — Remove....7686
            Lower Hood Latch — Install....7687
            Hood Seal....7688
            Remove....7688
            Install....7689
          Adjustments....7690
            Hood Adjustment and Alignment....7690
            Hood Stop Adjustment....7691
            Headlight Adjustment....7692
            Headlamp Replacement....7693
          Torque....7695
      Fifth Wheels and Misc.....7697
      Clutch....7701
        1. Clutch Control Linkage — 2000, 4000, 7000, and 8000 Series....7703
          Maintenance....7704
            Lubrication....7704
            Inspection....7704
          Adjustment....7705
            Push Type Clutches....7706
            Overview....7706
            Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....7706
            Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....7707
            Pull Type Clutches....7708
            Overview....7708
            Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....7708
            Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....7709
          Replacement....7710
            Clutch Pedal Shaft Bushing....7710
            Relay Shaft Bushing....7712
          Troubleshooting....7714
          Specifications....7715
          Torque....7716
      Engines....7717
        1. Air Cleaner....7719
          Air Cleaner - DuraStar....7719
            Overview....7719
          Air Cleaner - WorkStar....7720
            Overview....7720
        2. Block Heater....7721
          Block Heater - DuraStar....7721
            Overview....7721
          Block Heater Socket - DuraStar....7721
            Overview....7721
          Block Heater - WorkStar....7722
            Overview....7722
        3. Engine Features....7723
          Throttle Hand Control - DuraStar....7723
            Overview....7723
          Throttle Hand Control - WorkStar....7724
            Overview....7724
        4. Radiator / Cooling System....7725
          DESCRIPTION....7725
          Surge Tank (If Equipped)....7726
          Deaeration Tank....7726
          Fan Shroud....7727
          Fan Drive....7727
          A / C Condensor....7727
          Radiator / Charge Air Cooler Assembly....7727
          Cross-Member....7727
          Low Temperature Radiator (LTR)....7727
          Low Temperature Radiator (LTR) Thermostat....7727
          Fuel Cooler Control Assembly....7727
          Transmission Oil Cooler....7727
          Removal and Installation....7728
            Coolant Drain, Pressure Test, and Fill Procedures....7729
            Overview....7729
            Coolant Drain Procedure (Recommended)....7731
            Pressure Test Procedure (Recommended)....7734
            Coolant Fill Procedure (Recommended)....7737
            Coolant Gravity Drain Procedure (Optional)....7740
            Coolant Gravity Fill Procedure (optional) (MaxxForce® 7 and DT Engine)....7741
            Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....7746
            Splash Panel....7750
            Removal....7750
            Installation....7750
            Surge Tank (if equipped)....7751
            Surge Tank (with Cummins® ISB6.7 Engine) – Removal....7751
            Surge Tank (with Cummins® ISB6.7 Engine) – Installation....7752
            Deaeration Tank....7753
            Deaeration Tank (Radiators with Single Mega Bracket) - Removal....7753
            Deaeration Tank (Radiators with Single Mega Bracket) - Installation....7755
            Deaeration Tank (Radiators with Dual Mega Bracket) – Removal....7756
            Deaeration Tank (Radiators with Dual Mega Bracket) – Installation....7757
            Engine Coolant Level (ECL) Sensor....7758
            Removal....7758
            Overview....7758
            Special Tools....7758
            Equipment Conditions....7759
            Procedure....7760
            Follow-On Procedure....7760
            Installation....7761
            Overview....7761
            Special Tools....7761
            Torque Specification....7762
            Equipment Conditions....7762
            Procedure....7763
            Follow-On Procedure....7763
            A / C Condenser....7764
            Overview....7764
            A / C Condenser (ISB6.7) Engine – Removal....7765
            A / C Condenser – Installation....7767
            Fan Belts....7768
            Fan Belt with A / C (Cummins® ISB6.7 Engine) - Removal ....7768
            Fan Belt with A / C (Cummins® ISB6.7 Engine) – Installation ....7769
            Fan and Fan Drive Assembly....7770
            Overview....7770
            Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On....7771
            Removal....7771
            Install....7772
            Fan and 12TTB Fan Drive (Borg-Warner 790) Viscous Type, Screw On....7773
            Removal....7773
            Install....7774
            12THJ and 12THT Horton DA (optional)....7775
            Removal....7775
            Install....7776
            12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7....7777
            Removal....7777
            Install....7778
            12THJ Fan Drive Horton (DA) with ISB6.7....7779
            Removal....7779
            Install....7780
            12THT Horton (DMA) Serviceable Fan Drive....7781
            Remove....7781
            Install....7787
            12THT Pulley Bearing....7789
            Removal....7789
            Install....7789
            12THT Fan Drive Friction Liner....7790
            Removal....7790
            Install....7795
            12THT Clutch Pack Seal Face....7796
            Removal....7796
            Install....7796
            12THT Air Cartridge....7797
            Removal....7797
            Install....7799
            12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type....7802
            Removal....7802
            Install....7805
            12TTJ Fan Drive Horton VS217 Electronic Viscous Fan....7806
            Removal....7806
            Install....7812
            Fan Shroud....7813
            Overview....7813
            Fan Shroud (MaxxForce® DT and 9 Engines) - Removal....7813
            Fan Shroud (MaxxForce® DT and 9 Engines) - Installation....7816
            Fan Shroud (Cummins® ISB6.7 Engine) - Removal....7817
            Fan Shroud (Cummins® ISB6.7 Engine) - Installation....7817
            Coolant System Hoses....7818
            Overview....7818
            Heat Shrink Clamp ....7819
            Removal....7819
            Install....7820
            Deaeration Tank Hose (Single Mega Bracket) MaxxForce® 7 Engine....7823
            Removal....7823
            Install....7824
            Deaeration Tank Hose (Single Mega Bucket) MaxxForce® DT Engine without Interstage Charge Air Cooler (ISCAC) ....7825
            Removal....7825
            Install....7827
            Deaeration Tank Hose (Dual Mega Bracket) MaxxForce® DT or 9 Engine with Interstage Charge Air Cooler....7829
            Removal....7829
            Install....7835
            Deaeration Tank Hose (Dual Mega Bracket) N9® with Interstage Charge Air Cooler and SCR....7837
            Removal....7837
            Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine....7844
            Removal....7844
            Install....7846
            Fuel Cooler Valve (FCV) Hoses MaxxForce® 7 Engine....7848
            Removal....7848
            Install....7852
            Radiator Hoses DT Engine....7853
            Removal....7853
            Install....7854
            Radiator Hoses ISB6.7 One Piece....7856
            Removal....7856
            Install....7858
            Radiator Hoses MaxxForce® 7 Engine....7859
            Removal....7859
            Install....7860
            Coolant Package....7862
            Overview....7862
            Coolant Package – Removal....7862
            Coolant Package – Installation....7869
            Radiator Core / CAC Assembly....7871
            Overview....7871
            Radiator Core / CAC Assembly - Removal....7871
            Radiator Core / CAC Assembly - Installation....7873
            Fuel Cooler Control Radiator Assembly....7875
            Fuel Cooler Radiator Assembly - Removal....7875
            Fuel Cooler Radiator Assembly - Installation....7876
            Fuel Cooler Control Valve (FCCV)....7877
            Fuel Coolant Control Valve - Removal....7877
            Fuel Cooler Control Valve - Installation....7878
            Low Temperature Radiator (LTR)....7879
            Low Temperature Radiator – Removal....7879
            Low Temperature Radiator – Installation....7880
            Low Temperature Radiator (LTR) Thermostat....7881
            Low Temperature Radiator (LTR) Thermostat – Removal....7881
            Low Temperature Radiator (LTR) Thermostat – Installation....7882
            Low Temperature Radiator Hoses....7883
            Low Temperature Radiator Hoses – Removal....7883
            Low Temperature Radiator (LTR) Thermostat Hose – Installation....7887
          Removal and Installation — Cummins....7888
            Radiator and Component Removal....7888
            Cross-Member....7888
            Engine Coolant Level (ECL) Sensor....7890
            Overview....7890
            Special Tools....7891
            Equipment Conditions....7891
            Procedure....7893
            Follow-On Procedure....7893
            Surge Tank....7894
            Charge Air Cooler Pipes....7896
            Cooling System Radiator Hose....7898
            Radiator....7901
            Radiator Shroud and Frame....7902
            Charge Air Cooler....7905
            Radiator Core....7905
            Radiator and Component Installation....7906
            Radiator Core....7906
            Radiator Hose....7906
            Charge Air Cooler Pipes....7909
            Surge Tank....7909
            Engine Coolant Level (ECL) Sensor....7910
            Overview....7910
            Special Tools....7911
            Torque Specification....7911
            Equipment Conditions....7911
            Procedure....7912
            Follow-On Procedure....7912
            Front Cross-Member....7913
          Cooling Package Cleaning Procedures....7914
            Overview....7914
            Cleaning Cooling Package (MaxxForce® DT, 9, and 10 Engines)....7916
            Cleaning Cooling Package (Navistar® 11 and 13 Engines)....7917
          Inspection Procedures....7919
            Deaeration Tank and Cap Inspection Procedures....7919
            Deaeration Tank....7919
            Deaeration Tank Cap Vacuum Relief Check....7921
            Fan Drive Pulley and Pulley Groove Inspection Procedures....7922
            Pulley Crack Inspection....7922
            Pulley Nick Inspection....7923
            12TTB Fan Drive (Borg-Warner 790) Viscous Type Inspection Procedures....7924
            Fan Drive Movement....7924
            12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....7925
            Fan Drive Movement....7925
            12TTJ Fan Drive Horton VS217 Inspection Procedures....7926
            Fan Drive Movement....7926
            12THT Horton Drivemaster Advantage Fan Drive Inspection Procedures....7928
            Fan Drive Movement....7928
            Clutch Pack Face Seal....7930
            Cartridge Assembly Seal and Spring....7931
            Friction Liner Measurement....7932
            Fan Drive Bearing Measurement and Inspection....7933
            12TTD Borg – Warner 842B Visctronics Inspection Procedure....7934
            Fan Drive Movement....7934
            Fuel Cooler Valve (FCV) Inspection Procedure....7935
            Fuel Cooler Valve (FCV) Filter Screen – Removal....7935
            Fuel Cooler Valve (FCV) Filter Screen – Installation....7937
          12THT and 12THJ Horton DriveMaster Advantage (DMA) Fan Drive System Diagnostics....7938
            12THT and 12THJ Horton DriveMaster Advantage (DMA) System: Operational Checkout Procedure....7938
            Overview....7938
            Operational Checks – Start Fan Drive Diagnostics Here....7939
            Visual Air Leak Check....7939
            Symptom 1: Fan Always ON....7941
            Symptom 2: Fan Always Off....7960
            Symptom 3: Fan Cycles Too Frequently....7968
            Symptom 4: Excessive Noise From Fan Drive....7970
          12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics....7973
            12TTD Borg-Warner 842B Visctronic Fan Drive: Operational Checkout Procedure....7973
            Overview....7973
            Tools Required....7973
            Operational Checks – Start Fan Drive Diagnostics Here....7973
            Symptom 1: Fan Always ON....7975
            Symptom 2: Fan Always OFF....7982
            Symptom 3: Cycles Too Frequently....7999
            Symptom 4: Excessive Noise From Fan Drive....8002
          12TTJ Horton Drivemaster VS217 Fan Drive Assembly System Diagnostics....8005
            12TTJ Horton Drivemaster VS217 Fan Drive Assembly: Operational Checkout Procedure....8005
            Overview....8005
            Tools Required....8005
            Operational Checks – Start Fan Drive Diagnostics Here....8005
            Symptom 1: Fan Always ON....8007
            Symptom 2: Fan Always OFF....8014
            Symptom 3: Fan Drive Cycles Too Frequently....8036
            Symptom 4: Excessive Noise From Fan Drive....8037
          12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....8039
            12TSY Borg-Warner SA85 Fan Drive Assembly: Operational Checkout Procdure....8039
            Overview....8039
            Tools Required....8039
          12TTB Borg-Warner Series 790 Viscous Fan Drive Assembly System Diagnostics....8041
            12TTB Borg-Warner 790 Fan Drive Assembly: Operational Checkout Procedure....8041
            Overview....8041
            Tools Required....8041
          Radiator Shutters....8043
          Overview....8043
            Operation....8045
            Overview....8045
            Air Shutter Controls....8046
            Hydraulic Shutter Controls....8046
            Shutters on Vehicles with Air Conditioning....8046
            Shutters on Vehicles with ON / OFF Fan Drive Clutch....8047
            Shutters on Vehicles with Viscous Fan Drive....8049
            Maintenance....8050
            Troubleshooting....8051
            Overview....8051
            Troubleshooting Chart....8051
            Replace....8051
            Overview....8051
            3000 / 4000 Series Vehicles....8051
            Shutter-to-Radiator....8051
            Shutter-to-Charge Air Cooler....8051
            8000 Series Vehicles....8053
            Overview....8053
            8100....8053
            8200 / 8300....8055
          Specifications....8057
      Transmissions....8059
        1. 6 Speed Transmissions International Model ES52–7A and ESO65–7A 6–Plus....8065
          General Information....8065
            How to Shift the Transmission — Synchronizer Information....8065
            Description....8065
            Upshifting....8065
            Downshifting....8066
            Towing....8066
          Troubleshooting....8067
            Important Procedure....8067
            Check Function Prior to Disassembly....8067
            Inspect Thoroughly During Disassembly....8067
            Repair or Replace Worn Part....8067
            Noisy Operation....8067
            Noise in Neutral....8069
            Noise in Gear....8069
            Back-Up Lights Do Not Operate....8069
            Oil Leaks....8069
            Walking or Jumping Out of Gear....8070
            Hard Shifting....8071
            Sticking in Gear....8071
            Bearing Failures....8071
            Dirt....8072
            Fatigue....8072
            Corrosion....8072
            Shaft Fits....8072
            Installation and Removal of Bearings....8072
            Interchangeability....8072
            Clutch Troubleshooting....8073
          Disassembly....8074
            General....8074
            Overview....8074
            Cleanliness....8074
            Bearings....8074
            Front Bearing Retainer and Seal....8074
            End Yokes and Flanges....8074
            Power Take Offs....8075
            Shift Tower....8075
            Rear Case....8077
            Main Case....8091
            Mainshaft Disassembly....8103
            Countershaft Disassembly and Reassembly....8110
          Clean and Inspection....8112
          Reassembly....8114
            Mainshaft....8114
            Main Case....8119
            Rear Case....8124
            Shift Tower....8135
            Shift Knob Installation....8136
          Lubrication....8137
            Recommended Lubricants....8137
            Oil Changes....8137
            Refill....8137
            Overfilling....8137
          Specifications....8139
          Torque....8140
        2. 6 Speed Transmissions Eaton Series FS-5106 and FS-6206....8141
          Identification....8141
          Maintenance....8142
          Precautions....8144
            Disassembly....8144
            Inspection....8144
            Reassembly....8146
          Remove....8147
            Gear Shift Lever Assembly....8147
            Shifter Housing....8148
            Yoke....8149
            Clutch Housing....8151
            Input Shaft....8153
            Mainshaft....8156
            Countershaft and Reverse Idler....8159
          Disassemble....8164
            Gear Shift Lever Assembly....8164
            Shifter Housing....8168
            Mainshaft....8174
            Countershaft and Reverse Idler....8191
          Reassemble....8198
            Gear Shift Lever Assembly....8198
            Shifter Housing....8201
            Countershaft and Reverse Idler....8207
            Mainshaft....8213
          Install....8235
            Countershaft and Reverse Idler....8235
            Mainshaft....8242
            Clutch Housing....8251
            Yoke....8252
            Shifter Housing Assembly....8253
            Gear Shift Lever Housing....8255
          Lubrication....8256
            General....8256
            Proper Oil Level....8256
            Draining Oil....8256
            Refilling....8256
            Operating Temperatures....8257
          Specifications....8258
          Torque....8259
        3. 5 Speed Transmissions Spicer ES43–5 and ES53–5....8262
          General Safety Precautions....8262
          Operation....8263
            How to Shift the Transmission....8263
            Synchronizer Information....8263
            Upshifting....8263
            Downshifting....8264
          Disassembly....8265
            General....8265
            Inspect Thoroughly During Disassembly....8265
            Rebuild Facilities....8265
            Cleanliness....8265
            Bearings....8265
            Shift Tower....8265
            Clutch Housing....8267
            Case and Shift Forks....8268
            Mainshaft....8285
          Clean and Inspect....8293
            Clean....8293
            Inspect....8293
            Clutch Gears....8293
            Gears....8293
            Thrust Washers....8293
            Snap Rings....8293
            Mainshaft....8293
            Bearings....8293
            Housings....8294
          Reassembly....8295
            General....8295
            End Yokes and Flanges....8295
            Power Take-Offs....8295
            Mainshaft....8295
            Case....8301
            Shift Tower....8318
            Shift Knob Installation....8319
          Lubrication....8321
            Recommended Lubricants....8321
            Oil Changes....8321
            Refill....8321
            Overfilling....8321
          Troubleshooting....8322
            Troubleshooting Procedure....8322
            Noisy Operation....8322
            Troubleshooting Chart....8323
            Bearings....8326
            Dirt....8326
            Fatigue....8326
            Corrosion....8327
            Shaft Fits....8327
            Installation and Removal of Bearings....8327
            Interchangeability....8327
            Clutch Troubleshooting....8327
          Specifications....8328
            Gear Ratios....8328
            Gimbal Tower Shift Pattern....8328
            Torque....8329
            Special Tools....8331
        4. 7 Speed Transmissions Spicer PS110–7, PS145–7....8332
          General Safety Precautions....8332
          Operation....8333
            How to Shift Spicer PS110–7A, PS145–7A, and PS110–7B Transmissions....8333
            Overview....8333
            Starting....8333
            Upshifting....8333
            Downshifting....8334
            Replacement Parts....8334
          Maintenance....8335
            Tool Reference....8335
            Road Test....8335
            Check Remote Control....8335
          Disassemble....8336
            General....8336
            Inspect Thoroughly During Assembly....8336
            Rebuild Facilities....8336
            Cleanliness....8336
            Bearings....8336
            Power Take-Offs....8336
            Shift Tower....8337
            Remote Control....8339
            Shifter Housing....8340
            Case and Gears....8345
            Mainshaft....8359
            Input Shaft....8366
          Clean and Inspect....8367
            Clean....8367
            Inspect....8367
            Overview....8367
            Clutch Gears....8367
            Gears....8367
            Thrust Washers....8367
            Snap Rings....8367
            Mainshaft....8368
            Bearings....8368
            Housings....8368
          Reassemble....8369
            General....8369
            End Yokes and Flanges....8369
            Power Take-Offs....8369
            Input Shaft....8369
            Countershaft....8372
            Mainshaft....8374
            Case and Gears....8380
            Shifter Housing....8392
            Remote Control....8394
            Shift Tower....8394
          Lubrication....8395
            Recommended Lubricants....8395
            Oil Changes....8395
            Refill....8395
            Overfilling....8395
          Troubleshooting....8396
          Noise....8396
            Overview....8396
            Growling, Humming, and Grinding....8396
            Hissing, Thumping, and Bumping....8396
            Gear Whine....8397
            Metallic Rattles....8397
          Troubleshooting Chart....8397
          Bearings....8400
            Dirt....8400
            Fatigue....8400
            Corrosion....8400
            Shaft Fits....8401
            Installation and Removal....8401
            Interchangeability....8401
          Clutch....8401
          Specifications....8402
            Gear Ratios....8403
            Shift Pattern....8403
            Torque....8404
            Special Tools....8406
        5. Meritor Transfer Cases MTC–4208, MTC–4210 and MTC–4213....8407
          Description....8407
          Transfer Case Model Nomenclature....8418
          Operation....8419
            Front Axle Declutch....8419
            Full Torque Power Take-Off (PTO)....8419
          Removal....8420
          Disassembly....8423
            Front and Rear Output Yokes....8423
            Front Input Shaft, Input Bearing Cage and Pump Assembly....8423
            Front Input Shaft, Input Shaft Bearing Cage and Oil Pump....8430
            Idle Gear Shaft....8432
            Optional PTO Assembly on MTC–4208 and MTC–4208 Transfer Cases....8433
          Prepare Parts for Assembly....8434
            Ground and Polished Parts....8434
            Parts with a Rough Finish....8434
            Transfer Case Assemblies....8435
            To prevent damage to property, never use a metallic scraper and / or wire brush when cleaning aluminum components and / or sealing surfaces.  Metallic scrapers and wire brushes are made of materials harder than aluminum that can scratch, gouge, scrape, or....8435
            Dry Cleaned Parts....8435
            Prevent Corrosion....8435
            Oil Seals and O-Rings....8435
            Inspect Parts....8436
            Overview....8436
            General....8436
            Helical Gears....8439
            Shafts....8441
            PTO Components....8442
            High and Low Shifting Components....8442
            Oil and Lubrication System....8442
            Transfer Case Halves....8443
            Preparing Case and Cover Seal Replacement....8443
            To prevent damage to property, never use a metallic scraper and / or wire brush when cleaning aluminum components and / or sealing surfaces.  Metallic scrapers and wire brushes are made of materials harder than aluminum that can scratch, gouge, scrape, or....8443
          Assembly....8444
            General....8444
            MTC–4213 Rear Output Shaft End Play Adjustment....8447
            MTC–4208 and MTC-4210 Rear output Shaft End Play Adjustment....8449
            Idler Shaft Bearing End Play Adjustment....8450
            Front Output Shaft End Play Adustment....8451
            Shim Assembly....8452
            High and Low Shifter Assembly....8452
            Front Axle Shifter Assembly....8454
            Front Input Shaft, Input Shaft Bearing Cage and Oil Pump Assembly....8455
            Input Bearing Cage and Oil Pump Assembly Installation, Bearing End Play Adjustment and Transfer Case Final Assembly....8457
            Transfer Case Shifting Check....8459
            Adjust Oil Level....8460
            Transfer Case Assembly Test....8460
          Power Take-Off (PTO)....8461
            Remove Transfer Case Rear Access Cover....8461
            Install Yoke Onto PTO....8462
            Install Optional Indicator Switch....8462
            Install PTO Onto Transfer Case....8463
            Test PTO Installation....8463
            Overview....8463
            PTO Without an Optional Indicator Switch....8464
            PTO With an Optional Indicator Switch....8464
            Test Transfer Case with PTO Assembly Installed....8465
            PTO MDP-10–AF-100....8467
            PTO Assembly....8470
          Installation....8474
            General....8474
            Check and Adjust Oil....8474
          Diagnostics....8476
          Lubrication and Maintenance....8482
            Lubrication....8482
            Overview....8482
            Lubricant Temperatures....8482
            Multi-Viscosity Oils....8482
            Do Not Install API GL-5 Oils....8482
            Petroleum-Base and Synthentic-Base Oils....8483
            Operating Information....8483
            Magnets and Magnetic Drain Plugs....8483
            Breather....8483
            Seals....8484
            Temperature Indicator....8484
            Check and Adjust Oil Level....8484
            Drain and Replace Oil....8485
          Torque....8487
      Rear Axle and Suspension....8489
        1. IROS....8491
          Description....8491
          Height Control Valve....8493
          Operation....8495
          Service Checls (Valve on Truck)....8496
          Ride Height Adjustment Procedure....8497
          Overview....8497
          Special Tools....8497
          Specifications....8497
          Equipment Conditions....8497
          Procedure....8497
          Follow-On Procedure....8500
          Travel exceeds specification:....8500
          Travel is less than specification:....8501
          Rod Cutting Instructions....8502
          Final Assembly Instructions....8502
          Air Lines....8504
          Suspension Dump Feature....8505
            Operation....8506
          Main Support Member....8508
            Main Support Member Removal....8508
            Main Support Member Install....8509
          Shock Absorbers....8511
          Torque Rods....8511
          Remove and Install....8511
            Suspension Air Springs Removal....8512
            Suspension Air Spring Install....8514
          Shock Absorbers....8515
            Removal Suspension System Shock Absorbers....8515
            Install Shock Absorber....8517
          Main Support Members....8518
            Remove....8518
            Install....8518
          Torque Rods....8520
            Remove....8520
            Install....8520
           Main Support Member Bushings....8521
          U-Bolts and U-Bolt Nuts Installation....8523
            Installing U-Bolts and U-Bolt Nuts....8523
            Overview....8523
            Special Tools....8523
            Torque Specifications....8523
            Equipment Condition....8523
            Procedure....8524
            Follow-On Procedure....8525
            Checking U-Bolt Nut Torque and U-Bolt Nut Tightening....8526
          Torque....8527
      Fuel System....8529
        1. DEF Tank....8531
          DEF Tank - DuraStar....8531
            Overview....8531
            DEF....8531
            DEF Tank....8531
            DEF Supply Module....8532
            DEF Tank Pickup Assembly....8532
            DEF Lines....8532
            DEF Coolant Lines....8532
            DEF Tank Heater Valve....8532
            DEF Line Heater....8532
          DEF Tank - WorkStar....8532
            Overview....8532
            DEF....8533
            DEF Tank....8533
            DEF Supply Module....8533
            DEF Tank Pickup Assembly....8533
            DEF Lines....8533
            DEF Coolant Lines....8533
            DEF Tank Heater Valve....8534
            DEF Line Heater....8534
        2. Dual Draw Dual Return Fuel Tanks....8534
          Overview....8534
          Removal....8535
          Installation....8539
        3. Fuel/Water....8540
          Fuel Heater - WorkStar....8540
            Overview....8540
          Fuel / Water Separator - DuraStar....8541
            Overview....8541
          Fuel / Water Separator - WorkStar....8543
            Davco....8543
            Overview....8543
            Racor....8545
            Overview....8545
            Cummins....8546
            Overview....8546
          Fuel Cooler - DuraStar....8547
            Overview....8547
          Fuel Cooler - WorkStar....8547
            Overview....8547
      Cab....8549
        1. HVAC....8551
          HVAC System Repair....8551
            A/C Condenser....8551
            Blend Door Actuator....8552
            Removal....8552
            Installation....8553
            Blend Door Gear Train....8554
            Removal....8554
            Installation....8557
            Blower Assembly....8558
            Removal....8558
            Installation....8559
            Blower Scroll Housing....8560
            Removal....8560
            Installation....8561
            Compressor....8562
            Removal....8562
            Installation....8563
            Evaporator....8564
            Removal....8564
            Installation....8565
            Filter-Drier....8566
            Removal....8566
            Installation....8568
            Freeze Probe....8569
            Removal....8569
            Installation....8570
            Fresh Air Module....8571
            Removal....8571
            Installation....8573
            Heater Core....8574
            Removal....8574
            Installation....8576
            Heater Hoses / Lines....8577
            HVAC Air Filter....8578
            Removal....8578
            Installation....8579
            HVAC Control Panel Assembly....8580
            Removal....8580
            Installation....8581
            Interior Module....8582
            Removal....8582
            Installation....8588
            Interior Module Trim Cover....8590
            Removal....8590
            Installation....8591
            Linear Power Module (LPM)....8592
            Removal....8592
            Installation....8594
            Low Pressure Switch....8595
            Removal....8595
            Installation....8596
            Mode Door Actuator....8597
            Removal....8597
            Installation....8598
            Mode Door Gear Train....8599
            Removal....8599
            Installation....8602
            Pressure Transducer....8603
            Removal....8603
            Installation....8604
            Recirculation Door Actuator....8605
            Removal....8605
            Installation....8606
            Recirculation Door Gear Train....8607
            Removal....8607
            Installation....8609
            Recirculation Filters....8610
            Removal....8610
            Installation....8612
            Recirculation, Mode, and Blend Doors....8613
            Refrigerant Line....8614
            Removal....8614
            Installation....8616
            Separating Blower Scroll Housing....8617
            Removal....8617
            Installation....8619
            Separating Front HVAC Module....8620
            Removal....8620
            Installation....8624
            Thermostatic Expansion Valve (TXV)....8625
            Removal....8625
            Installation....8626
          Service Procedures....8627
            Charge A/C System (Charge Mode)....8627
            Discharge A/C System (Recycle Mode)....8629
            Evacuate A/C System (Vacuum Mode)....8631
            Checking Compressor Oil Level....8633
            Overview....8633
            Special Tools....8633
            Equipment Conditions....8633
            Procedure....8633
            Follow-On Procedure....8635
            Oil Fill Guidelines....8636
            Overview....8636
            Special Tools....8636
            Equipment Conditions....8636
            Procedure....8638
            Oil separation during refrigerant recovery....8638
            Component replacement....8638
            Oil loss due to refrigerant leak....8638
            Compressor replacement due to internal compressor failure....8638
            Compressor replacement due to clutch failure....8638
            Follow-On Procedure....8638
            Refrigerant Identification....8639
            Overview....8639
            Special Tools....8639
            Equipment Conditions....8639
            Procedure....8639
            Follow-On Procedure....8639
          Flush and Purge A/C System....8640
            Evaporator....8640
            Overview....8640
            Special Tools....8640
            Equipment Conditions....8640
            Evaporator Flush and Purge Procedure....8643
            Follow-On Procedure....8645
            Supply and Return Lines....8646
            Overview....8646
            Special Tools....8646
            Equipment Conditions....8646
            Supply and Return Line Flush and Purge Procedure....8646
            Follow-On Procedure....8648
            Condenser....8649
            Overview....8649
            Special Tools....8649
            Equipment Conditions....8649
            Condenser Flush and Purge Procedure....8650
            Follow-On Procedure....8653
      Front Wheels....8655
      Rear Wheels....8659
  tables....5787
    Service Procedures....5787
    Adjusted Chamber Stroke Chart....5795
    Troubleshooting Chart....5813
    Torque Chart....5815
    Troubleshooting Chart....5821
    Torque Chart....5823
    Length of Slack Adjuster/Size of Chamber Table....5831
    Maximum Stroke Available Chart....5836
    Service Procedures....5861
    Torque Specifications....5871
    Torque Specifications....5888
    Torque Specifications....5898
    Torque Specifications....5909
    Torque....5926
    Service Procedures....5929
    Torque Specifications....5935
    Torque Specifications....5987
    Torque Specifications....5994
    Torque Specifications....6002
    Torque Specifications....6006
    Torque Specifications....6015
    Torque Specifications....6022
    Torque Specifications....6028
    Torque Specifications....6037
    Torque Specifications....6061
    Torque Specifications....6070
    Torque Specifications....6079
    Torque Chart....6110
    Drag Link Nut Torque Chart....6137
    Dual Steering Gear Drag Link Nut Torque Chart....6140
    Master Gear Drag Link Nut Torque Chart....6140
    Drag Link Torque Chart....6151
    Specifications....6194
    M-Series Torque Chart....6194
    All Steering Applications Torque Chart....6195
    Special Tools....6195
    Service Information....6199
    Service Information....6199
    Service Information....6199
    Procedures....6230
    DuraStar....6255
    WorkStar....6256
    Torque Specifications....6257
    Torque Specifications....6262
    Approximate CAN DC Voltage Measurements (Key ON)....6274
    Approximate CAN Resistance Measurements (Batteries Disconnected)....6274
    Feature Codes....6278
    Remote Start Stop....6278
    Feature Code....6289
    Diagnostic Trouble Codes....6290
    Remote Start/Stop Preliminary Check....6291
    Diagnostic Section....6294
    Diagnostics....6300
    500K Input Diagnostic Section....6319
    Diagnostic Section....6324
    Battery Type....6334
    Description....6334
    Battery Chemistry....6334
    Description....6334
    Battery Type....6339
    Description....6339
    Battery Chemistry....6340
    Description....6340
    Individual Battery Test RESULTS....6342
    Recommended Action....6342
    Starting System RESULTS....6343
    Recommended Action....6343
    RESULTS....6347
    Recommended Action....6347
    Operational Checkout....6364
    Heated Drain Valve Test....6364
    Air Dryer Test....6365
    Feature Codes....6366
    Diagnostic Trouble Codes....6366
    Air Horns Preliminary Checks....6367
    Feature Code....6369
    Diagnostic Trouble Codes....6370
    Air Solenoid Preliminary Check....6379
    Operational Checkout....6381
    Aux Power Source Tests....6382
    Operational Checkout....6387
    Axle Pressure Transducer Voltage Checks....6388
    C.B. Radio Power Source Preliminary Check....6391
    C.B. Radio Power Connector Tests....6392
    Cigar Lighter and Power Feed Preliminary Check....6393
    Cigar Lighter Tests....6394
    Cigar Lighter Power Source Tests....6394
    Two Post Power Source Tests....6395
    Feature Codes....6396
    Diagnostic Trouble Codes....6397
    Cruise Control Preliminary Check....6398
    Steering Wheel Mounted Cruise Control Command Switch Test (0595AYJ)....6399
    Steering Wheel Mounted Cruise Control Command Switch Test (0595AAP)....6400
    Diagnostic Trouble Codes....6402
    Operational Checkout....6403
    Lift Gate Test....6403
    Diagnostic Trouble Codes....6406
    Operational Checkout....6407
    (0595ACT) Differential Lock Test....6408
    (0595ACU) Differential Lock Test....6409
    Feature Codes....6410
    Diagnostic Trouble Codes....6410
    Electric Horn Preliminary Check....6411
    Diagnostic Trouble Codes....6414
    Operational Checkout....6414
    Fifth Wheel Slide Test....6415
    Diagnostic Trouble Codes....6418
    Operational Checkout....6419
    Fuel Transfer Pump Won’t Run Test....6420
    Fuel Transfer Pump Continuously Runs Test....6422
    Operational Checkout....6427
    Heated Mirrors Test....6427
    Left Heated Mirror Test....6428
    Right Heated Mirror Test....6428
    Operational Checkout....6429
    Heated Seat Test....6429
    Feature Code....6430
    Diagnostic Trouble Codes....6431
    Diagnostic Trouble Codes....6433
    Power Divider Lock Preliminary Check....6434
    Power Divider Lock Test....6434
    Additional Signals Used for PTO Operation....6438
    Feature Description....6439
    Fault Codes....6450
    PTO Hour Meter/ PTO Indicator Checks....6462
    Feature Codes....6463
    Diagnostic Trouble Codes....6464
    Power Locks Preliminary Check....6466
    Power Windows Preliminary Check....6469
    One Power Window Inop Test....6470
    All Power Windows Inop Test....6470
    Power Locks Preliminary Check....6473
    One Door Lock Inop Test....6474
    All Door Locks Inop Test....6474
    Power Mirror Preliminary Check....6476
    Power Mirror Tests....6477
    Radio Preliminary Check....6479
    Radio Test....6480
    Fault Codes....6482
    RPM Checks....6487
    Feature Codes....6488
    Lighted Air Shield DTC....6488
    Roof Auxiliary Load Preliminary Check....6489
    IP Mounted Roof Auxiliary Load Switch Test....6490
    Operational Checkout....6494
    0595BAG Seat Belt Test....6494
    Operational Checkout....6495
    Self Contained Air Seat Test....6495
    Diagnostic Trouble Codes....6498
    Operational Checkout....6499
    Suspension Dump Test....6500
    Feature Codes....6501
    Theft Deterrent Diagnostics....6502
    Diagnostic Trouble Codes....6507
    Operational Checkout....6507
    Two-Speed Switch Test....6507
    Two-Way Radio Circuit Tests....6508
    Feature Codes....6509
    Diagnostic Trouble Codes....6509
    Operational Checkout....6509
    Water Probe Test....6510
    Additional Signals Used for Wheelchair Lift Interlock Operation....6513
    Wheelchair Lift Interlock Checks....6516
    Parked Regeneration (Particulate_Trap_Regeneration_Force_Switch = 1)....6536
    Inhibit Regeneration (Particulate_Trap_Regeneration_Inhibit_Switch = 1)....6537
    DuraStar....6540
    WorkStar....6540
    Service Information....6544
    DuraStar....6550
    WorkStar....6550
    Service Information....6553
    DuraStar....6554
    WorkStar....6554
    Service Information....6558
    Warning Indicators....6660
    Sensor Check Pins ....6684
    Warning Indicators....6691
    Test Procedure....6710
    Test Procedure....6715
    Specifications....6722
    Specifications....6737
    Test Procedure....6740
    Test Procedure....6747
     Exhaust Brake Switch Test....6902
    RESCM Checks....6912
    Switch Pack Preliminary Check....6928
    Switch Pack Test....6929
    System Pressure Test Chart....6982
    R-134a Static Temperature / Pressure Table....7033
    System Performance Test Specifications....7035
    Air gauge feature codes....7058
    Air 1 gauge fault codes....7059
    Check for short to GND in Primary Air Pressure signal circuit....7064
    Check for short to GND in Primary Air Pressure signal circuit B40....7065
    Check for VREF and GND at Primary Air Pressure Transducer....7066
    Check for Open or high resistance in Primary Air Pressure signal circuit....7067
    Check for Open or high resistance in Primary Air Pressure signal circuit A40....7068
    Check for Open or high resistance in Primary Air Pressure signal circuit B40....7069
    Body Controller output test....7070
    Air gauge feature codes....7071
    Air 2 gauge fault codes....7072
    Check for short to GND in Secondary Air Pressure signal circuit....7077
    Check for short to GND in Secondary Air Pressure signal circuit B40A....7078
    Check for VREF and GND at Secondary Air Pressure Transducer....7079
    Check for Open or high resistance in Secondary Air Pressure signal circuit....7080
    Check for Open or high resistance in Secondary Air Pressure signal circuit A40A....7081
    Check for Open or high resistance in Secondary Air Pressure signal circuit B40A....7082
    Body Controller output test....7082
    Gauge Table....7084
    Gauge Response to Faults....7085
    Axle Temperature Sensor Voltage Checks....7093
    Rear- Rear Axle Temperature Sensor Voltage Checks....7095
    Air Pressure Transducer Voltage Checks....7098
    Feature Codes....7099
    Compass Module Voltage Checks....7100
    DEF level feature codes....7101
    DEF level fault codes....7101
    Coolant temperature feature codes....7103
    Coolant temperature fault codes....7103
    Oil pressure feature codes....7104
    Oil pressure fault codes....7104
    Oil temperature feature codes....7105
    Oil temperature fault codes....7105
    Engine speed feature codes....7106
    Engine speed fault codes....7106
    Fuel gauge feature codes....7107
    Fuel gauge fault codes....7107
    Fault codes....7113
    Ambient Air Temperature Sensor Table....7114
    Transmission temperature feature codes....7116
    Transmission temperature fault codes....7116
    Transmission oil temp sensor resistance specification....7120
    Measure resistance of transmission oil temperature circuit at Connector 1702....7121
    Measure resistance of transmission oil temperature sensor....7121
    Vehicle speed feature codes....7122
    Vehicle speed fault codes....7122
    Feature Codes....7125
    Dome and Courtesy Light Fault Codes....7125
    Door Switch Short Circuit Tests....7127
    Door Switch Open Circuit Tests....7127
    Dome Light Short Circuit Test....7127
    Dome Light Open Circuit Test....7128
     Back Up Light Fault Codes....7129
    Backup Light Relay Tests....7131
    Backup Light Ball Switch Tests....7131
    Brake Switch Diagnostics....7139
    Brake Switch Fault Code Diagnostics....7139
    Tech Tips....7139
    Feature Codes....7160
    Fog Light Diagnostics....7160
    Fog Light Fault Code Diagnostics....7160
    Feature Codes....7196
    Low Beam Headlight Diagnostics....7197
    High Beam Headlight Diagnostics....7197
    Feature Codes....7264
    Park / Marker Lights....7265
    Feature Codes....7291
    Snow Plow Light Diagnostics....7292
    Diagnostic Section....7311
    Software Feature Codes....7311
    Turn Signal Input and Front Turn Lamp Diagnostics....7321
    Combined Stop and Turn Lamps....7368
    Separate Stop and Turn Lamps....7398
    Feature Codes....7422
    Trailer Lights Diagnostics....7423
    Feature Codes....7475
    Diagnostic Trouble Codes....7475
    Trailer Auxiliary Power Circuit Preliminary Checks....7476
    Feature Code....7478
    Diagnostic Trouble Codes....7478
    Electric Trailer Brake Preliminary Check....7479
    Feature Codes....7483
    Dome and Courtesy Light Fault Codes....7483
    Work Light System Preliminary Checks....7484
    Work Light Switch Test....7485
    Work Light Open Circuit Test....7485
    Work Light Short Circuit Test....7485
    Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....7499
    LCT Column Shifter Interlock Checks....7500
    TCM Power, Ground and Data Link Circuit Checks....7501
    Shift Selector Power and Ground Circuit Checks....7502
    Diagnostic Section....7505
    Software Feature Codes....7505
    Diagnostic Trouble Codes (DTC)....7522
    Feature Codes....7530
    Windshield Wiper Diagnostics....7531
    Washer Pump Diagnostics....7532
    Windshield Wiper Input Switch....7532
    Torque Chart....7695
    Troubleshooting Table....7714
    Specifications....7715
    Torque Chart....7716
    Troubleshooting Chart....8051
    Torque Chart....8057
    Lubrication Table....8137
    Specifications Table....8139
    Torque Chart....8140
    Specifications Table....8258
    Torque Chart....8259
    Troubleshooting Chart....8323
    Specifications....8328
    Gear Ratio Table....8328
    Torque Chart....8329
    Troubleshooting Chart....8397
    Specifications....8402
    Gear Ratios Table....8403
    Torque Chart....8404
    Example of Shim Selection....8452
    Possible Combinations that meet required shim stack:....8452
    Kit 2540....8461
    PTO Switch Option....8462
    PTO Yoke Options and Dimensions....8466
    PTO MDP-10–AF-100 Components....8469
    Transfer Case Oil Change Intervals....8485
    Transfer Case Oil Specifications (NOTES 1, 2, 3)....8486
    Transfer Case Oil Capacities....8486
    Dry Weight....8486
    Torque Chart....8488
    Torque Chart....8528
    Torque Specifications....8633
    Oil Capacity by Component....8636
0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 4....8664
  toc....8666
    Table of Contents....8666
    Safety Terminology....8669
    Safety Instructions....8669
    Work Area....8669
    Safety Equipment....8669
    Protective Measures....8669
    Vehicle....8669
    Engine....8670
    Fire Prevention....8670
    Batteries....8670
    Compressed Air....8670
    Tools....8670
    Fluids Under Pressure....8671
    Fuel....8671
    Removal of Tools, Parts, and Equipment....8671
      Frame....8672
      Front Axle....8676
      Front Suspension....8680
      Brakes....8684
        1. Air Brakes....8688
          Bendix ABS Air Brakes....8688
            4–Channel with Electronic Stability and Automatic Traction Control....8688
            Overview....8688
            6–Channel with Electronic Stability and Automatic Traction Control....8692
            Overview....8692
            Anti-Lock Brake System (ABS) Module Removal....8695
            Special Tools....8695
            Torque Specifications....8695
            Equipment Conditions....8695
            Removal Procedure....8695
            Follow-On Procedure....8695
            Anti-Lock Brake System (ABS) Module Installation....8696
            Special Tools....8696
            Torque Specifications....8696
            Equipment Conditions....8696
            Installation Procedure....8696
            Follow-On Procedure....8696
            Modulator Valve M-40 Removal....8697
            Modulator Valve M-40 Installation....8698
            Steering Angle Sensor Removal....8699
            Special Tools....8699
            Torque Specifications....8699
            Equipment Conditions....8699
            Removal Procedure....8699
            Follow-On Procedure....8701
            Steering Angle Sensor Installation....8702
            Special Tools....8702
            Torque Specifications....8702
            Equipment Conditions....8702
            Installation Procedure....8702
            Follow-On Procedure....8704
            Wheel Speed Sensor WS-24 Removal....8705
            Wheel Speed Sensor WS-24 Installation....8706
            Yaw Rate Sensor Removal....8707
            Yaw Rate Sensor Installation....8708
        2. Automatic Slack Adjusters: Rockwell....8709
          General....8709
            Clevis Types....8711
            Quick Connect Clevis....8711
            One Piece Clevis....8712
            Thread Sizes....8712
          Operation....8713
          Maintenance....8714
            Minor Inspections and Lubrication....8714
            Major Inspections....8714
          Troubleshooting....8716
          Remove....8718
          Disassemble....8720
          Clean and Inspect....8726
            Clean....8726
            Overview....8726
            Metal Parts with Polished Surfaces....8726
            Parts Not Made of Metal....8726
            Inspect....8727
            Corrosion Protection....8727
          Assemble....8728
          Install....8736
            Preparations for Installation....8736
            Installation of the Slack Adjuster....8739
            Adjust Chamber Stroke (Preferred)....8741
          Brake Adjustment....8743
          Follow-On Procedures....8746
          Lubrication....8747
            Anti-Seize Compound....8747
          Torque....8748
        3. Bosch Park Brake: Lever Actuated or Air Power....8750
          Brake Shoe Adjustment....8750
            Drum Off....8750
            Drum On....8752
          Inspection....8753
          Park Brake Cable Adjustment (Lever Actuated)....8754
          Park Brake: Power Brake....8756
            Manually Releasing Power Park Brake....8756
            Rod Stroke Sensor: Remove ....8757
            Rod Stroke Sensor: Install....8759
            Spring Chamber Assembly: Remove....8760
            Spring Chamber Assembly: Install....8762
          Special Tools....8764
        4. SmartTrac™ Brakes and Traction Control System....8765
          Hydraulic Brake System....8765
          Overview....8765
            Brake Bleed Procedure....8768
            Overview....8768
            Special Tools....8768
            Equipment Conditions....8768
            Procedure....8768
            Follow-On Procedure....8769
            Manual Brake Bleeding....8770
            Overview....8770
            Special Tools....8770
            Equipment Conditions....8770
            Procedure....8771
            Follow-On Procedure....8773
          Traction Control....8774
          Overview....8774
          Parking Brake....8776
          Overview....8776
            Parking Brake Cable....8777
            Overview....8777
        5. Full Power Hydraulic ABS Brake System for Models Built Starting 03 May 2007....8778
          Safety Precautions....8778
            General Warnings / Cautions for Servicing the Full Power Brake System....8778
            Asbestos and Non-Asbestos Fibers....8782
            Asbestos Fibers Warning....8782
            Hazard Summary....8782
            Recommended Work Practices....8782
            Regulatory Guidance....8783
            Non-Asbestos Fibers Warning....8784
            Hazard Summary....8784
            Recommended Work Practices....8784
            Regulatory Guidance....8785
          Overview....8786
          Standard Features....8786
          Optional Features....8786
            Service Brakes (Normal Braking)....8786
            Normal Braking with Electronic Brakeforce Distribution....8787
            Anti-lock Braking System (ABS)....8787
            Automatic Traction Control (ATC) System (Optional)....8788
            Overview....8788
            TRAC CTRL Indicator....8788
            Traction Control Mud/Snow Switch....8789
            Warning Indicators....8790
            System Layout....8793
            System Components....8795
            Overview....8795
            Master Cylinder and Reservoir....8796
            Hydraulic Compact Unit (HCU)....8797
            Electronic Control Unit (ECU)....8802
            Foundation Brakes (Rotors and Calipers)....8803
            Wheel Speed Sensors....8804
            Body Controller....8805
            Driveline Parking Brake Drum....8805
            Traction Control (Mud and Snow) Switch (with Optional ATC)....8806
            Electronic Gauge Cluster (EGC)....8808
            Brake Pressure Indicator....8808
            Brake Fluid Indicator....8808
            ABS Indicator....8808
            TRAC CTRL Indicator....8809
            Brake Indicator....8809
          Operation....8810
            Warning Indicators....8812
            Normal Breaking Operation....8815
            Overview....8815
            Normal Operation (Brakes Not Applied)....8815
            Normal Operation (Brakes Applied)....8817
            Anti-lock (ABS) Braking Mode....8818
            Overview....8818
            ABS Decrease Pressure Stage....8819
            ABS Hold Stage....8820
            ABS Increase Pressure Stage....8821
            Automatic Traction Control (ATC) Mode (Vehicles with Optional ATC)....8822
            Overview....8822
            ATC Inactive (ATC Circuit Operation with No ATC Event Occurring)....8823
            ATC Active (ATC Circuit Operation while Experiencing an ATC Event)....8825
          System Maintenance....8827
          Service Procedures....8828
          Equipment Conditions....8828
            Pressure Bleeding the Full Power Breaks System....8829
            Overview....8829
            Tools Required....8829
            Master Cylinder (MC) Bleeding Procedure....8830
            Brake Caliper Bleeding Procedure....8834
            Overview....8834
            Test Setup....8834
            Test Procedure....8834
            Wheel Speed Sensor Adjustment....8837
            Sensor Adjustment....8837
          Diagnostics and Troubleshooting....8838
            Diagnosis....8838
            Overview....8838
            Fault Detection....8839
            TOOLBOX™ Software....8839
            Diagnostic Trouble Codes....8839
            Observing Signals with the EZ-Tech® Service Tool....8840
            Definitions....8840
            Troubleshooting....8840
            Introduction....8840
            Troubleshooting Tables....8840
            General Information Regarding the Driver Interface....8840
            Troubleshooting Table (System Reaction)....8841
            Multiple Failures Table....8841
            Special System Conditions....8841
            Repair Instructions....8841
            Warning Indicators....8856
            General Electrical System....8856
            ABS and ATC Wiring....8858
            Wheel Speed Sensor Output Voltage Test....8858
            Front Axle....8858
            Rear Axle....8859
            Wheel Speed Sensor Resistance....8859
          Remove and Install....8861
            Master Cylinder (MC)....8865
            Overview....8865
            Remove....8866
            Install....8870
            Brake Light Switch (Mounted on MC)....8872
            Overview....8872
            Remove....8872
            Install....8872
            Master Cylinder Reservoir....8873
            Overview....8873
            Remove....8873
            Equipment Conditions....8873
            Remove Procedure....8873
            Install....8875
            Follow-On Procedures....8876
            Fluid Level Switch (Mounted on MC Reservoir)....8877
            Overview....8877
            Remove....8877
            Equipment Conditions....8877
            Remove Procedure....8877
            Install....8877
            Follow-On Procedure....8877
            Low Pressure Hose....8878
            Overview....8878
            Remove....8878
            Equipment Conditions....8878
            Remove Procedure....8878
            Install....8881
            Electronic Control Unit (ECU)....8883
            Overview....8883
            Remove....8884
            Install....8886
            Accumulator....8888
            Overview....8888
            Remove....8888
            Install....8890
            Accumulator Disposal Procedure....8892
            Hydraulic Compact Unit (HCU)....8894
            Overview....8894
            Remove....8895
            Install....8898
            HCU Reservoir....8901
            Overview....8901
            Remove....8901
            Install....8902
            Relay Valve Assembly....8903
            Overview....8903
            Remove....8903
            Install....8906
            HCU Pumps....8908
            Overview....8908
            Secondary HCU Pump Removal and Installation....8908
            Primary HCU Pump Removal and Installation....8912
            Brake Lines (General)....8913
            Overview....8913
            Remove....8913
             Install....8914
            Wheel Speed Sensor....8916
            Overview....8916
            Sensor Lube Specification....8917
            Remove....8917
            Install....8918
          Specifications....8919
            Torque....8919
            Full Power Brake System Specifications....8922
            Tire Size Range....8922
          Special Tools....8923
            Essential Tools....8923
            Overview....8923
            Brake Bleeding Adapter (ZTSE4678)....8923
            Regulator / Filter (ZTSE4757)....8923
            Electronic Service Tool (EST), EZ-TECH® ....8924
            TOOLBOX Diagnostic Software....8924
            Common Tools....8924
      Steering....8926
        1. Steering Wheel and Steering Column Assembly....8928
          Description....8928
            Steering Wheel....8928
            Clock Spring....8928
            Steering Column....8929
          Remove and Install Procedures....8930
          Equipment Conditions....8930
            Steering Wheel....8931
            Overview....8931
            Removal....8932
            Installation....8934
            Clock Spring....8936
            Removal....8936
            Installation....8939
            Steering Column....8941
            Overview....8941
            Removal....8941
            Installation....8942
          Checks and Adjustments....8944
            Steering Wheel....8944
            Check....8944
            Adjust....8944
          Torque....8945
        2. Power Steering Gear: Sheppard M-Series....8946
          Identification....8946
          Operation....8949
          OIL FLOW THROUGH THE GEAR....8950
          Steering System Diagnostics....8952
            Diagnostic Overview....8952
            Define the Concern....8952
            Perform Visual Inspection....8952
            Inspect Mechanical Components....8952
            Hydraulic Diagnosis....8952
            Oil Flow and Pressure Recommendations....8955
            Common Complaints....8955
          Troubleshooting....8958
            Symptoms Table....8958
            Re-phasing Column....8961
            Troubleshooting Checklist....8962
          Preventative Maintenance....8963
            Fluid and Filter Change....8963
            Input Shaft Seal Replacement — Disassembly....8965
            Input Shaft Seal Replacement — Assembly....8969
          Bleeding....8972
            Single Gear System....8972
            Dual Steering Gears....8974
          Set Relief Plungers....8977
          Pitman Arm....8978
            Remove....8978
            Install....8980
          Steering Gear Disassembly....8987
          Sub-assembly Repair....9002
          M-SERIES - OPTIONAL INTEGRAL RELIEF VALVE....9002
          Clean....9004
          Inspect....9005
          Parts Discolored (Blue)....9005
          Broken Housing....9005
          Housing or Piston Scoring....9005
          Sector Shaft Roller (Bearing Wear)....9005
          Actuating Shaft....9006
          Thrust Bearings....9006
          Actuating Shaft Thread Wear....9006
          Piston Rings Cut, Pinched, Sheered or Worn....9006
          Reassemble....9007
          Dual Steering System....9023
            Description....9023
            Operation....9023
            Integral Slave Gear....9026
          Adjustments....9028
            Final....9028
            Axle Stop....9028
          Specifications....9029
          Torque....9029
          Special Tools....9030
          Glossary of Terms and Definitions....9030
        3. Power Steering Gear with Hydro-Max® Brake System....9033
        Overview....9033
          Cummins ISB with TRW....9034
          Cummins ISB with Sheppard....9034
          N9 with TRW....9034
          Power Steering Fluid Flow Test....9035
          Overview....9035
          Special Tools....9035
          Equipment Conditions....9035
          Procedure....9036
          Follow-On Procedure....9037
      Drivelines....9038
      Exhaust....9042
      Electrical / Software....9046
        1. How to Use Diamond Logic® Builder (DLB)....9060
          Interface Device Selection....9060
          Connecting Diamond Logic® Builder Software....9062
          Activating Diagnostic mode....9063
          Making a Session with Diamond Logic® Builder....9064
        2. 12 Volt Electrical System....9065
          Battery Box....9065
          Overview....9065
            Battery Disconnect....9068
            Special Tools....9068
            Torque Specifications....9068
            Equipment Conditions....9068
            Disconnect Procedure....9069
            Follow-On Procedure....9069
            Battery Reconnect....9070
            Special Tools....9070
            Torque Specifications....9070
            Equipment Conditions....9070
            Reconnect Procedure....9071
            Follow-On Procedure....9071
          Battery Disconnect Switch....9072
            Overview....9072
          Brake Switch....9073
          Overview....9073
            SPN 597 FMI 0 – Brake Switch reading above normal range....9076
            Overview....9076
            Associated Faults....9076
            Fault Facts....9076
            Tools Required....9076
            Possible Causes....9076
            SPN 597 FMI 1 – Brake Switch reading below normal range....9079
            Overview....9079
            Associated Faults....9079
            Fault Facts....9079
            Possible Causes....9079
          CAN Systems....9081
            Overview....9081
            Faults....9081
            Short....9081
            Terminating Resistor Failure....9081
            Backbone Open....9081
            Node Open....9082
            Tests....9083
            Module Communication Test....9083
            Overview....9083
            Tools Required....9083
            Equipment Condition....9083
            Test Setup....9083
            Test Procedure....9084
            Follow-On Procedure....9084
          Remote Start / Stop....9085
            Remote Start Stop Overview....9085
            Remote Start / Stop with 500K....9087
            Overview....9087
            Operational Checkout Procedure....9088
            Overview....9088
            Remote Start / Stop Not Operating with 500K....9089
            Fault Overview....9089
            Fault Facts....9089
            Possible Causes....9089
            Pin-Point Test - Remote Start / Stop Not Operating with 500K....9096
            Tools Required....9096
            Remote Start / Stop with 250K....9097
            Overview....9097
            Operational Checkout Procedure....9099
          Troubleshooting....9100
            Operational Checkout Procedure....9100
            Electrical System Operational Checkout Procedure....9100
            Starting System....9102
            System Overview....9102
            Battery Pack....9102
            Starter....9102
            Control....9102
            No Click No Crank....9103
            Overview....9103
            Possible Causes....9103
            Click No Crank....9105
            Overview....9105
            Possible Causes....9105
            Low Cranking Speed....9106
            Overview....9106
            Possible Causes....9106
            250K Input Diagnostics....9107
            Overview....9107
            Navistar Starter Input Diagnostics....9108
            Navistar Starter Input Pinpoint Tests....9111
            Cummins Starter Input Diagnostics....9117
            Cummins Starter Input Pinpoint Tests....9121
            500K Input Diagnostics....9124
            Overview....9124
            Key Switch and Grid Control....9124
            Crank Inhibit....9124
            GridCtrl_CrankInhibit....9124
            Crank_Inhibit_Reason....9124
            Lower_Clutch_Signal....9125
            Neutral_Status_TCM....9125
            Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal)....9125
            Hood_Switch....9125
            500K Input Operational Checkout Procedure....9127
            Overview....9127
            Charging System....9131
            System Overview....9131
            Battery Pack....9131
            Alternator....9131
            Red Battery Warning Light....9132
            Overview....9132
            Possible Causes....9132
            Repeated Jump Starts....9133
            Overview....9133
            Possible Causes....9133
            Battery Gauge Reading High....9135
            Overview....9135
            Possible Causes....9135
            Battery Gauge Reading Low / Fluctuating....9136
            Overview....9136
            Possible Causes....9136
            Tests....9138
            Battery Test....9138
            Overview....9138
            Tools Required....9138
            Equipment Condition....9138
            Test Setup....9138
            Test Procedure....9138
            Expected Outcome....9139
            Follow-On Procedure....9140
            Electrical System Test....9141
            Overview....9141
            Tools Required....9141
            Equipment Condition....9141
            Test Setup....9141
            Test Procedure....9141
            Starter System Test Procedure....9144
            Charging System Test Procedure....9145
            Expected Outcome....9146
            Follow-On Procedure....9146
            Cable Drop Test....9147
            Overview....9147
            Tools Required....9147
            Equipment Condition....9147
            Test Setup....9147
            Test Procedure....9147
            Expected Outcome....9148
            Follow-On Procedure....9148
            Parasitic Draw Test....9149
            Overview....9149
            Tools Required....9149
            Equipment Condition....9149
            Test Setup....9149
            Test Procedure....9150
            Expected Outcome....9152
            Follow-On Procedure....9152
            Manual Engine Bar Test....9153
            Overview....9153
            Tools Required....9153
            Equipment Condition....9153
            Test Setup....9153
            Test Procedure....9153
            Expected Outcome....9153
            Follow-On Procedure....9153
            Starter Control Circuit Test....9154
            Overview....9154
            Tools Required....9154
            Equipment Condition....9154
            Test Setup....9154
            Test Procedure....9154
            Expected Outcome....9154
            Follow-On Procedure....9155
            Inspections....9156
            Ring Gear Inspection....9156
            Overview....9156
            Tools Required....9156
            Equipment Condition....9156
            Inspection Procedure....9156
            Expected Outcome....9157
            Follow-On Procedure....9157
            Electrical System Inspection....9158
            Overview....9158
            Tools Required....9158
            Equipment Condition....9158
            Inspection Procedure....9158
            Expected Outcome....9158
            Follow-On Procedure....9158
        3. Accessories....9159
          Air Dryer and Heated Drain Valve....9159
            Overview....9159
            Diagnostics....9159
          Air Horn....9160
            Overview....9160
            Operational Checkout Procedure....9162
            Air Horn Test....9163
          Air Solenoid....9163
            Overview....9163
            Operational Checkout Procedure....9174
            Air Solenoid Diagnosis....9175
          Auxiliary Power Source....9175
            Overview....9175
            Diagnostics....9176
          Axle Load Monitor....9177
            Overview....9177
            User Programmable Parameters....9178
            Diagnostic Trouble Codes (DTC)....9180
            Diagnostics....9182
            Body Controller Signals....9184
            Body Controller Functions....9185
            To activate the axle load monitor feature, the following conditions must be true:....9185
          C.B. Power Radio....9186
            Overview....9186
            Diagnostics....9186
          Cigar Lighter and Power Feed ....9187
            Overview....9187
            Diagnostics....9188
          Cruise Control....9190
            Overview....9190
            Operational Checkout Procedure....9193
            Cruise Control Switch Tests....9195
          Customer Installed Lift Gate Power Source....9196
            Overview....9196
            User Programmable Parameters....9197
            Diagnostics....9199
          Differential Lock, Air Controlled....9199
            Overview....9199
            User Programmable Parameters....9201
            Diagnostics....9204
          Electric Horn....9206
            Overview....9206
            Operational Checkout Procedure....9208
            Electric Horn Test....9209
          Fifth Wheel Slide, Air Controlled....9209
            Overview....9209
            User Programmable Parameters....9210
            Diagnostics....9211
          Fuel Transfer Pump....9212
            Overview....9212
            User Programmable Parameters....9212
            Diagnostics....9215
          Heated Mirrors....9218
            Overview....9218
            Feature Codes....9220
            Diagnostic Trouble Codes....9222
            Diagnostics....9223
          Heated Seats....9225
            Overview....9225
            Diagnostics....9226
          Load Shedding....9227
            Overview....9227
            Latching Relay Diagnostics....9227
          Power Divider Lock, Air Controlled....9228
            Overview....9228
            User Programmable Parameters....9229
            Diagnostics....9231
          Power Take Off (PTO)....9232
            Overview....9232
            Operational Checkout Procedure....9257
            PTO Test....9259
          Power Windows and Locks....9263
            Overview....9263
            Operational Checkout Procedure....9267
            Power Windows....9268
            Power Window Overview....9268
            Operational Checkout Procedure....9270
            Power Window Test....9271
            Power Door Locks....9272
            Power Door Lock Overview....9272
            Operational Checkout Procedure....9274
            Power Door Lock Tests....9275
          Power Mirrors....9279
            Overview....9279
            Diagnostics....9280
          Radio and Speakers....9284
            Overview....9284
            Diagnostics....9284
          Remote Power Module....9285
            Overview....9285
            RPM Addressing....9286
            Operational Checkout Procedure....9290
            RPM Diagnostics....9291
          Roof Auxiliary and Air Shield Light....9293
            Overview....9293
            Roof Auxiliary Load....9294
            Overview....9294
            Operational Checkout Procedure....9294
            Roof Auxiliary Load Test....9295
            Lighted Air Shield....9296
            Overview....9296
            Lighted Air Shield Preliminary Check....9296
            Lighted Air Shield Test....9297
          Seat Belt and Seat Sensor....9298
            Overview....9298
            Feature Codes....9298
            User programmable parameters....9298
            Diagnostics....9299
          Self Contained Air Seat....9300
            Overview....9300
            Diagnostics....9300
          Suspension Dump....9304
            Overview....9304
            User Programmable Parameters....9304
            Diagnostics....9307
          Theft Deterrent System....9308
            Overview....9308
            Operational Checkout Procedure....9310
            Theft Deterrent System Not Responding....9311
            Fault Overview....9311
            Fault Facts....9311
            Possible Causes....9311
          Two-speed Axle Switch....9313
            Overview....9313
            Diagnostics....9314
          Two-way Radio....9314
            Overview....9314
            Diagnostics....9315
          Water In Fuel Monitor Test....9316
            Overview....9316
            Diagnostics....9317
          Wheelchair Lift Interlock....9317
            Overview....9317
            Activate Wheelchair Lift Solenoid....9318
            Activate Audible Alarm....9318
            Diagnostic Trouble Codes....9320
            Operational Checkout Procedure....9321
        4. Aftertreatment....9324
          Overview....9324
          Operation....9324
          Aftertreatment Definitions....9325
          Soot Accumulation Level Indications....9325
          Feature Related Text Messages in the Gauge Cluster....9327
          Feature Codes....9327
          Diagnostic Trouble Codes....9329
          Body Controller Signals....9332
          Body Controller Functions....9334
          Parked Regeneration....9335
          Inhibit Regeneration....9336
          Parked Regeneration Switch Indicator....9337
          Inhibit Regeneration Switch Indicator....9338
          DPF Status Warning Lamp....9339
          HEST Warning Lamp....9340
          Audible Alarm....9341
          Aftertreatment Troubleshooting....9342
            Parked Regeneration Switch Test....9342
            Parked Regeneration Switch Indicator Test....9343
            Inhibit Regeneration Switch Test....9343
            Inhibit Regeneration Switch Indicator Test....9344
            DPF Status Warning Lamp Test....9344
            HEST Warning Lamp Test....9344
            Lamp Check....9344
            Lost Communication and Warning Lamp Diagnostics....9345
        5. Brakes and Traction Control System....9346
          Bendix Air Brake System....9346
            Anti-Lock Brake System (ABS)....9346
            Overview....9346
            Inputs....9349
            Outputs....9350
            Operational Checkout Procedure....9352
            Overview....9352
            Symptom 1: ABS Module Loss of Communication....9353
            Overview....9353
            Fault Facts....9353
            Tools Required....9353
            Possible Causes....9353
            Automatic Traction Control System....9356
            Overview....9356
            Inputs....9358
            Outputs....9358
            Electronic Stability Control (ESC) System....9360
            Overview....9360
            Inputs....9361
            Outputs....9362
          Parking Brake....9364
          Overview....9364
          Park Brake Indicator....9365
            Park Brake Switch Diagnostics....9366
            Overview....9366
            Associated Faults....9366
            Fault Facts....9366
            Special Tools....9366
            Possible Causes....9366
          SmartTrac™ Hydraulic Brake System....9370
          Overview....9370
            Operational Checkout Procedure....9376
            Overview....9376
            Low Brake Fluid Level Diagnostics....9379
            Overview....9379
            Associated Faults....9379
            Fault Facts....9379
            Special Tools....9379
            Possible Causes....9379
            ABS Diagnostics....9382
            Overview....9382
            Associated Faults....9383
            Fault Facts....9383
            Special Tools....9383
            Possible Causes....9383
            SPN 1044 FMI 3 Hydraulic Pump Motor – Above Normal....9390
            Overview....9390
            Associated Faults....9390
            Fault Facts....9390
            Special Tools....9390
            Possible Causes....9390
            SPN 1044 FMI 4 Hydraulic Pump Motor – Below Normal....9394
            Overview....9394
            Associated Faults....9394
            Fault Facts....9394
            Special Tools....9394
            Possible Causes....9394
            SPN 1044 FMI 5 Hydraulic Pump Motor – Open....9400
            Overview....9400
            Associated Faults....9400
            Fault Facts....9400
            Special Tools....9400
            Possible Causes....9400
            SPN 2584 FMI 3 Hydraulic Brake Pressure Warning State Circuit 1 – Above Normal....9404
            Overview....9404
            Associated Faults....9404
            Fault Facts....9404
            Special Tools....9404
            Possible Causes....9404
            SPN 2584 FMI 4 Hydraulic Brake Pressure Warning State Circuit 1 – Below Normal....9410
            Overview....9410
            Associated Faults....9410
            Fault Facts....9410
            Special Tools....9410
            Possible Causes....9410
            SPN 2584 FMI 5 Hydraulic Brake Pressure Warning State Circuit 1 – Open....9416
            Overview....9416
            Associated Faults....9416
            Fault Facts....9416
            Special Tools....9416
            Possible Causes....9416
            SPN 520941 FMI 5 Hydro-Max Control output of BC – Open....9422
            Overview....9422
            Associated Faults....9422
            Fault Facts....9422
            Special Tools....9422
            Possible Causes....9422
            SPN 520941 FMI 6 Hydro-Max Control output of BC – Shorted to Ground / Over Current....9431
            Overview....9431
            Associated Faults....9431
            Fault Facts....9431
            Special Tools....9431
            Possible Causes....9431
            Tests and Inspections....9435
            Hydraulic Brake System Inspection....9435
            Overview....9435
            Special Tools....9435
            Equipment Condition....9435
            Test Setup....9436
            Test Procedure....9436
            Expected Outcome....9436
          Traction Control System....9437
          Overview....9437
        6. Collision Avoidance Systems....9440
          Collision Mitigation System....9440
            Bendix® Wingman® Advanced™....9440
            Overview....9440
            Adaptive Cruise Control (ACC)....9443
            Alerts....9443
            Collision Mitigation Braking....9443
            Tech Tips....9445
            Operational Checkout Procedure....9446
            Overview....9446
            Symptom 1: Radar Sensor Loss of Communication....9448
            Overview....9448
            Fault Facts....9448
            Tools Required....9448
            Possible Causes....9448
            Radar Sensor Removal....9451
            Special Tools....9451
            Torque Specifications....9451
            Equipment Conditions....9451
            Removal Procedure....9451
            Follow-On Procedure....9452
            Radar Sensor Installation....9453
            Special Tools....9453
            Torque Specifications....9453
            Equipment Conditions....9453
            Installation Procedure....9453
            Follow-On Procedure....9454
            Radar Sensor Adjustment....9455
            Special Tools....9455
            Equipment Conditions....9455
            Lateral Adjustment Procedure....9456
            Vertical Adjustment Procedure....9458
            Follow-On Procedure....9460
            Bendix® Wingman® Fusion™....9461
            Overview....9461
            Adaptive Cruise Control (ACC)....9463
            Alerts....9463
            Collision Mitigation Braking....9464
            SafetyDirect Capability....9464
            Stationary Vehicle Braking (SVB)....9464
            Tech Tips....9466
            Operational Checkout Procedure....9467
            Overview....9467
            Symptom 2: Camera Sensor Loss of Communication....9470
            Overview....9470
            Fault Facts....9470
            Tools Required....9470
            Possible Causes....9470
            Symptom 3: SafetyDirect® Module Loss of Communication....9473
            Overview....9473
            Fault Facts....9473
            Tools Required....9473
            Possible Causes....9473
            Camera Removal....9476
            Special Tools....9476
            Torque Specifications....9476
            Equipment Conditions....9476
            Removal Procedure....9476
            Follow-On Procedure....9477
            Camera Installation....9478
            Special Tools....9478
            Torque Specifications....9478
            Equipment Conditions....9478
            Installation Procedure....9478
            Follow-On Procedure....9479
            SafetyDirect® Module Removal....9480
            Special Tools....9480
            Torque Specifications....9480
            Equipment Conditions....9480
            Removal Procedure....9480
            Follow-On Procedure....9480
            SafetyDirect® Module Installation....9481
            Special Tools....9481
            Torque Specifications....9481
            Equipment Conditions....9481
            Installation Procedure....9481
            Follow-On Procedure....9481
        7. Engine Accessories....9482
          Engine Cooling Fan Control....9482
          Overview....9482
          Operation....9482
          Feature Codes....9483
          Diagnostic Trouble Codes....9484
          Operational Checkout....9485
          Body Controller Signals....9486
          Body Controller Functions....9488
          Fan Control — General Information....9488
          ON/OFF Fan Control....9488
          Low Air Pressure Engine Fan Override (0595BBB)....9489
          Variable Speed Fan Control (0595AYH)....9489
          Exhaust Brake....9492
          Overview....9492
          Operation....9492
          Feature Codes....9492
          Diagnostic Trouble Codes....9492
          Operational Checkout....9494
           Exhaust Brake Switch Test....9495
          Body Controller Signals....9496
          Body Controller Functions....9496
          To activate the exhaust brake feature, the following conditions must be true:....9496
          If the conditions to activate the feature (above) are true, then the following will occur:....9496
          Remote Engine Speed Control Module (RESCM)....9497
          Overview....9497
          Operation....9497
          Feature Codes....9498
          User Programmable Parameters....9498
          Diagnostic Trouble Codes....9499
          RESCM Preliminary Check....9504
          Body Controller Signals....9505
          Body Controller Functions....9508
          Snow Valve (engine intake) (big bore engines)....9509
            Overview....9509
            Operation....9509
            Feature Codes....9510
            User Programmable Parameters....9510
            Diagnostic Trouble Codes....9510
            Snow Valve Operational Checkout....9511
            Snow Valve Mechanical Checks....9512
            Snow Valve Switch Test....9513
            Snow Valve Module Checks....9514
            Body Controller Signals....9516
            Body Controller Functions....9516
            To activate the feature, the following conditions must be true:....9516
            If the conditions to activate the feature (above) are true, then the following will occur:....9516
            If any of the following conditions occur, then the feature will be deactivated.....9517
            If any of the conditions to deactivate the feature (above) are true, then the following will occur:....9517
          Snow Valve (engine intake) (non big bore engines)....9518
            Overview....9518
            Operation....9518
            Operational Checkout....9518
            Snow Valve Mechanical Checks....9519
             Snow Valve Module Checks....9519
            Feature Codes....9520
        8. Data Link System....9521
          Overview....9521
          J1708 Datalink....9521
            J1708 Data Link (ATA)....9521
            J1708 Switch Pack Data Link....9522
            Overview....9522
        9. HVAC System....9524
          Overview....9524
          Air Distribution (General)....9526
          Air Distribution (Air Conditioning)....9528
          Air Distribution (Heat and Ventilation)....9529
          Air Distribution (Defrost)....9529
          A/C Refrigerant Flow....9530
          General Operation of the HVAC Electrical System....9532
          Operational Checkout Procedure....9533
          1.0 – Front HVAC System Operational Checkout Procedure....9533
          Symptoms....9535
          1.1 – A/C Blows Warm All the Time (Incorrect System Pressure)....9535
          Overview....9535
          Possible Causes....9535
          1.2 – Heater Does Not Blow Warm....9539
          1.3 – Compressor Does Not Cycle....9540
          Overview....9540
          Possible Causes....9540
          1.4 – Operator Not Able to Control Air Flow Outlet....9543
          Overview....9543
          Special Tools....9547
            A/C System Flush Tool 19-000-01....9547
            Servicing System RHS980C-NAV....9548
            RHS980C-NAV TEMPERATURE PROBES....9549
            REFRIGERANT IDENTIFIER ....9549
            Air Conditioning Oil and Dye Injection Equipment 12401-NAV....9550
            D-400A AND D440A-NAV REFRIGERANT LEAK DETECTORS....9551
            TOOLS OBTAINED LOCALLY....9552
            Fault Codes....9554
            SPN 876 FMI 5 – Compressor Clutch Circuit ....9554
            Fault Overview....9554
            Associated Faults....9554
            Fault Facts....9554
            Possible Causes....9554
            SPN 1079 FMI 1 – 5 Volt Sensor Supply Below Normal....9555
            SPN 1552 FMI 2 – A/C Control Head Temperature Mix DM1....9556
            Fault Overview....9556
            Associated Faults....9556
            Fault Facts....9556
            Possible Causes....9556
            Pin-Point Test SPN 1552 FMI 2....9557
            Tools Required....9557
            SPN 2609 FMI 16 – A/C High Pressure Protection....9558
            Fault Overview....9558
            Associated Faults....9558
            Fault Facts....9558
            Possible Causes....9558
            SPN 3981 FMI 2 – A/C Control Head Mode Fault DM1....9561
            Fault Overview....9561
            Associated Faults....9561
            Fault Facts....9561
            Possible Causes....9561
            Pin-Point Test SPN 3981 FMI 2....9562
            Tools Required....9562
            SPN 3984 FMI 2 – A/C Control Head Air Inlet DM1....9563
            Fault Overview....9563
            Associated Faults....9563
            Fault Facts....9563
            Possible Causes....9563
            Pin-Point Test SPN 3984 FMI 2....9564
            Tools Required....9564
            SPN 3985 FMI 9 – A/C Control Head Circuit Failed To Communicate With Body Controller....9565
            Fault Overview....9565
            Associated Faults....9565
            Fault Facts....9565
            Possible Causes....9565
            Pin-Point Test SPN 3985 FMI 9....9566
            Tools Required....9566
            SPN 520465 FMI 2 – A/C Control Head Multiple Motor Faults....9568
            Fault Overview....9568
            Associated Faults....9568
            Fault Facts....9568
            Possible Causes....9568
            Pin-Point Test SPN 520465 FMI 2....9570
            Tools Required....9570
            Tests and Inspections....9573
            A/C Compressor Clutch Electrical Tests....9573
            Overview....9573
            Tools Required....9573
            Equipment Condition....9573
            Test Setup....9573
            Test Procedure....9573
            Expected Outcome....9576
            Follow-On Procedure....9576
            A/C Request Electrical Tests....9577
            Overview....9577
            Tools Required....9577
            Equipment Condition....9577
            Test Setup....9577
            Test Procedure....9577
            Expected Outcome....9578
            Follow-On Procedure....9578
            A/C System Functional Test....9579
            Overview....9579
            Tools Required....9579
            Equipment Condition....9579
            Test Setup....9579
            Test Procedure....9579
            Expected Outcome....9579
            Follow-On Procedure....9579
            A/C System Inspection....9580
            Overview....9580
            Tools Required....9580
            Equipment Condition....9580
            Inspection Procedure....9581
            Expected Outcome....9588
            A/C System Internal Damage Inspection....9589
            Overview....9589
            Tools Required....9589
            Equipment Condition....9589
            Inspection Procedure....9589
            Expected Outcome....9592
            A/C System Restriction Test....9593
            Overview....9593
            Tools Required....9593
            Equipment Condition....9593
            Test Setup....9593
            Test Procedure....9593
            Expected Outcome....9594
            Blend Door Tests....9595
            Overview....9595
            Tools Required....9595
            Equipment Condition....9595
            Test Setup....9595
            Test Procedure....9596
            Expected Outcome....9599
            Follow-On Procedure....9599
            Blower Motor Electrical Tests....9600
            Overview....9600
            Tools Required....9600
            Equipment Condition....9600
            Test Setup....9600
            Test Procedure....9600
            Expected Outcome....9603
            Follow-On Procedure....9603
            Body Controller Power and GND Tests....9605
            Overview....9605
            Tools Required....9605
            Equipment Condition....9605
            Test Setup....9605
            Test Procedure....9605
            Expected Outcome....9606
            Follow-On Procedure....9606
            Charge Quantity Measurement Test....9607
            Overview....9607
            Tools Required....9607
            Equipment Condition....9607
            Test Setup....9607
            Test Procedure....9607
            Expected Outcome....9607
            Compressor Clutch Signal Check....9608
            Overview....9608
            Tools Required....9608
            Equipment Condition....9608
            Test Setup....9608
            Test Procedure....9609
            Expected Outcome....9611
            Follow-On Procedure....9611
            Control Head Electrical Tests....9612
            Overview....9612
            Tools Required....9612
            Equipment Condition....9612
            Test Setup....9612
            Test Procedure....9612
            Expected Outcome....9614
            Follow On Procedure....9614
            Freeze Probe Electrical Tests....9615
            Overview....9615
            Tools Required....9615
            Equipment Condition....9615
            Test Setup....9615
            Test Procedure....9615
            Expected Outcome....9617
            Follow On Procedure....9617
            Heater Core Seal Leak Test....9618
            Overview....9618
            Tools Required....9618
            Equipment Condition....9618
            Test Setup....9618
            Test Procedure....9619
            Expected Outcome....9620
            Follow On Procedure....9620
            HVAC Actuator Calibration Procedure....9621
            Overview....9621
            Tools Required....9621
            Equipment Condition....9621
            Test Setup....9621
            Test Procedure....9621
            Expected Outcome....9621
            HVAC Module Inspection....9622
            Overview....9622
            Tools Required....9622
            Equipment Condition....9622
            Test Setup....9622
            Inspection Procedure....9622
            Expected Outcome....9624
            Leak Detection Test....9625
            Overview....9625
            Tools Required....9625
            Equipment Condition....9625
            Test Procedure Refrigerant Present....9625
            Test Procedure No Refrigerant Present....9626
            Test Procedure No Refrigerant Present - High Pressure Nitrogen....9627
            Expected Outcome....9628
            Low-Pressure Switch Electrical Tests....9629
            Overview....9629
            Tools Required....9629
            Equipment Condition....9629
            Test Setup....9629
            Test Procedure....9629
            Expected Outcome....9631
            Follow On Procedure....9631
            Mode Door Tests....9632
            Overview....9632
            Tools Required....9632
            Equipment Condition....9632
            Test Setup....9632
            Test Procedure....9633
            Expected Outcome....9636
            Follow On Procedure....9636
            Pressure Transducer Electrical Tests....9637
            Overview....9637
            Tools Required....9637
            Equipment Condition....9637
            Three-wire Pressure Transducer Test Procedure....9637
            Expected Outcome....9639
            Pressure Transducer Functional Test....9640
            Overview....9640
            Tools Required....9640
            Equipment Condition....9640
            Test Setup....9640
            Pressure Test Procedure....9640
            Temperature Test Procedure....9640
            Expected Outcome....9641
            Recirculation Door Tests....9642
            Overview....9642
            Tools Required....9642
            Equipment Condition....9642
            Test Setup....9642
            Test Procedure....9643
            Expected Outcome....9646
            Follow On Procedure....9646
            Static Pressure Test....9647
            Overview....9647
            Tools Required....9647
            Equipment Condition....9647
            Test Setup....9647
            Test Procedure....9647
            Expected Outcome....9648
            Follow On Procedure....9648
            System Performance Test....9649
            Overview....9649
            Tools Required....9649
            Equipment Condition....9649
            Test Setup....9649
            Test Procedure....9649
            Expected Outcome....9650
            Follow-On Procedure....9650
            Switch Pack Electrical Tests....9651
            Overview....9651
            Tools Required....9651
            Equipment Condition....9651
            Test Setup....9651
            Test Procedure....9651
            Expected Outcome....9654
            Follow On Procedure....9654
          Flush and Purge HVAC System....9656
            Flush HVAC System....9656
            Overview....9656
            Tools Required....9658
            Equipment Conditions....9661
            Flush Procedure....9662
            Refrigerant Line Flush....9669
            Purge HVAC System....9670
            Overview....9670
            Purge Procedure....9671
          Service Procedures....9672
            Charging the System (Charge Mode)....9672
            Checking Compressor Oil Level....9673
            Discharging the System (Recycle Mode)....9676
            Evacuating the System (Vacuum Mode)....9678
            Oil Fill....9680
            Oil Fill Guidelines....9680
            Oil Separation During Refrigerant Recovery....9682
            Excessive Oil Loss Due to Refrigerant Leaks....9682
            Refrigerant Identification....9685
            Overview....9685
            Tools Required....9685
            Procedure....9685
            Remove and Install Procedures....9686
            A / C Condenser – Removal....9686
            Analog Controls – Installation....9687
            Blend Door Actuator – Removal....9688
            Blend Door Actuator – Installation....9689
            Blend Door Gear Train – Removal....9690
            Blend Door Gear Train – Installation....9693
            Blower Assembly – Removal....9694
            Blower Assembly – Installation....9695
            Blower Scroll Housing – Removal....9696
            Blower Scroll Housing – Installation....9697
            Compressor / Clutch – Removal....9698
            Digital Controls – Installation....9699
            Evaporator – Removal....9700
            Evaporator – Installation....9701
            Filter-Drier – Removal....9702
            Filter-Drier – Installation....9704
            Front HVAC Module – Removal....9705
            Freeze Probe – Removal....9711
            Freeze Probe – Installation....9712
            Fresh Air Module – Removal....9713
            Fresh Air Module – Installation....9715
            Heater Core – Removal....9716
            Heater Core – Installation....9718
            Heater Hoses / Lines....9719
            HVAC Air Filter – Removal....9720
            HVAC Air Filter – Installation....9721
            HVAC Control Panel Assembly – Removal....9722
            HVAC Control Panel Assembly – Installation....9723
            Interior Module – Installation....9724
            Interior Module Trim Cover – Removal....9726
            Interior Module Trim Cover – Installation....9727
            Linear Power Module (LPM) – Removal....9728
            Linear Power Module (LPM) – Installation....9730
            Low Pressure Switch – Removal....9731
            Low Pressure Switch – Installation....9732
            Mode Door Actuator – Removal....9733
            Mode Door Actuator – Installation....9734
            Mode Door Gear Train – Removal....9735
            Mode Door Gear Train – Installation....9738
            Pressure Transducer – Removal....9739
            Pressure Transducer – Installation....9740
            Recirculation Door Actuator – Removal....9741
            Recirculation Door Actuator – Installation....9742
            Recirculation Door Gear Train – Removal....9743
            Recirculation Door Gear Train – Installation....9745
            Recirculation Filters – Removal....9746
            Recirculation Filters – Installation....9748
            Recirculation, Mode, and Blend Doors – Removal....9749
            Refrigerant Line – Removal....9750
            Refrigerant Line – Installation....9752
            Separating Blower Scroll Housing – Removal....9753
            Separating Front HVAC Module – Removal....9755
            Splitting / Separating Blower Scroll Housing – Installation....9758
            Splitting / Separating Interior Module – Installation....9759
            Thermostatic Expansion Valve (TXV) – Removal....9760
            Thermostatic Expansion Valve (TXV) – Installation....9761
        10. Instrumentation and Gauges....9762
          Overview....9762
          Operational Checkout Procedure....9762
          Overview....9762
          Step-Based Diagnostics....9763
          Audible Alarm....9765
            One-time Five-short-beeps Alarm....9765
            Repetitive One-short-beep Alarm....9765
            One-time Ten-short-beeps Alarm ....9765
            One-time Three-long-beeps Alarm....9766
            Repetitive Short Duration Blips ....9766
          EGC Programming....9766
          Gauges....9767
            Air 1 Gauge....9767
            Overview....9767
            Possible Causes....9768
            Step Based Diagnostics....9768
            Pin-Point Tests — Air 1 Gauge....9771
            Tools Required....9772
            Air 2 Gauge....9780
            Overview....9780
            Possible Causes....9781
            Step Based Diagnostics....9781
            Pin-Point Tests — Air 2 Gauge....9784
            Tools Required....9785
            Auxiliary Gauge Switch Pack....9792
            Overview....9792
            In-Gauge Warning Lamps....9792
            Gauge Sweep....9792
            Lost Communication....9793
            Gauge Faults....9794
            Diagnostic Trouble Codes....9795
            Operational Checkout Procedure....9797
            Eaton Hybrid Auxiliary Gauge Pack....9798
            AGSP Power and Data Link Voltage Checks....9798
            Gauge Troubleshooting Procedure....9799
            Troubleshooting Specific Gauges....9800
            Forward-Rear Axle Temperature Gauge Troubleshooting....9800
            Rear-Rear Axle Temperature Gauge Troubleshooting....9802
            Air Application Gauge Troubleshooting....9806
            Ammeter Gauge Troubleshooting....9808
            Compass Display....9808
            Overview....9808
            Diagnostic Trouble Codes....9809
            DEF Level....9811
            Overview....9811
            Possible Causes....9811
            Step Based Diagnostics....9811
            Engine Coolant Temperature....9813
            Overview....9813
            Step Based Diagnostics....9813
            Engine Oil Pressure....9814
            Overview....9814
            Step Based Diagnostics....9814
            Engine Oil Temperature....9815
            Overview....9815
            Step Based Diagnostics....9815
            Engine Speed (Tachometer)....9816
            Overview....9816
            Step Based Diagnostics....9816
            Fuel Level....9817
            Overview....9817
            Possible Causes....9817
            Step Based Diagnostics....9818
            Outside Air Temperature....9823
            Overview....9823
            Step Based Diagnostics....9824
            Transmission Temperature....9826
            Overview....9826
            Possible Causes....9826
            Step-Based Diagnostics....9826
            Pin-Point Tests....9830
            Vehicle Speed (Speedometer)....9832
            Overview....9832
            Step Based Diagnostics....9832
            Voltage....9833
            Overview....9833
            Possible Causes....9833
            Step Based Diagnostics....9833
            Special Tools....9833
        11. Interior Lighting....9835
          Dome and Courtesy Lights....9835
            Overview....9835
            Operational Checkout Procedure....9836
            Dome and Courtesy Light Tests....9837
        12. Exterior Lighting....9839
          Back Up Lights....9839
            Overview....9839
            Operational Checkout Procedure....9840
            Back Up Lights Test....9841
          Brake Switch ....9843
            Operational Checkout Procedure....9844
            Air Brakes - Feature Code 4091 / 4092 ....9848
            Overview....9848
            Brake Switch is Not Working....9851
            Feature Code Overview....9851
            Fault Facts....9851
            Possible Causes....9851
            Pin-Point Test - Feature Code 4091 / 4092....9854
            Tools Required....9854
            SPN 597 FMI 0 - Brake Switch Input short to PWR with Air Brakes 4091 / 4092....9857
            Fault Overview....9857
            Associated Faults....9857
            Fault Facts....9857
            Possible Causes....9857
            Pin-Point Test - SPN 597 FMI 0 with Air Brakes (4091 / 4092)....9859
            Tools Required....9859
            SPN 597 FMI 1 - Brake Switch Reading Below Normal Range with Air Brakes 4091 / 4092....9863
            Fault Overview....9863
            Associated Faults....9863
            Fault Facts....9863
            Possible Causes....9863
            SPN 597 FMI 2 - Analog Brake Switch signal does not agree with Digital brake switch signal....9865
            Fault Overview....9865
            Associated Faults....9865
            Fault Facts....9865
            Possible Causes....9865
            Full Power Hydraulic Brakes - Feature Code 4085....9867
            Overview....9867
            Brake Switch Not Working....9870
            Overview....9870
            Fault Facts....9870
            Possible Causes....9870
            Pin-Point Test - Full Power Hydraulic Brakes (4085)....9873
            Tools Required....9873
            SPN 597 FMI 0 - Brake Switch Input short to PWR with Full Power Hydraulic Brakes (4085)....9878
            Fault Overview....9878
            Associated Faults....9878
            Fault Facts....9878
            Possible Causes....9878
            Pin-Point Test - SPN 597 FMI 0 Full Power Hydraulic Brakes 4085....9880
            Tools Required....9880
            SPN 597 FMI 1 - Brake Switch Reading Below Normal Range with Hydraulic Brakes 4085....9881
            Fault Overview....9881
            Associated Faults....9881
            Fault Facts....9881
            Possible Causes....9881
            SPN 597 FMI 2 - Analog Brake Switch signal does not agree with Digital brake switch signal....9883
            Fault Overview....9883
            Associated Faults....9883
            Fault Facts....9883
            Possible Causes....9883
            SPN 597 FMI 3 - Voltage above Normal or Short to High Source with Full Power Hydraulic Brakes 4085....9885
            Fault Overview....9885
            Associated Faults....9885
            Fault Facts....9885
            Possible Causes....9885
            Pin-Point Test - SPN 597 FMI 3 with Full Power Hydraulic Brakes (4085)....9887
            Tools Required....9887
            SPN 3541 FMI 6- Current above normal or Grounded Circuit with Full Power Hydraulic Brakes 4085....9889
            Fault Overview....9889
            Associated Faults....9889
            Fault Facts....9889
            Possible Causes....9889
            Pin-Point Test - SPN 3541 FMI 6 with Full Power Hydraulic Brakes (4085)....9891
            Tools Required....9891
          Fog Lights....9893
            Overview....9893
            Operational Checkout Procedure....9895
            Overview....9895
            Fog Light Input Diagnostics....9898
            Fault Overview....9898
            Fault Facts....9898
            Possible Causes....9898
            Fog Light Output - Not Illuminating....9900
            Fault Overview....9900
            Fault Facts....9900
            Possible Causes....9900
            Pin-Point Test - Fog Light Output - Not Illuminating....9905
            Tools Required....9905
            Fog Light Output Diagnostics - Illuminating When Not Requested....9909
            Fault Overview....9909
            Fault Facts....9909
            Possible Causes....9909
            Pin-Point Test -Fog Light Output - Illuminating When Not Requested....9912
            Tools Required....9912
            SPN 2388 FMI 5 - Left Fog Light Open Circuit....9914
            Fault Overview....9914
            Associated Faults....9914
            Fault Facts....9914
            Possible Causes....9914
            Pin-Point Test - SPN 2388 FMI 5....9916
            Tools Required....9916
            SPN 2388 FMI 6 - Left Fog Light Short to GND....9918
            Fault Overview....9918
            Associated Faults....9918
            Fault Facts....9918
            Possible Causes....9918
            Pin-Point Test - SPN 2388 FMI 6....9920
            Tools Required....9920
            SPN 4008 FMI 5 - Right Fog Light Open Circuit....9922
            Fault Overview....9922
            Associated Faults....9922
            Fault Facts....9922
            Possible Causes....9922
            Pin-Point Test - SPN 4008 FMI 5....9924
            Tools Required....9924
            SPN 4008 FMI 6 - Right Fog Light Short to GND....9926
            Fault Overview....9926
            Associated Faults....9926
            Fault Facts....9926
            Possible Causes....9926
            Pin-Point Test - SPN 4008 FMI 6....9928
            Tools Required....9928
          Headlights and Daytime Running Lights....9930
            Overview....9930
            Operational Checkout Procedure....9933
            Overview....9933
            Low Beam Input Diagnostics....9938
            Fault Overview....9938
            Fault Facts....9938
            Possible Causes....9938
            Low Beam Output Diagnostics - Not illuminating....9940
            Fault Overview....9940
            Fault Facts....9940
            Possible Causes....9940
            Pin-Point Test - Low Beam Head Lamp Output - Not Illuminating....9945
            Tools Required....9945
            Low Beam Output Diagnostics - Illuminating When Not Requested....9949
            Fault Overview....9949
            Fault Facts....9949
            Possible Causes....9949
            Pin-Point Test - Low Beam Head Lamp Output - Illuminating When Not Requested....9952
            Tools Required....9952
            SPN 2653 FMI 5 - Left Low Beam Open Circuit....9954
            Fault Overview....9954
            Associated Faults....9954
            Fault Facts....9954
            Possible Causes....9954
            Pin-Point Test - SPN 2653 FMI 5....9956
            Tools Required....9956
            Pin-Point Test - SPN 2653 FMI 5....9957
            SPN 2653 FMI 6 - Left Low Beam Short to GND....9958
            Fault Overview....9958
            Associated Faults....9958
            Fault Facts....9958
            Possible Causes....9958
            Pin-Point Test - SPN 2653 FMI 6....9960
            Tools Required....9960
            SPN 2655 FMI 5 - Right Low Beam Open Circuit....9961
            Fault Overview....9961
            Associated Faults....9961
            Fault Facts....9961
            Possible Causes....9961
            Pin-Point Test - SPN 2655 FMI 5....9963
            Tools Required....9963
            SPN 2655 FMI 6 - Right Low Beam Short to GND....9964
            Fault Overview....9964
            Associated Faults....9964
            Fault Facts....9964
            Possible Causes....9964
            Pin-Point Test - SPN 2655 FMI 6....9966
            Tools Required....9966
            High Beam Input Diagnostics....9967
            Fault Overview....9967
            Fault Facts....9967
            Possible Causes....9967
            Pin-Point Test - High Beam Lamps Input....9970
            Tools Required....9970
            High Beam Output Diagnostics - Not Illuminating....9973
            Fault Overview....9973
            Fault Facts....9973
            Possible Causes....9973
            Pin-Point Test - High Beam Head Lamp Output - Not Illuminating....9978
            Tools Required....9978
            High Beam Output Diagnostics - Illuminating When Not Requested....9982
            Fault Overview....9982
            Fault Facts....9982
            Possible Causes....9982
            Pin-Point Test - High Beam Head Lamp Output - Illuminating When Not Requested....9985
            Tools Required....9985
            SPN 4011 FMI 5 - Left High Beam Open Circuit....9987
            Fault Overview....9987
            Associated Faults....9987
            Fault Facts....9987
            Possible Causes....9987
            Pin-Point Test - SPN 4011 FMI 5....9989
            Tools Required....9989
            SPN 4011 FMI 6 - Left High Beam Short to Ground....9990
            Fault Overview....9990
            Associated Faults....9990
            Fault Facts....9990
            Possible Causes....9990
            Pin-Point Test - SPN 4011 FMI 6....9992
            Tools Required....9992
            SPN 4012 FMI 5 - Right High beam Open Circuit....9993
            Fault Overview....9993
            Associated Faults....9993
            Fault Facts....9993
            Possible Causes....9993
            Pin-Point Test - SPN 4012 FMI 5....9995
            Tools Required....9995
            SPN 4012 FMI 6 - Right High Beam Short to Ground....9996
            Fault Overview....9996
            Associated Faults....9996
            Fault Facts....9996
            Possible Causes....9996
            Pin-Point Test - SPN 4012 FMI 6....9998
            Tools Required....9998
          Park and Marker Lights....9999
            Overview....9999
            Operational Checkout Procedure....10001
            Overview....10001
            Park Light Input Diagnostics....10005
            Fault Overview....10005
            Fault Facts....10005
            Possible Causes....10005
            Park Light Output - Not Illuminating....10007
            Fault Overview....10007
            Fault Facts....10007
            Possible Causes....10007
            Pin-Point Test - Park Light Output - Not Illuminating....10010
            Tools Required....10010
            Park Light Output Diagnostics - Illuminating When Not Requested....10012
            Fault Overview....10012
            Fault Facts....10012
            Possible Causes....10012
            Pin-Point Test - Park Light Output - Illuminating When Not Requested....10014
            Tools Required....10014
            SPN 2378 FMI 5 - Park Light UnderCurrent....10016
            Fault Overview....10016
            Associated Faults....10016
            Fault Facts....10016
            Possible Causes....10016
            Pin-Point Test - SPN 2378 FMI 5....10018
            Tools Required....10018
            SPN 2378 FMI 6 - Park Light OverCurrent....10020
            Fault Overview....10020
            Associated Faults....10020
            Fault Facts....10020
            Possible Causes....10020
            Pin-Point Test - SPN 2378 FMI 6....10022
            Tools Required....10022
            SPN 40242 FMI 2 - Marker Light Interrupt Switch Failure....10024
            Fault Overview....10024
            Associated Faults....10024
            Fault Facts....10024
            Possible Causes....10024
          Snow Plow Lights....10026
            Snow Plow Light System Overview....10026
            Operational Checkout Procedure....10028
            Overview....10028
            Snow Plow Light Input Diagnostics....10031
            Fault Overview....10031
            Fault Facts....10031
            Possible Causes....10031
            Snow Plow Light Output - Not Illuminating....10033
            Fault Overview....10033
            Fault Facts....10033
            Possible Causes....10033
            Pin-Point Test - Snow Plow Light Output - Not Illuminating....10037
            Tools Required....10037
            Snow Plow Low Beam Gen 4 Output - Not illuminating....10038
            Fault Overview....10038
            Fault Facts....10038
            Possible Causes....10038
            Pin-Point Test - Snow Plow Low Beam Gen 4 Output - Not illuminating....10041
            Tools Required....10041
            Snow Plow High Beam Gen 4 Output - Not illuminating....10042
            Fault Overview....10042
            Fault Facts....10042
            Possible Causes....10042
            Pin-Point Test - Snow Plow High Beam Gen 4 Output - Not illuminating....10045
            Tools Required....10045
          Stop, Turn, and Hazard Lights....10046
            Overview....10046
            Operational Checkout Procedure....10047
            Overview....10047
            Turn Signal, Hazard, and Front Turn Lamp Diagnostics....10055
            Overview....10055
            Hazard Input Diagnostics....10057
            Feature Code Overview....10057
            Fault Facts....10057
            Possible Causes....10057
            Pin-Point Test - Hazard Input Diagnostics....10060
            Tools Required....10060
            Turn Signal Input Diagnostics....10066
            Feature Code Overview....10066
            Fault Facts....10066
            Possible Causes....10066
            Pin-Point Test - Turn Signal Input Diagnostics....10069
            Tools Required....10069
            Front Turn Lamp Not Illuminating....10075
            Feature Code Overview....10075
            Fault Facts....10075
            Possible Causes....10075
            Pin-Point Test- Front Turn Lamp Output Not Illuminating....10079
            Tools Required....10079
            Front Turn Lamps Illuminating When Not Requested....10083
            Feature Code Overview....10083
            Fault Facts....10083
            Possible Causes....10083
            Pin-Point Test - Front Turn Lamps Illuminating When Not Requested....10085
            Tools Required....10085
            SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10087
            Fault Overview....10087
            Associated Faults....10087
            Fault Facts....10087
            Possible Causes....10087
            Pin-Point Test SPN 2368 FMI 5....10089
            Tools Required....10089
            SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10091
            Fault Overview....10091
            Associated Faults....10091
            Fault Facts....10091
            Possible Causes....10091
            Pin-Point Test SPN 2368 FMI 6....10093
            Tools Required....10093
            SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10095
            Fault Overview....10095
            Associated Faults....10095
            Fault Facts....10095
            Possible Causes....10095
            Pin-Point Test SPN 2370 FMI 5....10097
            Tools Required....10097
            SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10099
            Fault Overview....10099
            Associated Faults....10099
            Fault Facts....10099
            Possible Causes....10099
            Pin-Point Test SPN 2370 FMI 6....10101
            Tools Required....10101
            Combined Stop and Turn Lamps Diagnostics....10103
            Overview....10103
            Combined Stop and Turn Lamps - Rear Turn Lamp Not Illuminating....10105
            Feature Code Overview....10105
            Fault Facts....10105
            Possible Causes....10105
            Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....10109
            Tools Required....10109
            Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10113
            Feature Code Overview....10113
            Fault Facts....10113
            Possible Causes....10113
            Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10115
            Tools Required....10115
            SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10117
            Fault Overview....10117
            Associated Fault....10117
            Fault Facts....10117
            Possible Causes....10117
            Pin-Point Test SPN 2372 FMI 5....10119
            Tools Required....10119
            SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10121
            Fault Overview....10121
            Associated Faults....10121
            Fault Facts....10121
            Possible Causes....10121
            Pin-Point Test SPN 2372 FMI 6....10123
            Tools Required....10123
            SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10125
            Fault Overview....10125
            Associated Faults....10125
            Fault Facts....10125
            Possible Causes....10125
            Pin-Point Test SPN 2374 FMI 5....10127
            Tools Required....10127
            SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10129
            Fault Overview....10129
            Associated Faults....10129
            Fault Facts....10129
            Possible Causes....10129
            Pin-Point Test SPN 2374 FMI 6....10131
            Tools Required....10131
            Separate Stop and Turn Lamps Diagnostics....10133
            Overview....10133
            Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....10134
            Feature Code Overview....10134
            Fault Facts....10134
            Possible Causes....10134
            Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....10138
            Tools Required....10138
            Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10142
            Feature Code Overview....10142
            Fault Facts....10142
            Possible Causes....10142
            Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10144
            Tools Required....10144
            Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....10146
            Feature Code Overview....10146
            Fault Facts....10146
            Possible Causes....10146
            Pin-Point Test - Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....10149
            Tools Required....10149
            Separate Stop and Turn Lamps- Stop Lamps Illuminating When Not Requested....10153
            Feature Code Overview....10153
            Fault Facts....10153
            Possible Causes....10153
            Pin-Point Test - Separate Stop and Turn Lamps- Rear Stop Lamps Illuminating When Not Requested....10155
            Tools Required....10155
          Trailer Lighting....10157
            Trailer Lighting Overview....10157
            Operational Checkout Procedure....10159
            Overview....10159
            Pin-Point Test - Trailer Lights Operational Checkout Procedure....10161
            Tools Required....10161
            Trailer Marker Lights - Not Illuminating....10165
            Fault Overview....10165
            Fault Facts....10165
            Possible Causes....10165
            Pin-Point Test - Trailer Marker Light Output - Not Illuminating....10168
            Tools Required....10168
            Trailer Tail Lights - Not Illuminating....10174
            Fault Overview....10174
            Fault Facts....10174
            Possible Causes....10174
            Pin-Point Test - Trailer Tail Light Output - Not Illuminating....10177
            Tools Required....10177
            Trailer Left Turn Lights - Not Illuminating....10183
            Fault Overview....10183
            Fault Facts....10183
            Possible Causes....10183
            Pin-Point Test - Trailer Left Turn Output - Not Illuminating....10186
            Tools Required....10186
            Trailer Right Turn Lights - Not Illuminating....10192
            Fault Overview....10192
            Fault Facts....10192
            Possible Causes....10192
            Pin-Point Test - Trailer Right Turn Output - Not Illuminating....10195
            Tools Required....10195
            Trailer Brake Lights - Not Illuminating....10201
            Fault Overview....10201
            Fault Facts....10201
            Possible Causes....10201
            Pin-Point Test - Trailer Brake Light Output - Not Illuminating....10204
            Tools Required....10204
            Trailer Auxiliary Power Circuit....10210
            Overview....10210
            Operational Checkout Procedure....10211
            Trailer Auxiliary Power Test....10212
            Electric Trailer Brakes....10213
            Overview....10213
            Operational Checkout Procedure....10214
            Electric Trailer Brake Test....10215
          Work Lights....10217
            Overview....10217
            Operation....10217
            Operational Checkout Procedure....10219
            Work Light Test....10220
        13. Transmission....10222
          Operation....10222
          Available Body Controller Configurations....10224
          User Programmable Parameters....10227
          Diagnostic Trouble Codes....10228
          Operational Checkout — All Transmissions....10230
          Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....10235
          LCT Column Shifter Interlock Checks....10236
          TCM Power, Ground and Data Link Circuit Checks....10237
          Shift Selector Power and Ground Circuit Checks....10238
          Body Controller Signals....10239
          Body Controller Functions....10241
            Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....10241
            PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....10241
          Auto Neutral....10242
            Auto Neutral Overview....10242
            Overview....10242
            Operational Checkout Procedure....10243
            Overview....10243
            Auto Neutral with Gen 2 Body Controller....10244
            Overview....10244
            Diagnostic Trouble Codes....10245
            Activate Auto Neutral....10247
            Error Operation....10248
            Operational Checkout Procedure....10249
            Auto Neutral Does Not Engage....10250
            Auto Neutral Does Not Disengage....10251
            Auto Neutral Warning Lamp Inoperative....10252
            Auto Neutral with Gen 4 Body Controller....10254
            Overview....10254
            Auto Neutral Not Working Gen 4 Body Controller....10255
            Fault Overview....10255
            Fault Facts....10255
            Possible Causes....10255
        14. Windshield Wiper System....10258
          Windshield Wiper Diagnostics....10258
            Overview....10258
            Wiper Operation....10258
            Park Operation....10258
            Washer Operation....10258
            Operational Checkout Procedure....10263
            Overview....10263
            Windshield Wiper Input 0 Not Working....10269
            Fault Overview....10269
            Fault Fact....10269
            Possible Causes....10269
            Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working....10272
            Tools Required....10272
            Windshield Wiper Input 1 Not Working....10276
            Feature Overview....10276
            Fault Fact....10276
            Possible Causes....10276
            Pin-Point Test - Windshield Wiper Input 1 Not Working....10278
            Tools Required....10278
            Windshield Wiper Input 2 Not Working....10282
            Feature Overview....10282
            Fault Fact....10282
            Possible Causes....10282
            Pin-Point Test - Windshield Wiper Input 2 Not Working....10285
            Tools Required....10285
            Windshield Wiper Low Speed Not Functioning....10289
            Feature Code Overview....10289
            Fault Facts....10289
            Possible Causes....10289
            Pin-Point Test - Windshield Wiper Low Speed Not Functioning....10294
            Tools Required....10294
            Windshield Wiper High Speed Not Functioning....10301
            Feature Code Overview....10301
            Fault Facts....10301
            Possible Causes....10301
            Pin-Point Test - Windshield Wiper High Speed Not Functioning....10306
            Tools Required....10306
            SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit....10314
            Fault Overview....10314
            Associated Faults....10314
            Fault Facts....10314
            Possible Causes....10314
            Pin-Point Test - SPN 2636 FMI 5....10316
            Tools Required....10316
            SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current....10318
            Fault Overview....10318
            Associated Faults....10318
            Fault Facts....10318
            Possible Causes....10318
            Pin-Point Test - SPN 2636 FMI 6....10319
            Tools Required....10319
            SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or High Resistance....10321
            Fault Overview....10321
            Associated Faults....10321
            Fault Facts....10321
            Possible Causes....10321
            Pin-Point Test - SPN 2637 FMI 5....10323
            Tools Required....10323
            SPN 2637 FMI 6 - Wiper High / Low Relay Over Current....10325
            Fault Overview....10325
            Associated Faults....10325
            Fault Facts....10325
            Possible Causes....10325
            Pin-Point Test - SPN 2637 FMI 6....10327
            Tools Required....10327
            SPN 4057 FMI 5 - Wiper Motor Under Current....10329
            Fault Overview....10329
            Associated Faults....10329
            Fault Facts....10329
            Possible Causes....10329
            Pin-Point Test - SPN 4057 FMI 5....10333
            Tools Required....10333
            SPN 4057 FMI 6 - Wiper Motor Over Current....10339
            Fault Overview....10339
            Associated Faults....10339
            Fault Facts....10339
            Possible Causes....10339
            Pin-Point Test - SPN 4057 FMI 6....10343
            Tools Required....10343
            Windshield Washer Pump is Not Working with Windshield Wipers....10347
            Feature Overview....10347
            Fault Fact....10347
            Possible Causes....10347
            Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....10350
            Tools Required....10350
            Windshield Wiper Not Working with Washer Pump....10355
            Feature Overview....10355
            Fault Fact....10355
            Possible Causes....10355
            Pin-Point Test - Windshield Wiper Not Working with Washer Pump....10357
            Tools Required....10357
            Windshield Wiper and Washer Pump Not Working....10359
            Feature Overview....10359
            Fault Fact....10359
            Possible Causes....10359
            Pin-Point Test - Windshield Wiper and Washer Pump Not Working....10362
            Tools Required....10362
          Windshield Washer Pump....10364
            Windshield Washer Pump is Not Working with Windshield Wipers....10364
            Feature Overview....10364
            Fault Fact....10364
            Possible Causes....10364
            Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....10368
            Tools Required....10368
            Windshield Wiper Not Working with Washer Pump....10373
            Feature Overview....10373
            Fault Fact....10373
            Possible Causes....10373
            Pin-Point Test - Windshield Wiper Not Working with Washer Pump....10375
            Tools Required....10375
            Windshield Wiper and Washer Pump Not Working....10377
            Feature Overview....10377
            Fault Fact....10377
            Possible Causes....10377
            Pin-Point Test - Windshield Wiper and Washer Pump Not Working....10380
            Tools Required....10380
      Front End....10384
        1. Hood, Grille, Fenders, and Bumper — 4100, 4200, 4300, 4400....10386
          Description....10386
            Bumper....10386
            Hood....10387
            Splash Panels....10387
            Mud Guards....10388
            Grille....10388
            Air Intakes....10389
            Fenders....10390
            Fender Extensions....10390
            Hood Seal....10391
          Remove and Install....10393
            4100 / 4200 / 4300 / 4400 Series Bumper....10393
            Remove....10393
            Install....10393
            4100 / 4200 / 4300 / 4400 Series Hood....10394
            Remove....10394
            Install....10398
            Splash Panels....10400
            Remove....10400
            Passenger Side....10401
            Driver Side....10401
            Install....10402
            Mud Guards....10403
            Remove....10403
            Install....10403
            Grille....10404
            Remove....10404
            Install....10405
            Air Intakes....10406
            Remove....10406
            Install....10406
            Fenders....10407
            Overview....10407
            Fender Lower Section — Remove....10408
            Valance — Remove....10408
            Fender Valance — Install....10408
            Headlights — Remove....10410
            Headlights — Install....10411
            Clearance Lights — Remove....10412
            Clearance Lights — Install....10412
            Upper Hood Latch — Remove....10413
            Upper Hood Latch — Install....10413
            Fender Extensions....10414
             Fender Extension — Remove....10414
            Fender Extension — Install....10416
            Hood Latch Lower Assembly — Remove....10417
            Lower Hood Latch — Install....10418
            Hood Seal....10419
            Remove....10419
            Install....10420
          Adjustments....10421
            Hood Adjustment and Alignment....10421
            Hood Stop Adjustment....10422
            Headlight Adjustment....10423
            Headlamp Replacement....10424
          Torque....10426
      Fifth Wheels and Misc.....10428
      Clutch....10432
        1. Clutch Control Linkage — 2000, 4000, 7000, and 8000 Series....10434
          Maintenance....10435
            Lubrication....10435
            Inspection....10435
          Adjustment....10436
            Push Type Clutches....10437
            Overview....10437
            Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....10437
            Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....10438
            Pull Type Clutches....10439
            Overview....10439
            Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....10439
            Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....10440
          Replacement....10441
            Clutch Pedal Shaft Bushing....10441
            Relay Shaft Bushing....10443
          Troubleshooting....10445
          Specifications....10446
          Torque....10447
      Engines....10448
        1. Radiator / Cooling System....10450
          DESCRIPTION....10450
          Surge Tank (If Equipped)....10451
          Deaeration Tank....10451
          Fan Shroud....10451
          Fan Drive....10451
          A / C Condensor....10451
          Radiator / Charge Air Cooler Assembly....10451
          Cross-Member....10451
          Low Temperature Radiator (LTR)....10451
          Low Temperature Radiator (LTR) Thermostat....10451
          Fuel Cooler Control Assembly....10452
          Transmission Oil Cooler....10452
          Removal and Installation....10453
            Coolant Drain, Pressure Test, and Fill Procedures....10454
            Overview....10454
            Coolant Drain Procedure (Recommended)....10456
            Pressure Test Procedure (Recommended)....10459
            Coolant Fill Procedure (Recommended)....10462
            Coolant Gravity Drain Procedure (Optional)....10465
            Coolant Gravity Fill Procedure (optional) (MaxxForce® 7 and DT Engine)....10466
            Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....10471
            Splash Panel....10475
            Removal....10475
            Installation....10475
            Surge Tank (if equipped)....10476
            Surge Tank (with Cummins® ISB6.7 Engine) – Removal....10476
            Surge Tank (with Cummins® ISB6.7 Engine) – Installation....10477
            Deaeration Tank....10478
            Deaeration Tank (Radiators with Single Mega Bracket) - Removal....10478
            Deaeration Tank (Radiators with Single Mega Bracket) - Installation....10480
            Deaeration Tank (Radiators with Dual Mega Bracket) – Removal....10481
            Deaeration Tank (Radiators with Dual Mega Bracket) – Installation....10482
            A / C Condenser....10483
            Overview....10483
            A / C Condenser (ISB6.7) Engine – Removal....10484
            A / C Condenser – Installation....10486
            Fan Belts....10487
            Fan Belt with A / C (Cummins® ISB6.7 Engine) - Removal ....10487
            Fan Belt with A / C (Cummins® ISB6.7 Engine) – Installation ....10488
            Fan and Fan Drive Assembly....10489
            Overview....10489
            Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On....10490
            Removal....10490
            Install....10491
            Fan and 12TTB Fan Drive (Borg-Warner 790) Viscous Type, Screw On....10492
            Removal....10492
            Install....10493
            12THJ and 12THT Horton DA (optional)....10494
            Removal....10494
            Install....10495
            12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7....10496
            Removal....10496
            Install....10497
            12THJ Fan Drive Horton (DA) with ISB6.7....10498
            Removal....10498
            Install....10499
            12THT Horton (DMA) Serviceable Fan Drive....10500
            Remove....10500
            Install....10506
            12THT Pulley Bearing....10508
            Removal....10508
            Install....10508
            12THT Fan Drive Friction Liner....10509
            Removal....10509
            Install....10514
            12THT Clutch Pack Seal Face....10515
            Removal....10515
            Install....10515
            12THT Air Cartridge....10516
            Removal....10516
            Install....10518
            12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type....10521
            Removal....10521
            Install....10524
            12TTJ Fan Drive Horton VS217 Electronic Viscous Fan....10525
            Removal....10525
            Install....10531
            Fan Shroud....10532
            Overview....10532
            Fan Shroud (MaxxForce® DT and 9 Engines) - Removal....10532
            Fan Shroud (MaxxForce® DT and 9 Engines) - Installation....10535
            Fan Shroud (Cummins® ISB6.7 Engine) - Removal....10536
            Fan Shroud (Cummins® ISB6.7 Engine) - Installation....10536
            Coolant System Hoses....10537
            Overview....10537
            Heat Shrink Clamp ....10538
            Removal....10538
            Install....10539
            Deaeration Tank Hose (Single Mega Bracket) MaxxForce® 7 Engine....10542
            Removal....10542
            Install....10543
            Deaeration Tank Hose (Single Mega Bucket) MaxxForce® DT Engine without Interstage Charge Air Cooler (ISCAC) ....10544
            Removal....10544
            Install....10546
            Deaeration Tank Hose (Dual Mega Bracket) MaxxForce® DT or 9 Engine with Interstage Charge Air Cooler....10548
            Removal....10548
            Install....10554
            Deaeration Tank Hose (Dual Mega Bracket) N9® with Interstage Charge Air Cooler and SCR....10556
            Removal....10556
            Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine....10563
            Removal....10563
            Install....10565
            Fuel Cooler Valve (FCV) Hoses MaxxForce® 7 Engine....10567
            Removal....10567
            Install....10571
            Radiator Hoses DT Engine....10572
            Removal....10572
            Install....10573
            Radiator Hoses ISB6.7 One Piece....10575
            Removal....10575
            Install....10577
            Radiator Hoses MaxxForce® 7 Engine....10578
            Removal....10578
            Install....10579
            Coolant Package....10581
            Overview....10581
            Coolant Package – Removal....10581
            Coolant Package – Installation....10588
            Radiator Core / CAC Assembly....10590
            Overview....10590
            Radiator Core / CAC Assembly - Removal....10590
            Radiator Core / CAC Assembly - Installation....10592
            Fuel Cooler Control Radiator Assembly....10594
            Fuel Cooler Radiator Assembly - Removal....10594
            Fuel Cooler Radiator Assembly - Installation....10595
            Fuel Cooler Control Valve (FCCV)....10596
            Fuel Coolant Control Valve - Removal....10596
            Fuel Cooler Control Valve - Installation....10597
            Low Temperature Radiator (LTR)....10598
            Low Temperature Radiator – Removal....10598
            Low Temperature Radiator – Installation....10599
            Low Temperature Radiator (LTR) Thermostat....10600
            Low Temperature Radiator (LTR) Thermostat – Removal....10600
            Low Temperature Radiator (LTR) Thermostat – Installation....10601
            Low Temperature Radiator Hoses....10602
            Low Temperature Radiator Hoses – Removal....10602
            Low Temperature Radiator (LTR) Thermostat Hose – Installation....10606
          Removal and Installation — Cummins....10607
            Radiator and Component Removal....10607
            Cross-Member....10607
            Surge Tank....10609
            Charge Air Cooler Pipes....10612
            Cooling System Radiator Hose....10613
            Radiator....10616
            Radiator Shroud and Frame....10618
            Charge Air Cooler....10619
            Radiator Core....10619
            Radiator and Component Installation....10619
            Radiator Core....10619
            Radiator Hose....10620
            Charge Air Cooler Pipes....10622
            Surge Tank....10623
            Front Cross-Member....10623
          Cooling Package Cleaning Procedures....10625
            Overview....10625
            Cleaning Cooling Package (MaxxForce® DT, 9, and 10 Engines)....10627
            Cleaning Cooling Package (Navistar® 11 and 13 Engines)....10628
          Inspection Procedures....10630
            Deaeration Tank and Cap Inspection Procedures....10630
            Deaeration Tank....10630
            Deaeration Tank Cap Vacuum Relief Check....10632
            Fan Drive Pulley and Pulley Groove Inspection Procedures....10633
            Pulley Crack Inspection....10633
            Pulley Nick Inspection....10634
            12TTB Fan Drive (Borg-Warner 790) Viscous Type Inspection Procedures....10635
            Fan Drive Movement....10635
            12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....10636
            Fan Drive Movement....10636
            12TTJ Fan Drive Horton VS217 Inspection Procedures....10637
            Fan Drive Movement....10637
            12THT Horton Drivemaster Advantage Fan Drive Inspection Procedures....10639
            Fan Drive Movement....10639
            Clutch Pack Face Seal....10641
            Cartridge Assembly Seal and Spring....10642
            Friction Liner Measurement....10643
            Fan Drive Bearing Measurement and Inspection....10644
            12TTD Borg – Warner 842B Visctronics Inspection Procedure....10645
            Fan Drive Movement....10645
            Fuel Cooler Valve (FCV) Inspection Procedure....10646
            Fuel Cooler Valve (FCV) Filter Screen – Removal....10646
            Fuel Cooler Valve (FCV) Filter Screen – Installation....10648
          12THT and 12THJ Horton DriveMaster Advantage (DMA) Fan Drive System Diagnostics....10649
            12THT and 12THJ Horton DriveMaster Advantage (DMA) System: Operational Checkout Procedure....10649
            Overview....10649
            Operational Checks – Start Fan Drive Diagnostics Here....10650
            Visual Air Leak Check....10650
            Symptom 1: Fan Always ON....10652
            Symptom 2: Fan Always Off....10671
            Symptom 3: Fan Cycles Too Frequently....10679
            Symptom 4: Excessive Noise From Fan Drive....10681
          12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics....10684
            12TTD Borg-Warner 842B Visctronic Fan Drive: Operational Checkout Procedure....10684
            Overview....10684
            Tools Required....10684
            Operational Checks – Start Fan Drive Diagnostics Here....10684
            Symptom 1: Fan Always ON....10686
            Symptom 2: Fan Always OFF....10694
            Symptom 3: Cycles Too Frequently....10712
            Symptom 4: Excessive Noise From Fan Drive....10715
          12TTJ Horton Drivemaster VS217 Fan Drive Assembly System Diagnostics....10718
            12TTJ Horton Drivemaster VS217 Fan Drive Assembly: Operational Checkout Procedure....10718
            Overview....10718
            Tools Required....10718
            Operational Checks – Start Fan Drive Diagnostics Here....10718
            Symptom 1: Fan Always ON....10720
            Symptom 2: Fan Always OFF....10727
            Symptom 3: Fan Drive Cycles Too Frequently....10750
            Symptom 4: Excessive Noise From Fan Drive....10751
          12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....10754
            12TSY Borg-Warner SA85 Fan Drive Assembly: Operational Checkout Procdure....10754
            Overview....10754
            Tools Required....10754
          12TTB Borg-Warner Series 790 Viscous Fan Drive Assembly System Diagnostics....10756
            12TTB Borg-Warner 790 Fan Drive Assembly: Operational Checkout Procedure....10756
            Overview....10756
            Tools Required....10756
          Radiator Shutters....10758
          Overview....10758
            Operation....10760
            Overview....10760
            Air Shutter Controls....10761
            Hydraulic Shutter Controls....10761
            Shutters on Vehicles with Air Conditioning....10761
            Shutters on Vehicles with ON / OFF Fan Drive Clutch....10762
            Shutters on Vehicles with Viscous Fan Drive....10764
            Maintenance....10765
            Troubleshooting....10766
            Overview....10766
            Troubleshooting Chart....10766
            Replace....10766
            Overview....10766
            3000 / 4000 Series Vehicles....10766
            Shutter-to-Radiator....10766
            Shutter-to-Charge Air Cooler....10766
            8000 Series Vehicles....10768
            Overview....10768
            8100....10768
            8200 / 8300....10770
          Specifications....10772
      Transmissions....10774
        1. 6 Speed Transmissions International Model ES52–7A and ESO65–7A 6–Plus....10780
          General Information....10780
            How to Shift the Transmission — Synchronizer Information....10780
            Description....10780
            Upshifting....10780
            Downshifting....10781
            Towing....10781
          Troubleshooting....10782
            Important Procedure....10782
            Check Function Prior to Disassembly....10782
            Inspect Thoroughly During Disassembly....10782
            Repair or Replace Worn Part....10782
            Noisy Operation....10782
            Noise in Neutral....10784
            Noise in Gear....10784
            Back-Up Lights Do Not Operate....10784
            Oil Leaks....10784
            Walking or Jumping Out of Gear....10785
            Hard Shifting....10786
            Sticking in Gear....10786
            Bearing Failures....10786
            Dirt....10787
            Fatigue....10787
            Corrosion....10787
            Shaft Fits....10787
            Installation and Removal of Bearings....10787
            Interchangeability....10787
            Clutch Troubleshooting....10788
          Disassembly....10789
            General....10789
            Overview....10789
            Cleanliness....10789
            Bearings....10789
            Front Bearing Retainer and Seal....10789
            End Yokes and Flanges....10789
            Power Take Offs....10790
            Shift Tower....10790
            Rear Case....10792
            Main Case....10806
            Mainshaft Disassembly....10818
            Countershaft Disassembly and Reassembly....10825
          Clean and Inspection....10827
          Reassembly....10829
            Mainshaft....10829
            Main Case....10834
            Rear Case....10839
            Shift Tower....10850
            Shift Knob Installation....10851
          Lubrication....10852
            Recommended Lubricants....10852
            Oil Changes....10852
            Refill....10852
            Overfilling....10852
          Specifications....10854
          Torque....10855
        2. 6 Speed Transmissions Eaton Series FS-5106 and FS-6206....10856
          Identification....10856
          Maintenance....10857
          Precautions....10859
            Disassembly....10859
            Inspection....10859
            Reassembly....10861
          Remove....10862
            Gear Shift Lever Assembly....10862
            Shifter Housing....10863
            Yoke....10864
            Clutch Housing....10866
            Input Shaft....10868
            Mainshaft....10871
            Countershaft and Reverse Idler....10874
          Disassemble....10879
            Gear Shift Lever Assembly....10879
            Shifter Housing....10883
            Mainshaft....10889
            Countershaft and Reverse Idler....10906
          Reassemble....10913
            Gear Shift Lever Assembly....10913
            Shifter Housing....10916
            Countershaft and Reverse Idler....10922
            Mainshaft....10928
          Install....10950
            Countershaft and Reverse Idler....10950
            Mainshaft....10957
            Clutch Housing....10966
            Yoke....10967
            Shifter Housing Assembly....10968
            Gear Shift Lever Housing....10970
          Lubrication....10971
            General....10971
            Proper Oil Level....10971
            Draining Oil....10971
            Refilling....10971
            Operating Temperatures....10972
          Specifications....10973
          Torque....10974
        3. 5 Speed Transmissions Spicer ES43–5 and ES53–5....10977
          General Safety Precautions....10977
          Operation....10978
            How to Shift the Transmission....10978
            Synchronizer Information....10978
            Upshifting....10978
            Downshifting....10979
          Disassembly....10980
            General....10980
            Inspect Thoroughly During Disassembly....10980
            Rebuild Facilities....10980
            Cleanliness....10980
            Bearings....10980
            Shift Tower....10980
            Clutch Housing....10982
            Case and Shift Forks....10983
            Mainshaft....11000
          Clean and Inspect....11008
            Clean....11008
            Inspect....11008
            Clutch Gears....11008
            Gears....11008
            Thrust Washers....11008
            Snap Rings....11008
            Mainshaft....11008
            Bearings....11008
            Housings....11009
          Reassembly....11010
            General....11010
            End Yokes and Flanges....11010
            Power Take-Offs....11010
            Mainshaft....11010
            Case....11016
            Shift Tower....11033
            Shift Knob Installation....11034
          Lubrication....11036
            Recommended Lubricants....11036
            Oil Changes....11036
            Refill....11036
            Overfilling....11036
          Troubleshooting....11037
            Troubleshooting Procedure....11037
            Noisy Operation....11037
            Troubleshooting Chart....11038
            Bearings....11041
            Dirt....11041
            Fatigue....11041
            Corrosion....11042
            Shaft Fits....11042
            Installation and Removal of Bearings....11042
            Interchangeability....11042
            Clutch Troubleshooting....11042
          Specifications....11043
            Gear Ratios....11043
            Gimbal Tower Shift Pattern....11043
            Torque....11044
            Special Tools....11046
        4. 7 Speed Transmissions Spicer PS110–7, PS145–7....11047
          General Safety Precautions....11047
          Operation....11048
            How to Shift Spicer PS110–7A, PS145–7A, and PS110–7B Transmissions....11048
            Overview....11048
            Starting....11048
            Upshifting....11048
            Downshifting....11049
            Replacement Parts....11049
          Maintenance....11050
            Tool Reference....11050
            Road Test....11050
            Check Remote Control....11050
          Disassemble....11051
            General....11051
            Inspect Thoroughly During Assembly....11051
            Rebuild Facilities....11051
            Cleanliness....11051
            Bearings....11051
            Power Take-Offs....11051
            Shift Tower....11052
            Remote Control....11054
            Shifter Housing....11055
            Case and Gears....11060
            Mainshaft....11074
            Input Shaft....11081
          Clean and Inspect....11082
            Clean....11082
            Inspect....11082
            Overview....11082
            Clutch Gears....11082
            Gears....11082
            Thrust Washers....11082
            Snap Rings....11082
            Mainshaft....11083
            Bearings....11083
            Housings....11083
          Reassemble....11084
            General....11084
            End Yokes and Flanges....11084
            Power Take-Offs....11084
            Input Shaft....11084
            Countershaft....11087
            Mainshaft....11089
            Case and Gears....11095
            Shifter Housing....11107
            Remote Control....11109
            Shift Tower....11109
          Lubrication....11110
            Recommended Lubricants....11110
            Oil Changes....11110
            Refill....11110
            Overfilling....11110
          Troubleshooting....11111
          Noise....11111
            Overview....11111
            Growling, Humming, and Grinding....11111
            Hissing, Thumping, and Bumping....11111
            Gear Whine....11112
            Metallic Rattles....11112
          Troubleshooting Chart....11112
          Bearings....11115
            Dirt....11115
            Fatigue....11115
            Corrosion....11115
            Shaft Fits....11116
            Installation and Removal....11116
            Interchangeability....11116
          Clutch....11116
          Specifications....11117
            Gear Ratios....11118
            Shift Pattern....11118
            Torque....11119
            Special Tools....11121
        5. Meritor Transfer Cases MTC–4208, MTC–4210 and MTC–4213....11122
          Description....11122
          Transfer Case Model Nomenclature....11133
          Operation....11134
            Front Axle Declutch....11134
            Full Torque Power Take-Off (PTO)....11134
          Removal....11135
          Disassembly....11138
            Front and Rear Output Yokes....11138
            Front Input Shaft, Input Bearing Cage and Pump Assembly....11138
            Front Input Shaft, Input Shaft Bearing Cage and Oil Pump....11145
            Idle Gear Shaft....11147
            Optional PTO Assembly on MTC–4208 and MTC–4208 Transfer Cases....11148
          Prepare Parts for Assembly....11149
            Ground and Polished Parts....11149
            Parts with a Rough Finish....11149
            Transfer Case Assemblies....11150
            Dry Cleaned Parts....11150
            Prevent Corrosion....11150
            Oil Seals and O-Rings....11150
            Inspect Parts....11151
            Overview....11151
            General....11151
            Helical Gears....11154
            Shafts....11156
            PTO Components....11157
            High and Low Shifting Components....11157
            Oil and Lubrication System....11157
            Transfer Case Halves....11158
            Preparing Case and Cover Seal Replacement....11158
          Assembly....11159
            General....11159
            MTC–4213 Rear Output Shaft End Play Adjustment....11162
            MTC–4208 and MTC-4210 Rear output Shaft End Play Adjustment....11164
            Idler Shaft Bearing End Play Adjustment....11165
            Front Output Shaft End Play Adustment....11166
            Shim Assembly....11167
            High and Low Shifter Assembly....11168
            Front Axle Shifter Assembly....11169
            Front Input Shaft, Input Shaft Bearing Cage and Oil Pump Assembly....11170
            Input Bearing Cage and Oil Pump Assembly Installation, Bearing End Play Adjustment and Transfer Case Final Assembly....11172
            Transfer Case Shifting Check....11174
            Adjust Oil Level....11175
            Transfer Case Assembly Test....11175
          Power Take-Off (PTO)....11176
            Remove Transfer Case Rear Access Cover....11176
            Install Yoke Onto PTO....11177
            Install Optional Indicator Switch....11177
            Install PTO Onto Transfer Case....11178
            Test PTO Installation....11178
            Overview....11178
            PTO Without an Optional Indicator Switch....11179
            PTO With an Optional Indicator Switch....11179
            Test Transfer Case with PTO Assembly Installed....11180
            PTO MDP-10–AF-100....11182
            PTO Assembly....11185
          Installation....11189
            General....11189
            Check and Adjust Oil....11189
          Diagnostics....11191
          Lubrication and Maintenance....11197
            Lubrication....11197
            Overview....11197
            Lubricant Temperatures....11197
            Multi-Viscosity Oils....11197
            Do Not Install API GL-5 Oils....11197
            Petroleum-Base and Synthentic-Base Oils....11198
            Operating Information....11198
            Magnets and Magnetic Drain Plugs....11198
            Breather....11198
            Seals....11199
            Temperature Indicator....11199
            Check and Adjust Oil Level....11199
            Drain and Replace Oil....11200
          Torque....11202
      Rear Axle and Suspension....11204
        1. IROS....11206
          Description....11206
          Height Control Valve....11208
          Operation....11210
          Service Checls (Valve on Truck)....11211
          Ride Height Adjustment....11212
          Rod Cutting Instructions....11213
          Final Assembly Instructions....11213
          Air Lines....11215
          Suspension Dump Feature....11216
            Operation....11217
          Main Support Member....11219
            Main Support Member Removal....11219
            Main Support Member Install....11220
          Shock Absorbers....11222
          Torque Rods....11222
          Remove and Install....11222
            Suspension Air Springs Removal....11223
            Suspension Air Spring Install....11225
          Shock Absorbers....11226
            Removal Suspension System Shock Absorbers....11226
            Install Shock Absorber....11228
          Main Support Members....11229
            Remove....11229
            Install....11229
          Torque Rods....11231
            Remove....11231
            Install....11231
           Main Support Member Bushings....11232
          U-Bolts and U-Bolt Nuts Installation....11234
            Installing U-Bolts and U-Bolt Nuts....11234
            Checking U-Bolt Nut Torque and U-Bolt Nut Tightening....11235
          Ride Height Dimensions....11236
          Procedure for checking/setting ride height on the international ride optimized suspension (iros)....11236
          1.    If the axle travel exceeds specifications, ....11237
          2.    If the axle travel is less than specifications,....11238
          Torque....11241
      Fuel System....11244
        1. Dual Draw Dual Return Fuel Tanks....11246
          Overview....11246
          Removal....11247
          Installation....11251
      Cab....11254
      Front Wheels....11258
      Rear Wheels....11262
  tables....8716
    Troubleshooting Chart....8716
    Length of Slack Adjuster/Size of Chamber Table....8736
    Maximum Stroke Available Chart....8741
    Adjusted Chamber Stroke Chart....8742
    Torque Chart....8748
    Torque....8766
    Warning Indicators....8790
    Warning Indicators....8812
    Sensor Check Pins ....8860
    Torque Chart....8919
    Special Service Tools....8923
    Torque Chart....8945
    Drag Link Nut Torque Chart....8972
    Dual Steering Gear Drag Link Nut Torque Chart....8975
    Master Gear Drag Link Nut Torque Chart....8975
    Drag Link Torque Chart....8986
    Specifications....9029
    M-Series Torque Chart....9029
    All Steering Applications Torque Chart....9030
    Special Tools....9030
    Service Information....9034
    Service Information....9034
    Service Information....9034
    DuraStar....9065
    WorkStar....9066
    Torque Specifications....9067
    Approximate CAN DC Voltage Measurements (Key ON)....9082
    Approximate CAN Resistance Measurements (Batteries Disconnected)....9082
    Feature Codes....9086
    Remote Start Stop....9086
    Feature Code....9097
    Diagnostic Trouble Codes....9098
    Remote Start/Stop Preliminary Check....9099
    Diagnostic Section....9100
    Diagnostic Section....9102
    Diagnostics....9107
    500K Input Diagnostic Section....9126
    Diagnostic Section....9131
    Operational Checkout....9159
    Heated Drain Valve Test....9159
    Air Dryer Test....9160
    Feature Codes....9160
    Diagnostic Trouble Codes....9161
    Air Horns Preliminary Checks....9162
    Feature Code....9164
    Diagnostic Trouble Codes....9165
    Air Solenoid Preliminary Check....9174
    Operational Checkout....9176
    Aux Power Source Tests....9177
    Operational Checkout....9182
    Axle Pressure Transducer Voltage Checks....9183
    C.B. Radio Power Source Preliminary Check....9186
    C.B. Radio Power Connector Tests....9187
    Cigar Lighter and Power Feed Preliminary Check....9188
    Cigar Lighter Tests....9189
    Cigar Lighter Power Source Tests....9189
    Two Post Power Source Tests....9190
    Feature Codes....9191
    Diagnostic Trouble Codes....9192
    Cruise Control Preliminary Check....9193
    Steering Wheel Mounted Cruise Control Command Switch Test (0595AYJ)....9195
    Steering Wheel Mounted Cruise Control Command Switch Test (0595AAP)....9196
    Diagnostic Trouble Codes....9198
    Operational Checkout....9199
    Lift Gate Test....9199
    Diagnostic Trouble Codes....9203
    Operational Checkout....9204
    (0595ACT) Differential Lock Test....9205
    (0595ACU) Differential Lock Test....9206
    Feature Codes....9207
    Diagnostic Trouble Codes....9207
    Electric Horn Preliminary Check....9208
    Diagnostic Trouble Codes....9211
    Operational Checkout....9211
    Fifth Wheel Slide Test....9212
    Diagnostic Trouble Codes....9214
    Operational Checkout....9215
    Fuel Transfer Pump Won’t Run Test....9216
    Fuel Transfer Pump Continuously Runs Test....9218
    Operational Checkout....9223
    Heated Mirrors Test....9224
    Left Heated Mirror Test....9224
    Right Heated Mirror Test....9225
    Operational Checkout....9226
    Heated Seat Test....9226
    Feature Code....9227
    Diagnostic Trouble Codes....9228
    Diagnostic Trouble Codes....9230
    Power Divider Lock Preliminary Check....9231
    Power Divider Lock Test....9231
    Additional Signals Used for PTO Operation....9235
    Feature Description....9236
    Fault Codes....9247
    PTO Hour Meter/ PTO Indicator Checks....9259
    Feature Codes....9263
    Diagnostic Trouble Codes....9265
    Power Locks Preliminary Check....9267
    Power Windows Preliminary Check....9270
    One Power Window Inop Test....9271
    All Power Windows Inop Test....9271
    Power Locks Preliminary Check....9274
    One Door Lock Inop Test....9275
    All Door Locks Inop Test....9275
    Power Mirror Preliminary Check....9280
    Power Mirror Tests....9281
    Radio Preliminary Check....9284
    Radio Test....9285
    Fault Codes....9286
    RPM Checks....9291
    Feature Codes....9293
    Lighted Air Shield DTC....9293
    Roof Auxiliary Load Preliminary Check....9294
    IP Mounted Roof Auxiliary Load Switch Test....9295
    Operational Checkout....9299
    0595BAG Seat Belt Test....9300
    Operational Checkout....9300
    Self Contained Air Seat Test....9301
    Diagnostic Trouble Codes....9306
    Operational Checkout....9307
    Suspension Dump Test....9308
    Feature Codes....9309
    Theft Deterrent Diagnostics....9309
    Diagnostic Trouble Codes....9313
    Operational Checkout....9314
    Two-Speed Switch Test....9314
    Two-Way Radio Circuit Tests....9315
    Feature Codes....9316
    Diagnostic Trouble Codes....9316
    Operational Checkout....9317
    Water Probe Test....9317
    Additional Signals Used for Wheelchair Lift Interlock Operation....9319
    Wheelchair Lift Interlock Checks....9322
    Parked Regeneration (Particulate_Trap_Regeneration_Force_Switch = 1)....9342
    Inhibit Regeneration (Particulate_Trap_Regeneration_Inhibit_Switch = 1)....9343
    DuraStar....9346
    WorkStar....9346
    Service Information....9350
    DuraStar....9356
    WorkStar....9356
    Service Information....9358
    DuraStar....9360
    WorkStar....9360
    Service Information....9363
    Service Information....9444
    Specifications....9455
    Service Information....9465
     Exhaust Brake Switch Test....9495
    RESCM Checks....9505
    Switch Pack Preliminary Check....9522
    Switch Pack Test....9523
    System Pressure Test Chart....9594
    Expected System Static Pressure ....9648
    System Performance Test Specifications....9650
    Oil Capacity by Component....9681
    Air gauge feature codes....9767
    Air 1 gauge fault codes....9768
    Check for short to GND in Primary Air Pressure signal circuit....9773
    Check for short to GND in Primary Air Pressure signal circuit B40....9774
    Check for VREF and GND at Primary Air Pressure Transducer....9775
    Check for Open or high resistance in Primary Air Pressure signal circuit....9776
    Check for Open or high resistance in Primary Air Pressure signal circuit A40....9777
    Check for Open or high resistance in Primary Air Pressure signal circuit B40....9778
    Body Controller output test....9779
    Air gauge feature codes....9780
    Air 2 gauge fault codes....9781
    Check for short to GND in Secondary Air Pressure signal circuit....9786
    Check for short to GND in Secondary Air Pressure signal circuit B40A....9787
    Check for VREF and GND at Secondary Air Pressure Transducer....9788
    Check for Open or high resistance in Secondary Air Pressure signal circuit....9789
    Check for Open or high resistance in Secondary Air Pressure signal circuit A40A....9790
    Check for Open or high resistance in Secondary Air Pressure signal circuit B40A....9791
    Body Controller output test....9791
    Gauge Table....9793
    Gauge Response to Faults....9794
    Axle Temperature Sensor Voltage Checks....9802
    Rear- Rear Axle Temperature Sensor Voltage Checks....9805
    Air Pressure Transducer Voltage Checks....9808
    Feature Codes....9809
    Compass Module Voltage Checks....9810
    DEF level feature codes....9811
    DEF level fault codes....9811
    Coolant temperature feature codes....9813
    Coolant temperature fault codes....9813
    Oil pressure feature codes....9814
    Oil pressure fault codes....9814
    Oil temperature feature codes....9815
    Oil temperature fault codes....9815
    Engine speed feature codes....9816
    Engine speed fault codes....9816
    Fuel gauge feature codes....9817
    Fuel gauge fault codes....9817
    Fault codes....9823
    Ambient Air Temperature Sensor Table....9824
    Transmission temperature feature codes....9826
    Transmission temperature fault codes....9826
    Transmission oil temp sensor resistance specification....9830
    Measure resistance of transmission oil temperature circuit at Connector 1702....9831
    Measure resistance of transmission oil temperature sensor....9831
    Vehicle speed feature codes....9832
    Vehicle speed fault codes....9832
    Feature Codes....9835
    Dome and Courtesy Light Fault Codes....9835
    Door Switch Short Circuit Tests....9837
    Door Switch Open Circuit Tests....9837
    Dome Light Short Circuit Test....9837
    Dome Light Open Circuit Test....9838
     Back Up Light Fault Codes....9839
    Backup Light Relay Tests....9841
    Backup Light Ball Switch Tests....9842
    Software Feature Codes....9843
    Normal Operation....9849
    Symptom Diagnostics....9849
    Fault Code Diagnostics....9850
    Normal Operation....9867
    Full Power Hydraulic Brakes....9868
    Full Power Hydraulic Brakes Fault Codes....9868
    Feature Codes....9894
    Fog Light Symptom Diagnostics....9894
    Fog Light Fault Code Diagnostics....9894
    Feature Codes....9930
    Low Beam Headlight Diagnostics....9931
    High Beam Headlight Diagnostics....9932
    Feature Codes....9999
    Park / Marker Lights....10000
    Feature Codes....10026
    Snow Plow Light Symptom Diagnostics....10027
    Diagnostic Section....10046
    Software Feature Codes....10046
    Turn Signal Input and Front Turn Lamp Diagnostics....10056
    Combined Stop and Turn Lamps....10103
    Separate Stop and Turn Lamps....10133
    Feature Codes....10157
    Trailer Lights Symptom Diagnostics....10158
    Feature Codes....10210
    Diagnostic Trouble Codes....10210
    Trailer Auxiliary Power Circuit Preliminary Checks....10211
    Feature Code....10213
    Diagnostic Trouble Codes....10213
    Electric Trailer Brake Preliminary Check....10214
    Feature Codes....10218
    Dome and Courtesy Light Fault Codes....10218
    Work Light System Preliminary Checks....10219
    Work Light Switch Test....10220
    Work Light Open Circuit Test....10220
    Work Light Short Circuit Test....10221
    Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....10235
    LCT Column Shifter Interlock Checks....10236
    TCM Power, Ground and Data Link Circuit Checks....10237
    Shift Selector Power and Ground Circuit Checks....10238
    Diagnostic Section....10242
    Software Feature Codes....10242
    Feature Codes....10260
    Windshield Wiper Diagnostics....10261
    Washer Pump Diagnostics....10262
    Windshield Wiper Input Switch....10262
    Torque Chart....10426
    Troubleshooting Table....10445
    Specifications....10446
    Torque Chart....10447
    Troubleshooting Chart....10766
    Torque Chart....10772
    Lubrication Table....10853
    Specifications Table....10854
    Torque Chart....10855
    Specifications Table....10973
    Torque Chart....10974
    Troubleshooting Chart....11038
    Specifications....11043
    Gear Ratio Table....11043
    Torque Chart....11044
    Troubleshooting Chart....11112
    Specifications....11117
    Gear Ratios Table....11118
    Torque Chart....11119
    Example of Shim Selection....11167
    Possible Combinations that meet required shim stack:....11167
    Kit 2540....11176
    PTO Switch Option....11177
    PTO Yoke Options and Dimensions....11181
    PTO MDP-10–AF-100 Components....11184
    Transfer Case Oil Change Intervals....11200
    Transfer Case Oil Specifications (NOTES 1, 2, 3)....11201
    Transfer Case Oil Capacities....11201
    Dry Weight....11201
    Torque Chart....11203
    Torque Chart....11242
1087481R1 - 1000 Through 4000, 7000, 8000 Series Electrical Circuit Diagrams CTS-4417Circuit Diagrams....11267
  Blank Page....11268
4328434 - New Truck Processing Technical Manual....11437
  toc....11439
    Table of Contents....11439
      Introduction....11441
      Safety....11441
      UNDECKING AND STORAGE....11442
        INTRODUCTION....11442
        ASSISTANCE TO DEALER ....11442
        DEALER RESPONSIBILITIES FOR UNDECKING EXPENSE....11442
        CORRECT UNDECKING FACILITY CONFIGURATION....11442
        LOAD LIMIT....11443
        NEW VEHICLE RECEIVING PROCEDURES....11444
          CARRIER DELIVERY and INSPECTION RESPONSIBILITIES ....11444
          DEALER RECEIVING RESPONSIBILITIES ....11444
          DEALER DELIVERY and INSPECTION RESPONSIBILITIES ....11444
        VEHICLE STORAGE....11445
          Storage Duration — Two Months Or Less....11445
          Storage Duration — Over Two Months....11447
          Storage Facilities....11447
      NEW TRUCK RECEIVING AND DAMAGE CLAIM PROCESSING....11448
        INTRODUCTION....11448
          Exceptions....11448
          Concealed Damage:....11448
        CARRIER'S UNDECKING RESPONSIBILITIES....11448
        VEHICLE RECEIVING / INSPECTION....11449
        AFTER-HOURS DELIVERY....11449
        DELIVERIES TO BODY COMPANIES OR FLEET LOCATIONS....11450
        CONCEALED DAMAGE....11451
        CARRIER DELIVERY RECEIPT....11451
          Important:....11451
        FILLING OUT THE DELIVERY RECEIPT....11451
        FILING A DAMAGE AND LOSS CLAIM....11452
          Supporting Documents....11453
      VEHICLES NOT BUILT TO ORDER....11454
        INTRODUCTION....11454
        TRUCKS NOT BUILT TO ORDER — U.S. AND CANADA....11454
        CHECKING ORDER CONFIRMATION — U.S. and CANADA....11454
        CLAIM PROCEDURES (USE “TRUCK NOT BUILT TO ORDER” CLAIM FORM)....11455
          U.S. AND CANADA:....11455
        CLAIM FORM — TRUCK NOT BUILT TO ORDER....11457
        ORDER CONTENT CONFIRMATION REPORT....11458
      VEHICLE SAFETY CERTIFICATION....11462
        INTRODUCTION....11462
        INTERNATIONAL® MODEL LINEUP....11462
        PENALTIES FOR VIOLATIONS....11463
        CERTIFICATION....11463
      PREPARATION AND DELIVERY....11464
        INTRODUCTION....11464
        NEW VEHICLE PRE-DELIVERY SERVICE ....11464
          PREPARATION AND DELIVERY (P&D) REIMBURSEMENT (U.S. ONLY)....11464
          NON-REIMBURSEMENT ADDENDUM ....11464
          “Will Call”- Truck Specialty Center (TSC)....11465
          Vehicle Identification Label....11465
          CTS-1122, PRE-DELIVERY SERVICE IDENTIFICATION STICKER ....11465
          New Vehicle Processing Documentation....11466
          Quality Inspection Report....11466
      FINAL DELIVERY GUIDELINES....11467
        INTRODUCTION....11467
        FINAL DELIVERY GUIDELINES....11467
          Introduction....11467
          Before Vehicle Pick-Up Or Delivery....11467
          During Vehicle Pick-Up Or Delivery....11467
  tables....11443
    Table 1VEHICLE HOIST REQUIREMENT CHART....11443
CTS-5122K - 2000 , 4000 and 8000 Series September 1993 and Later Electrical Circuit Diagrams....11468
  Blank Page....11469
CTS-5122T - 2000, 4000, 8000 Series Built After February 1, 1996 Electrical Circuit Diagrams....11662
CTS4425 - Electrical System Troubleshooting Guide - U-HAUL 4600UH Service Manual....11938
  Blank Page....11939
  CTS4425.pdf....0
    Blank Page....11941
S02012 - Meritor Medium Duty Front Drive Steer Axle (Dec 2001) Service Manual....12098
S02014 - Carraro Axle Repair Manual (Feb 2009) Service Manual....12181
  02EZL WSM_HS6.12-CA368083-CA368084_Doc270024-1ed-v02.pdf....0
    Indice-Index....12187
    A INFORMAZIONI GENERALI....12188
      A.1 Utilizzo del manuale....12189
      A.2 Proprietà delle informazioni....12190
      A.3 Convenzioni e definizioni....12191
      A.4 Indicazioni generali....12193
      A.5 Indicazioni speciali....12194
    A General information....12188
      A.1 Manual use....12189
      A.2 Information property....12190
      A.3 Agreements and definitions....12191
      A.4 General description....12193
      A.5 Special recommendations....12194
    B INFORMAZIONI SULLA SICUREZZA....12196
      B.1 Indicazioni generali per la sicurezza....12197
      B.2 Simboli di sicurezza....12198
      B.3 Precauzioni generali....12199
    B Safety instructions....12196
      B.1 General safety recommendations....12197
      B.2 Safety symbols....12198
      B.3 General precautions....12199
    C CARATTERISTICHE GENERALI....12201
      C.1 Uso previsto....12202
      C.2 Identificazione del prodotto....12202
      C.3 Descrizione generale....12203
      C.4 Caratteristiche Tecniche....12204
      C.5 Grasso al montaggio....12211
      C.6 Adesivi e coppie di serraggio....12212
    C General specifications....12201
      C.1 Intended use....12202
      C.2 Product identification....12202
      C.3 General description....12203
      C.4 Technical Features....12204
      C.5 Maintenance and oil change....12208
      C.6 Grease in assembly....12211
      C.7 Adhesives and tightening torques....12212
    D SMONTAGGIO E ASSEMBLAGGIO....12216
      D.1 Gruppo freno....12217
      D.2 Gruppo mozzo ruota....12221
      D.3 Gruppo calotta....12228
      D.4 Gruppo supporto differenziale....12237
      D.5 Gruppo differenziale....12246
      D.6 Gruppo pignone....12250
      D.7 Gruppo trave....12260
      D.8 Convergenza/angolo di sterzata....12262
      D.9 Interventi speciali....12265
      D.10 Prove dopo montaggio....12272
    D Disassembly and assembly....12216
      D.1 Brake group....12217
      D.2 Wheel hub group....12221
      D.3 Swivel housing group....12228
      D.4 Differential support group....12237
      D.5 Differential group....12246
      D.6 Pinion group....12250
      D.7 Axle beam group....12260
      D.8 Toe-in/steering angle....12262
      D.9 Special repair operations....12265
      D.10 Testing after assembly....12272
    E RICERCA GUASTI....12273
      E.1 Controllo ed esame dei guasti....12276
      E.2 Diagnosi per problemi all'assale....12280
    E Troubleshooting....12273
      E.1 Troubleshooting....12278
      E.2 Axle problem and diagnosis....12281
    F ATTREZZATURE SPECIALI....12282
      F.1 Attrezzature speciali....12283
    F Special tools....12282
      F.1 Special tools....12283
    G TEMPI DI RIPARAZIONE....12289
      G.1 Prontuario dei tempi di riparazione....12290
    G Service operations time....12289
      G.1 Service operations time schedule....12290
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual....12293
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual....12314
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual....12328
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual....12369
S04004 - Air Compressor_ Bendix 2150, Supersedes CTS-5058 (March 1996) Service Manual....12403
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual....12435
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual....12479
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual....12484
S04010 - Air Compressor_ Bendix TU-FLO 501, Supersedes CTS-5145 (March 1996) Service Manual....12507
S04011 - Air Compressor_ Midland Models EL-1300 and EL-1600, Supersedes CTS-5146 (March 1996) Service Manual....12537
S04016K - Caliper Disc Brakes, Supersedes CTS-5009K (March 1996) Service Manual....12564
S04017Y - Hydro-Max Brake Booster and Master Cylinder, Supersedes CTS-5018K (Dec 2000) Service Manual....12600
S04018W - Reconditioning Rotors, Supersedes CTS-5086W (June 1998) Service Manual....12635
S04020X - DCM and DDM Drum Type Parking Brake, Supersedes CTS-5135TA (July 1997) Service Manual....12658
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual....12684
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual....12710
S04033 - Antilock Brakes_Traction Control_ Bendix - Troubleshooting, Supersedes CTS-5250 (June 1996) Service Manual....12736
S04038 - EC-17 Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Technical Manual....12780
S040393 - Lucas Varity _ TRW Hydraulic Antilock Brake System (Dec 2003) Technical Manual....12849
S04044 - Bosch Parking Brake_ Manual or Power Brake (Oct 2008) Service Manual....12963
S04045 - Meritor _ WABCO Hydraulic ABS for Medium-Duty Trucks, Buses and Motor Home Chassis (June 2000) Technical Manual....12976
S04050 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual....13032
S04051 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual....13173
S04053 - ECE-13 Brake System (2010) Service Manual....13314
S04055 - MCAC 465 Air Compressor (Dec 2010) Service Manual....13350
  toc....13352
    Table of Contents....13352
      1. DESCRIPTION....13354
        1.1. Components....13355
          Cylinder Head....13355
          Crankcase....13356
        1.2. Name Plate....13356
      2. Compressor Maintenance....13357
      3. Remove and Install Procedures....13358
        3.1. MCAC 476 Air Compressor....13359
          MCAC 476 Air Compressor – Removal....13359
          MCAC 476 Air Compressor – Installation....13360
        3.2. MCAC 476 Air Compressor Disassembly....13361
          Cylinder Head Disassembly....13361
          Crankcase Disassembly....13363
          Drive Gear Removal....13364
          Air Cylinder Cover Removal....13365
          Crankcase Removal....13366
          Air Cylinder Removal....13367
          Air Cylinder Disassembly....13368
          Clutch Housing Disassembly....13369
          Piston Removal....13370
        3.3. MCAC 476 Air Compressor – Assembly....13371
          Crankcase Assembly....13371
          Clutch Housing Assembly....13372
          Air Cylinder Assembly....13373
          Air Cylinder Installation....13374
          Crankshaft Installation....13375
          Air Cylinder Cover Installation....13376
          Center Shaft Installation....13377
          Center Shaft Nut Installation....13378
          Cylinder Head Assembly (Lower)....13379
          Cylinder Head Assembly (Upper)....13380
      4. Troubleshooting....13381
        4.1. Troubleshooting Table....13381
        4.2. Tests....13385
          Oil Leakage at the Head Gasket Test....13385
          Air Brake System and Accessory Leakage Test....13385
          Air Compressor Discharge Temperature and Air Dryer Inlet Tempera....13386
          Governor Malfunction Test....13387
          Governor Control Line Test....13387
          Compressor Clutch Operation - No Air Charging Test....13387
          Compressor Clutch Operation - Continuous Air Charging Test....13387
  tables....13388
    Table 3Torque Chart....13388
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual....13389
S05012 - Steering Column Assembly, Tilt_Telescoping Supersedes CTS-5167 (May 1996) Service Manual....13466
S05013 - Steering Column Assembly, Standard and Tilt, Supersedes CTS-5168 (April 1996) Service Manual....13480
S05016 - Steering Wheel Removal and Installation (Sept 2010) Service Manual....13495
S05021 - Steering Wheel and Steering Column Assembly (July 2012) Service Manual....13508
  toc....13510
    Table of Contents....13510
      1. DESCRIPTION....13512
        1.1. STEERING WHEEL....13512
        1.2. CLOCK SPRING....13512
        1.3. STEERING COLUMN....13513
      2. REMOVE AND INSTALL PROCEDURES....13514
        2.1. STEERING WHEEL....13515
          Steering Wheel – Removal....13515
          Steering Wheel – Installation....13518
        2.2. CLOCK SPRING....13519
          Clock Spring – Removal....13519
          Clock Spring – Installation....13521
        2.3. STEERING COLUMN....13523
          Steering Column – Removal....13523
          Steering Column – Installation....13525
      3. CHECKS AND ADJUSTMENTS....13526
        3.1. STEERING WHEEL....13526
          Steering Wheel – Check....13526
          Steering Wheel – Adjust....13526
  tables....13527
    Table 1Torque Chart....13527
S05022 - Steering Wheel _ Column Assembly _ Power Steering Reservoir (Jan 2011) Brazilian Market Service Manual....13528
S05025 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual....13550
  toc....13552
  tables....13569
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual....13570
S08034X - Instruments, Supersedes CTS-5088K (Oct 1999) Service Manual....13651
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual....13689
S08155X - Instruments (New Data Link Driven Instrument Cluster), Supersedes CTS-5228 (Oct 1999) Technical Manual....13718
S08186 - 2000, 4000, 8000 Models Built October 1, 1998 To September 30, 1999 Electrical Circuit Diagrams....13842
  toc....13844
    Table of Contents....13844
      INSTRUCTIONS AND CHARTS (Chapter 1)....13852
        1.1. Circuit Identification Chart, P. 1....13852
        1.2. Circuit Identification Chart, P. 2....13853
        1.3. Circuit Identification Chart, P. 3....13854
        1.4. Circuit Diagram Instructions, P. 4....13855
        1.5. Circuit Diagram Instructions, P. 5....13856
        1.6. Schematic Symbols, P. 6....13857
        1.7. Relay Function/Bus Bar Configuration (Fuse Block Connector)....13858
        1.8. Fuse Block Connector/Connection Tables, P. 8....13859
        1.9. Lamp Bulb Chart, P. 9....13860
        1.10. Fuse/Circuit Breaker Chart/Labels, P. 10....13861
        1.11. Relay Mounting Locations/Labels, P. 11....13862
      12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....13863
        2.1. Accessory, P. 1....13863
        2.2. Accessory (Cont.), P. 2....13864
        2.3. Battery, P. 3....13865
        2.4. Battery (Cont.), P. 4....13866
        2.5. Ignition, P. 5....13867
        2.6. Ignition (Cont.), P. 6....13868
        2.7. Ignition (Cont.), P. 7....13869
        2.8. Ground, P. 8....13870
        2.9. Ground (Cont.), P. 9....13871
      CAB ACCESSORIES (Chapter 3)....13872
        3.1. Power Window, P. 1....13872
        3.2. Horn, Single & Dual, P. 2....13873
        3.3. Mirrors, Heated W/Power Mirror, P. 3....13874
        3.4. Mirrors, Lighted, P. 4....13875
        3.5. Owner/Operator Connections — Rear Cab Junction Block, Acces....13876
        3.6. Radio, Cab, 2 Speakers, AM-FM Cassette Radio & CB Radio 2–W....13877
        3.7. Radio, Cab, 4 Speakers, AM-FM Cassette Premium Radio, P. 7....13878
        3.8. Radio, Sleeper, AM-FM Cassette Radio W/Sleeper Speakers, P.....13879
        3.9. Cigar Lighter, Power Seat, P. 9....13880
        3.10. Radio, Sleeper, AM-FM Cassette Premium Radio W/Sleeper Spe....13881
        3.11. Sleeper Cab, 42 Inch, P. 11....13882
        3.12. Sleeper Cab, 42 Inch (Cont.), P. 12....13883
        3.13. Turn Signals W/International T/S Switch W/Tractor & N/Pede....13884
        3.14. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....13885
        3.15. Turn Signals W/International T/S Switch W/Tractor/Truck & ....13886
        3.16. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....13887
        3.17. Turn Signals W/Sig-Stat 910/915 T/S Switch W/ & N/Pedestal....13888
        3.18. Windshield Wiper & Washer (Elect) W/International T/S Swit....13889
        3.19. Windshield Washer (Elect) W/Air Wipers & W/International T....13890
        3.20. Windshield Washer (Elect) W/Air Wipers & W/Sig–Stat T/S Sw....13891
        3.21. Windshield Wiper W/Intermittent Wiper/Washer W/Sig–Stat T/....13892
      12V CHARGING + CRANKING SYSTEM (Chapter 4)....13893
        4.1. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/I....13893
        4.2. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/N....13894
        4.3. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/C....13895
        4.4. Charging System (12V) Delco (90 AMP) CS-130 & 21SI (65, 100....13896
        4.5. Cranking System (12V) (8100) W/ISM, P. 5....13897
        4.6. Cranking System (12V) (8100) C-10, C-12, P. 6....13898
        4.7. Cranking System (12V) (2500, 2600) W/ISM, N14E PLUS, P. 7....13899
        4.8. Cranking System (12V) (2500, 2600) W/C-10, C-12, P. 8....13900
        4.9. Cranking System (12V) W/T 444E, I6 HEUI, P. 9....13901
        4.10. Ether Start W/ISM, C-10, C-12, I6 HEUI, P. 10....13902
      FANS (Chapter 5)....13903
        5.1. Horton Engine Fan With Cummins N14E PLUS W/ & N/Air Conditi....13903
        5.2. Horton Engine Fan With Cummins ISM Engine W/ & N/Air Condit....13904
        5.3. Radiator Shutter W/ISM, N14E PLUS, P 3....13905
        5.4. Horton Engine Fan With Cat. C-10, C-12 W/ & N/Air Condition....13906
        5.5. Shutter & Fan Wiring W/I6 HEUI, T 444E, P. 5....13907
      ELECTRONIC ENGINES (Chapter 6)....13908
        6.1. Engine Controls, Cummins N14E PLUS, P. 1....13908
        6.2. Engine Controls, Cummins N14E PLUS (Cont.), P. 2....13909
        6.3. Engine Controls, Cummins ISM Engine, P. 3....13910
        6.4. Engine Controls, Cummins ISM Engine (Cont.), P. 4....13911
        6.5. Engine Controls, Cummins ISM Engine (Cont.), P. 5....13912
        6.6. Engine Brake N/Electronic Transmission, Cummins N14E PLUS, ....13913
        6.7. Engine Brake N/Electronic Transmission, Cummins ISM, P. 7....13914
        6.8. Engine Brake, Caterpillar C-10, C-12, P. 8....13915
        6.9. Cruise Control, Caterpillar C-10, C-12, P. 9....13916
        6.10. Engine Controls, Caterpillar C-10, C-12, P. 10....13917
        6.11. Engine Shutdown Warning Lights, Low Coolant Switch, Caterp....13918
        6.12. Low Air Pressure (Brake) Alarm & Brake Systems Warning Lig....13919
        6.13. Module Power & Ground System W/T 444E, I6 HEUI, P. 13....13920
        6.14. Accelerator, BAP & Ambient Air Systems W/T 444E & I6 HEUI ....13921
        6.15. Accelerator, BAP & Ambient Air Temp. Sensor W/T 444E & I6 ....13922
        6.16. Cruise Control, Body Builder Connections W/T 444E, I6 HEUI....13923
      GAUGES (Chapter 7)....13924
        7.1. Oil Temperature Gauges — Fwd/RR & RR/RR Axles W/6x4, Rear A....13924
        7.2. Engine Oil W/ISM Engine & Transmission Oil Temperature Gaug....13925
        7.3. Engine Oil Temperature Gauge W/N14E PLUS Engine, P. 3....13926
        7.4. Engine Oil Temperature Gauge W/C-10, C-12, P. 4....13927
        7.5. Engine Water Temp., Tach, Gauge, Left Turn, HI Beam Ind. W/....13928
        7.6. Ammeter Wiring, P. 6....13929
        7.7. Fuel Gauge, Speedometer (N/T 444E), Voltmeter, Right Turn I....13930
        7.8. Speedometer, Tachometer, HI Beam, Right & Left T/S Ind. Lig....13931
        7.9. Pyrometer Gauge N/T 444E, I6 HEUI, P. 9....13932
      WARNING LIGHTS (Chapter 8)....13933
        8.1. Windshield Washer Low Fluid Warning Light, Power Divider Lo....13933
        8.2. Fuel Filter Wiring System W/T 444E, I6 HEUI, P. 2....13934
        8.3. Diagnostic/Programmable Conn., W/T 444E, I6 HEUI, P. 3....13935
        8.4. Surge Tank W/T 444E & I6 HEUI (Plastic or Metal Tanks), P. ....13936
        8.5. Engine Warning Lights/Alarm & Test Switch W/T 444E & I6 HEU....13937
      CHASSIS ACCESSORIES (Chapter 9)....13938
        9.1. Air Suspension W/Air Hydraulic Brakes, P. 1....13938
        9.2. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....13939
        9.3. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....13940
        9.4. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....13941
        9.5. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....13942
        9.6. Allison Automatic (Electronic) Transmission W/I6 or V8, P. ....13943
        9.7. Allison Automatic (Electronic) Transmission Retarder Contro....13944
        9.8. Allison Automatic (Electronic) Transmission Retarder Contro....13945
        9.9. Allison Automatic (Electronic) Transmission Retarder, P. 9....13946
        9.10. Auto Neutral, P. 10....13947
        9.11. Allison Automatic (Electronic) Transmission WTEC III HD, P....13948
        9.12. Allison Automatic (Electronic) Transmission WTEC III HD (C....13949
        9.13. Allison Automatic (Electronic) Transmission WTEC III HD (C....13950
        9.14. Allison Automatic (Electronic) Transmission WTEC III HD (C....13951
        9.15. Exhaust Brake, I6 HEUI W/Air ABS, W/Allison WT Transmissio....13952
        9.16. Exhaust Brake, I6 HEUI W/Air ABS, N/Allison WT Transmissio....13953
        9.17. Exhaust Brake W/Hyd. Brakes N/AT-MT Retarders or MD Transm....13954
        9.18. Exhaust Brake Solenoid, I6 HEUI, N/ABS, N/Allison WT Trans....13955
        9.19. Allison Automatic Transmission System W/I6 HEUI, T 444E, P....13956
        9.20. Axle, Two Speed, Wiring (Air) W/Allison (Elect.) Auto Tran....13957
        9.21. Axle, Two Speed, Wiring (Hyd.) W/Allison (Elect.) Auto Tra....13958
        9.22. Axle, Two Speed, Electric W/T 444E & I6 HEUI, P. 22....13959
        9.23. Axle, Two Speed, Electric (Air) & Air Dryer W/Auto or Manu....13960
        9.24. Axle, Two Speed, Electric (Hydraulic) W/Auto or Manual Tra....13961
        9.25. Brake System, Hydraulic, P. 25....13962
        9.26. Bendix Automatic Drain Valve (DV-2) W/Heater W/ & N/Exhaus....13963
        9.27. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Air ABS, ....13964
        9.28. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Hyd. ABS,....13965
        9.29. Locking Differential W/Allison WT Transmission, P. 29....13966
        9.30. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13967
        9.31. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13968
        9.32. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13969
        9.33. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13970
        9.34. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....13971
        9.35. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....13972
        9.36. Brake System, Hydraulic W/4000 & W/ or N/ABS, P. 36....13973
        9.37. Antilock Hydraulic Brakes (4 Channel) W/4000, P. 37....13974
        9.38. Antilock Hydraulic Brakes (4 Channel) W/4000 (Cont.), P. 3....13975
        9.39. Transfer Case Shift System Front Axle Warning Light, P. 39....13976
        9.40. Trailer Connection W/Regular Cab & W/Sleeper Box, P. 40....13977
        9.41. Trailer Connection W/Frame Mounted 7–Way & W/Tractor, P. 4....13978
        9.42. Trailer Connection W/Frame Mounted 7–Way & W/Truck & W/Air....13979
        9.43. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco, P. 43....13980
        9.44. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco (Cont.), ....13981
        9.45. Air Suspension, Main Cab Overlay Control Harness, P. 45....13982
        9.46. Meritor G Series Transmission, P. 46....13983
      LIGHT SYSTEMS (Chapter 10)....13984
        10.1. Back-Up Lights, P. 1....13984
        10.2. Clearance, Marker & Tail Lights W/Tractor N/T 444E, I6 HEU....13985
        10.3. Clearance, Marker & Tail Lights W/Truck N/T 444E, I6 HEUI,....13986
        10.4. Clearance, Marker & Tail Lights W/Tractor W/T 444E, I6 HEU....13987
        10.5. Clearance, Marker & Tail Lights W/Truck W/T 444E, I6 HEUI,....13988
        10.6. Cab Dome and Courtesy Lights, P. 6....13989
        10.7. Work Light W/Tractor & W/Reg. Cab, Sleeper Cab, P. 7....13990
        10.8. Work Light W/Truck, P. 8....13991
        10.9. Fog Light System W/ & N/DRL (USA) & N/T 444E, I6 HEUI, P. ....13992
        10.10. Fog Light System W/ & N/DRL (Canada) & N/T 444E, I6 HEUI,....13993
        10.11. Fog Light System W/ & N/DRL (USA) & W/T 444E, I6 HEUI, P.....13994
        10.12. Fog Light System W/DRL (Canada) & W/T 444E, I6 HEUI, P. 1....13995
        10.13. Headlight System N/DRL W/International Turn Signal Switch....13996
        10.14. Headlight System N/DRL W/International Turn Signal Switch....13997
        10.15. Headlight System N/DRL W/Sig-Stat 910 T/S Sw. W/Flr. Mtd.....13998
        10.16. Headlight System N/DRL W/Sig-Stat 915 T/S Sw. W/Push Btn.....13999
        10.17. Headlight System W/DRL (Canada) W/Sig-Stat 910 T/S Sw. W/....14000
        10.18. Headlight System W/DRL (Canada) W/Sig-Stat 915 T/S Sw. W/....14001
        10.19. Headlight System W/DRL (USA) W/Sig-Stat 910 T/S Sw. W/Air....14002
        10.20. Headlight System W/DRL (USA) W/Sig-Stat 915 T/S Sw. W/Air....14003
        10.21. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Hyd. Br....14004
        10.22. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Hyd. Brake....14005
        10.23. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14006
        10.24. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14007
        10.25. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14008
        10.26. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14009
        10.27. Additional Headlight Wiring W/Dual Drive Cab, P. 27....14010
        10.28. Hydraulic Park Brake Ind. Light W/Key Sw. or Push Button ....14011
        10.29. Panel Lights, P. 29....14012
        10.30. Stop Light Switch W/T 444E & I6 HEUI W/Air Brakes, P. 30....14013
        10.31. Stop Light Switch Truck W/Standard Air Brakes W/Internati....14014
        10.32. Stop Light Switch Truck W/Standard Air Brakes W/Sig-Stat ....14015
        10.33. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14016
        10.34. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14017
      HEATER AND AIR CONDITIONER (Chapter 11)....14018
        11.1. Heater / Air Conditioner, P. 1....14018
        11.2. Heater Only, P. 2....14019
      CONNECTOR COMPOSITES (Chapter 12)....14020
        12.1. Dash Connector (2) (N/T 444E or I6 HEUI), P. 1....14020
        12.2. Dash Connector (2) (W/T 444E or I6 HEUI), P. 2....14021
        12.3. Dash Connector Engine Connections (2A) (N/T 444E or I6 HEU....14022
        12.4. Dash Connector Engine Connections (2A) (W/T 444E or I6 HEU....14023
        12.5. Connector Composites (3 & 3A), P. 5....14024
        12.6. Connector Composite (3J), P. 6....14025
        12.7. Connector Composites (11), (12), (13), P. 7....14026
        12.8. Connector Composites (14), (14A), (15), (16), (17), (18), ....14027
        12.9. Connector Composites (20), (21), P. 9....14028
        12.10. Connector Composites (23), (24), (26), P. 10....14029
        12.11. Connector Composites (27), (28), (29), (30), (31), (32), ....14030
        12.12. Connector Composites (33), (34), (35), (36), (37), (38), ....14031
        12.13. Connector Composites (44), (46), (47 & 48), (49), (50), (....14032
        12.14. Connector Composites (53), (54), (55), (56), (57), (58), ....14033
        12.15. Connector Composites (66), (67), (69), (70), (71), P. 15....14034
        12.16. Connector Composites (72), (73), (74), (75), (76), (77), ....14035
        12.17. Connector Composites (80), (83), (84 & 85), (86), (90), (....14036
        12.18. Connector Composites (98), (99), (100), (101), (102), (10....14037
        12.19. Connector Composites (105), (106), (107), (108), (109), (....14038
        12.20. Connector Composites (117), (119), (121), (122), (123), (....14039
        12.21. Connector Composites (132), (133), (135), (136), P. 21....14040
        12.22. Connector Composites (137), (141), (142), (143), (144), (....14041
        12.23. Connector Composites (147), (148), (149), (153), P. 23....14042
        12.24. Connector Composites (153), (154), (156), (157), (158), (....14043
        12.25. Connector Composites (160), (161), (162), (163), (164), (....14044
        12.26. Connector Composites (169), (170), (171), (172), (173), (....14045
        12.27. Connector Composites (179), (180), (181), (182), (183), (....14046
        12.28. Connector Composites (194A), (199), (203), (210), (212), ....14047
        12.29. Connector Composites (214M), (218), (219), (220), (221), ....14048
        12.30. Connector Composites (223), (225), (226), (237), P. 30....14049
        12.31. Connector Composites (252), (257), (258), (259), (260), (....14050
        12.32. Connector Composites (270), (271), (272), (273), (274A), ....14051
        12.33. Connector Composites (274), (275), (276), (277), (279), P....14052
        12.34. Connector Composites (280), (284), (286), (287), P. 34....14053
        12.35. Connector Composites (288), (289), (290), (291), (292), (....14054
        12.36. Connector Composites (294), (295), (296), (297), (298), (....14055
        12.37. Connector Composites (304), (305), (306), (309), (310), (....14056
        12.38. Connector Composites (311), (312), (313), (314), (315), (....14057
        12.39. Connector Composites (320), (323), (325), P. 39....14058
        12.40. Connector Composites (325), (326), (327), (328), (329), (....14059
        12.41. Connector Composites (332), (333), (335), (336), (337), P....14060
        12.42. Connector Composites (338), (339), (340), (341), (342), (....14061
        12.43. Connector Composites (345), (346), (347), (348), (349), (....14062
        12.44. Connector Composites (355), (356), (357), (358), (359), (....14063
        12.45. Connector Composites (367), (368), (369), (370), (372), (....14064
        12.46. Connector Composites (377), (377A), (377B), P. 46....14065
        12.47. Connector Composites (379), (382), (382A), P. 47....14066
        12.48. Connector Composites (383), (384), (386), (387), (389), (....14067
        12.49. Connector Composites (391), (392), P. 49....14068
        12.50. Connector Composites (396), (399), (400), (401), P. 50....14069
        12.51. Connector Composites (402), (403), (404), P. 51....14070
        12.52. Connector Composites (406), (413), (417), P. 52....14071
        12.53. Connector Composite (418), P. 53....14072
        12.54. Connector Composites (419), (420), (421), (422), P. 54....14073
        12.55. Connector Composites (423), (425), (426), (427), (428), P....14074
        12.56. Connector Composites (430), (431), (432), (433), (434), (....14075
        12.57. Connector Composites (447), (449), (457), P. 57....14076
        12.58. Connector Composites (458), (459), (460), (463), (465), (....14077
        12.59. Connector Composites (467), (468), (469), (473), (480), (....14078
        12.60. Connector Composites (492), (493), (494), (495), P. 60....14079
        12.61. Connector Composites (499), (500), (501), (502), (503), (....14080
        12.62. Connector Composites (506), (507), (508), (510), (511), (....14081
        12.63. Connector Composites (555), (557), (558), (569), (570), (....14082
        12.64. Connector Composite (615), P. 64....14083
        12.65. Connector Composites (631), (632), P. 65....14084
        12.66. Connector Composites (633), (634), P. 66....14085
        12.67. Connector Composites (636), (637), (639), P. 67....14086
        12.68. Connector Composites (646), (646A), (647), (648), (649), ....14087
        12.69. Connector Composites (661), (662), (667), (675), (683), (....14088
        12.70. Connector Composites (700), (701), (702), (703), (707), P....14089
        12.71. Connector Composites (708), (734), (758), (759), (760), (....14090
        12.72. Connector Composites (766), (767), (768), (769), (770), (....14091
        12.73. Connector Composites (775), (776), (777), (778), (789), (....14092
        12.74. Connector Composites (791), (792), (807), (917), (918), (....14093
        12.75. Connector Composites (926), (958), (959), (960), (960A), ....14094
        12.76. Connector Composites (1000), (1001), (1002), (1003), (100....14095
        12.77. Connector Composites (1014), (1015), P. 77....14096
        12.78. Connector Composites (1016), (1017), (1091), P. 78....14097
        12.79. Connector Composites (1093), (1094), (1095), (1097), (109....14098
        12.80. Connector Composites (1110M), (1113F), (1117), (1119), (1....14099
        12.81. Connector Composites (1125), (1126), (1128), (1129), (113....14100
        12.82. Connector Composites (1132), (1133), (1134), (1135), (302....14101
S08186X - 2000, 4000, 8000 Models Built October 1, 1999 and After Electrical Circuit Diagrams....14102
  toc....14104
    Table of Contents....14104
      INSTRUCTIONS AND CHARTS (Chapter 1)....14112
        1.1. Circuit Identification Chart, p. 1....14112
        1.2. Circuit Identification Chart, p. 2....14113
        1.3. Circuit Identification Chart, p. 3....14114
        1.4. Circuit Diagram Instructions, p. 4....14115
        1.5. Circuit Diagram Instructions, p. 5....14116
        1.6. Schematic Symbols, p. 6....14117
        1.7. Relay Function/Bus Bar Configuration (Fuse Block Connector)....14118
        1.8. Fuse Block Connector/Connection Tables, p. 8....14119
        1.9. Lamp Bulb Chart, p. 9....14120
        1.10. Fuse/Circuit Breaker Chart/Labels, p. 10....14121
        1.11. Relay Mounting Locations/Labels, p. 11....14122
      12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....14123
        2.1. Accessory, p. 1....14123
        2.2. Accessory (Cont.), p. 2....14124
        2.3. Battery, p. 3....14125
        2.4. Battery (Cont.), p. 4....14126
        2.5. Ignition, p. 5....14127
        2.6. Ignition (Cont.), p. 6....14128
        2.7. Ignition (Cont.), p. 7....14129
        2.8. Ground, p. 8....14130
        2.9. Ground (Cont.), p. 9....14131
      CAB ACCESSORIES (Chapter 3)....14132
        3.1. Power Window, p. 1....14132
        3.2. Horn, Single & Dual, p. 2....14133
        3.3. Mirrors, Heated W/Power Mirror, p. 3....14134
        3.4. Mirrors, Lighted, p. 4....14135
        3.5. Owner/Operator Connections — Rear Cab Junction Block, Acces....14136
        3.6. Radio, Cab, 2 Speakers, AM-FM Cassette Radio & CB Radio 2–W....14137
        3.7. Radio, Cab, 4 Speakers, AM-FM Cassette Premium Radio, p. 7....14138
        3.8. Radio, Sleeper, AM-FM Cassette Radio W/Sleeper Speakers, p.....14139
        3.9. Cigar Lighter, Power Seat, p. 9....14140
        3.10. Radio, Sleeper, AM-FM Cassette Premium Radio W/Sleeper Spe....14141
        3.11. Sleeper Cab, 42 Inch, p. 11....14142
        3.12. Sleeper Cab, 42 Inch (Cont.), p. 12....14143
        3.13. Turn Signals W/International T/S Switch W/Tractor & N/Pede....14144
        3.14. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14145
        3.15. Turn Signals W/International T/S Switch W/Tractor/Truck & ....14146
        3.16. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14147
        3.17. Turn Signals W/Sig-Stat 910/915 T/S Switch W/ & N/Pedestal....14148
        3.18. Windshield Wiper & Washer (Elect) W/International T/S Swit....14149
        3.19. Windshield Washer (Elect) W/Air Wipers & W/International T....14150
        3.20. Windshield Washer (Elect) W/Air Wipers & W/Sig–Stat T/S Sw....14151
        3.21. Windshield Wiper W/Intermittent Wiper/Washer W/Sig–Stat T/....14152
      12V CHARGING + CRANKING SYSTEM (Chapter 4)....14153
        4.1. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/I....14153
        4.2. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/N....14154
        4.3. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/C....14155
        4.4. Charging System (12V) Delco (90 AMP) CS-130 & 21SI (65, 100....14156
        4.5. Cranking System (12V) (8100) W/ISM, p. 5....14157
        4.6. Cranking System (12V) (8100) C-10, C-12, p. 6....14158
        4.7. Cranking System (12V) (2500, 2600) W/ISM, N14E PLUS, p. 7....14159
        4.8. Cranking System (12V) (2500, 2600) W/C-10, C-12, p. 8....14160
        4.9. Cranking System (12V) W/T 444E, I6 HEUI, p. 9....14161
        4.10. Ether Start W/ISM, C-10, C-12, I6 HEUI, p. 10....14162
        4.11. Auto Neutral (813AAS), p. 11....14163
      FANS (Chapter 5)....14164
        5.1. Horton Engine Fan With Cummins N14E PLUS W/ & N/Air Conditi....14164
        5.2. Horton Engine Fan With Cummins ISM Engine W/ & N/Air Condit....14165
        5.3. Radiator Shutter W/ISM, N14E PLUS, p. 3....14166
        5.4. Horton Engine Fan With Cat. C-10, C-12 W/ & N/Air Condition....14167
        5.5. Shutter & Fan Wiring W/I6 HEUI, T 444E, p. 5....14168
      ELECTRONIC ENGINES (Chapter 6)....14169
        6.1. Engine Controls, Cummins N14E PLUS, p. 1....14169
        6.2. Engine Controls, Cummins N14E PLUS (Cont.), p. 2....14170
        6.3. Engine Controls, Cummins ISM Engine, p. 3....14171
        6.4. Engine Controls, Cummins ISM Engine (Cont.), p. 4....14172
        6.5. Engine Controls, Cummins ISM Engine (Cont.), p. 5....14173
        6.6. Engine Brake N/Electronic Transmission, Cummins N14E PLUS, ....14174
        6.7. Engine Brake N/Electronic Transmission, Cummins ISM, p. 7....14175
        6.8. Engine Brake, Caterpillar C-10, C-12, p. 8....14176
        6.9. Cruise Control, Caterpillar C-10, C-12, p. 9....14177
        6.10. Engine Controls, Caterpillar C-10, C-12, p. 10....14178
        6.11. Engine Shutdown Warning Lights, Low Coolant Switch, Caterp....14179
        6.12. Low Air Pressure (Brake) Alarm & Brake Systems Warning Lig....14180
        6.13. Module Power & Ground System W/T 444E, I6 HEUI, p. 13....14181
        6.14. Accelerator, BAP & Ambient Air Systems W/T 444E & I6 HEUI ....14182
        6.15. Accelerator, BAP & Ambient Air Temp. Sensor W/T 444E & I6 ....14183
        6.16. Cruise Control, Body Builder Connections W/T 444E, I6 HEUI....14184
      GAUGES (Chapter 7)....14185
        7.1. Oil Temperature Gauges — Fwd/RR & RR/RR Axles W/6x4, Rear A....14185
        7.2. Engine Oil W/ISM Engine & Transmission Oil Temperature Gaug....14186
        7.3. Engine Oil Temperature Gauge W/N14E PLUS Engine, p. 3....14187
        7.4. Engine Oil Temperature Gauge W/C-10, C-12, p. 4....14188
        7.5. Engine Water Temp., Tach, Gauge, Left Turn, HI Beam Ind. W/....14189
        7.6. Ammeter Wiring, p. 6....14190
        7.7. Fuel Gauge, Speedometer (N/T 444E), Voltmeter, Right Turn I....14191
        7.8. Speedometer, Tachometer, HI Beam, Right & Left T/S Ind. Lig....14192
        7.9. Pyrometer Gauge N/T 444E, I6 HEUI, p. 9....14193
      WARNING LIGHTS (Chapter 8)....14194
        8.1. Windshield Washer Low Fluid Warning Light, Power Divider Lo....14194
        8.2. Fuel Filter Wiring System W/T 444E, I6 HEUI, p. 2....14195
        8.3. Diagnostic/Programmable Conn., W/T 444E, I6 HEUI, p. 3....14196
        8.4. Surge Tank W/T 444E & I6 HEUI (Plastic or Metal Tanks), p. ....14197
        8.5. Engine Warning Lights/Alarm & Test Switch W/T 444E & I6 HEU....14198
        8.6. Air Actuated and Hydraulic Actuated Park Brake With Hydraul....14199
      CHASSIS ACCESSORIES (Chapter 9)....14200
        9.1. Air Suspension W/Air Hydraulic Brakes, p. 1....14200
        9.2. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....14201
        9.3. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....14202
        9.4. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....14203
        9.5. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....14204
        9.6. Allison Automatic (Electronic) Transmission W/I6 or V8, p. ....14205
        9.7. Allison Automatic (Electronic) Transmission Retarder Contro....14206
        9.8. Allison Automatic (Electronic) Transmission Retarder Contro....14207
        9.9. Allison Automatic (Electronic) Transmission Retarder, p. 9....14208
        9.10. Auto Neutral, p. 10....14209
        9.11. Allison Automatic (Electronic) Transmission WTEC III HD, p....14210
        9.12. Allison Automatic (Electronic) Transmission WTEC III HD (C....14211
        9.13. Allison Automatic (Electronic) Transmission WTEC III HD (C....14212
        9.14. Allison Automatic (Electronic) Transmission WTEC III HD (C....14213
        9.15. Exhaust Brake, I6 HEUI W/Air ABS, W/Allison WT Transmissio....14214
        9.16. Exhaust Brake, I6 HEUI W/Air ABS, N/Allison WT Transmissio....14215
        9.17. Exhaust Brake W/Hyd. Brakes N/AT-MT Retarders or MD Transm....14216
        9.18. Exhaust Brake Solenoid, I6 HEUI, N/ABS, N/Allison WT Trans....14217
        9.19. Allison Automatic Transmission System W/I6 HEUI, T 444E, p....14218
        9.20. Axle, Two Speed, Wiring (Air) W/Allison (Elect.) Auto Tran....14219
        9.21. Axle, Two Speed, Wiring (Hyd.) W/Allison (Elect.) Auto Tra....14220
        9.22. Axle, Two Speed, Electric W/T 444E & I6 HEUI, p. 22....14221
        9.23. Axle, Two Speed, Electric (Air) & Air Dryer W/Auto or Manu....14222
        9.24. Axle, Two Speed, Electric (Hydraulic) W/Auto or Manual Tra....14223
        9.25. Brake System, Hydraulic, p. 25....14224
        9.26. Bendix Automatic Drain Valve (DV-2) W/Heater W/ & N/Exhaus....14225
        9.27. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Air ABS, ....14226
        9.28. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Hyd. ABS,....14227
        9.29. Locking Differential W/Allison WT Transmission, p. 29....14228
        9.30. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14229
        9.31. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14230
        9.32. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14231
        9.33. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14232
        9.34. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....14233
        9.35. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....14234
        9.36. Brake System, Hydraulic W/4000 & W/ or N/ABS, p. 36....14235
        9.37. Antilock Hydraulic Brakes (4 Channel) W/4000, p. 37....14236
        9.38. Antilock Hydraulic Brakes (4 Channel) W/4000 (Cont.), p. 3....14237
        9.39. Transfer Case Shift System Front Axle Warning Light, p. 39....14238
        9.40. Trailer Connection W/Regular Cab & W/Sleeper Box, p. 40....14239
        9.41. Trailer Connection W/Frame Mounted 7–Way & W/Tractor, p. 4....14240
        9.42. Trailer Connection W/Frame Mounted 7–Way & W/Truck & W/Air....14241
        9.43. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco, p. 43....14242
        9.44. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco (Cont.), ....14243
        9.45. Air Suspension, Main Cab Overlay Control Harness, p. 45....14244
        9.46. Meritor G Series Transmission, p. 46....14245
        9.47. Allison LCT With Hydraulic Brakes, p. 47....14246
        9.48. Allison LCT With Hydraulic Brakes (Cont.), p. 48....14247
        9.49. Allison LCT With Hydraulic Brakes (Cont.), p. 49....14248
        9.50. Allison LCT With Hydraulic Brakes (Cont.), p. 50....14249
        9.51. Allison LCT With Hydraulic Brakes (Cont.), p. 51....14250
        9.52. Allison LCT With Hydraulic Brakes (Cont.), p. 52....14251
        9.53. Allison LCT With Hydraulic Brakes (Cont.), p. 53....14252
        9.54. Dual Neutral, p. 54....14253
      LIGHT SYSTEMS (Chapter 10)....14254
        10.1. Back-Up Lights, p. 1....14254
        10.2. Clearance, Marker & Tail Lights W/Tractor N/T 444E, I6 HEU....14255
        10.3. Clearance, Marker & Tail Lights W/Truck N/T 444E, I6 HEUI,....14256
        10.4. Clearance, Marker & Tail Lights W/Tractor W/T 444E, I6 HEU....14257
        10.5. Clearance, Marker & Tail Lights W/Truck W/T 444E, I6 HEUI,....14258
        10.6. Cab Dome and Courtesy Lights, p. 6....14259
        10.7. Work Light W/Tractor & W/Reg. Cab, Sleeper Cab, p. 7....14260
        10.8. Work Light W/Truck, p. 8....14261
        10.9. Fog Light System W/ & N/DRL (USA) & N/T 444E, I6 HEUI, p. ....14262
        10.10. Fog Light System W/ & N/DRL (Canada) & N/T 444E, I6 HEUI,....14263
        10.11. Fog Light System W/ & N/DRL (USA) & W/T 444E, I6 HEUI, p.....14264
        10.12. Fog Light System W/DRL (Canada) & W/T 444E, I6 HEUI, p. 1....14265
        10.13. Headlight System N/DRL W/International Turn Signal Switch....14266
        10.14. Headlight System N/DRL W/International Turn Signal Switch....14267
        10.15. Headlight System N/DRL W/Sig-Stat 910 T/S Sw. W/Flr. Mtd.....14268
        10.16. Headlight System N/DRL W/Sig-Stat 915 T/S Sw. W/Push Btn.....14269
        10.17. Headlight System W/DRL (Canada) W/Sig-Stat 910 T/S Sw. W/....14270
        10.18. Headlight System W/DRL (Canada) W/Sig-Stat 915 T/S Sw. W/....14271
        10.19. Headlight System W/DRL (USA) W/Sig-Stat 910 T/S Sw. W/Air....14272
        10.20. Headlight System W/DRL (USA) W/Sig-Stat 915 T/S Sw. W/Air....14273
        10.21. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Hyd. Br....14274
        10.22. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Hyd. Brake....14275
        10.23. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14276
        10.24. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14277
        10.25. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14278
        10.26. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14279
        10.27. Additional Headlight Wiring W/Dual Drive Cab, p. 27....14280
        10.28. Hydraulic Park Brake Ind. Light W/Key Sw. or Push Button ....14281
        10.29. Panel Lights, p. 29....14282
        10.30. Stop Light Switch W/T 444E & I6 HEUI W/Air Brakes, p. 30....14283
        10.31. Stop Light Switch Truck W/Standard Air Brakes W/Internati....14284
        10.32. Stop Light Switch Truck W/Standard Air Brakes W/Sig-Stat ....14285
        10.33. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14286
        10.34. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14287
      HEATER AND AIR CONDITIONER (Chapter 11)....14288
        11.1. Heater/Air Conditioner, p. 1....14288
        11.2. Heater Only, p. 2....14289
      CONNECTOR COMPOSITES (Chapter 12)....14290
        12.1. Dash Connector (2) (N/T 444E or I6 HEUI)....14290
        12.2. Dash Connector (2) (W/T 444E or I6 HEUI)....14291
        12.3. Dash Connector Engine Connections (2A) (N/T 444E or I6 HEU....14292
        12.4. Dash Connector Engine Connections (2A) (W/T 444E or I6 HEU....14293
        12.5. Connector Composites (3 & 3A)....14294
        12.6. Connector Composite (3J)....14295
        12.7. Connector Composites (11), (12), (13)....14296
        12.8. Connector Composites (14), (14A), (15), (16), (17), (18), ....14297
        12.9. Connector Composites (20), (21)....14298
        12.10. Connector Composites (23), (24), (26)....14299
        12.11. Connector Composites (27), (28), (29), (30), (31), (32)....14300
        12.12. Connector Composites (33), (34), (35), (36), (37), (38), ....14301
        12.13. Connector Composites (47 & 48), (47A), (47B), (49), (50),....14302
        12.14. Connector Composites (53), (54), (55), (56), (57), (58), ....14303
        12.15. Connector Composites (66), (67), (69), (70), (71)....14304
        12.16. Connector Composites (72), (73), (74), (75), (76), (77), ....14305
        12.17. Connector Composites (80), (83), (84 & 85), (86), (90), (....14306
        12.18. Connector Composites (98), (99), (100), (101), (102), (10....14307
        12.19. Connector Composites (105), (106), (107), (108), (109), (....14308
        12.20. Connector Composites (117), (119), (121), (122), (123), (....14309
        12.21. Connector Composites (132), (133), (135), (136)....14310
        12.22. Connector Composites (137), (141), (142), (143), (144), (....14311
        12.23. Connector Composites (147), (148), (149), (153)....14312
        12.24. Connector Composites (153), (154), (156), (157), (158), (....14313
        12.25. Connector Composites (160), (161), (162), (163), (164), (....14314
        12.26. Connector Composites (169), (170), (171), (172), (173), (....14315
        12.27. Connector Composites (179), (180), (181), (182), (183), (....14316
        12.28. Connector Composites (194A), (199), (203), (210), (212), ....14317
        12.29. Connector Composites (214M), (218), (219), (220), (221), ....14318
        12.30. Connector Composites (223), (225), (226), (231), (232M), ....14319
        12.31. Connector Composites (252), (257), (258), (259), (260), (....14320
        12.32. Connector Composites (270), (271), (272), (273), (274A), ....14321
        12.33. Connector Composites (274), (275), (276), (277), (279)....14322
        12.34. Connector Composites (280), (284), (286), (287)....14323
        12.35. Connector Composites (288), (289), (290), (291), (292), (....14324
        12.36. Connector Composites (294), (295), (296), (297), (298), (....14325
        12.37. Connector Composites (304), (305), (306), (309), (310), (....14326
        12.38. Connector Composites (311), (312), (313), (314), (315), (....14327
        12.39. Connector Composites (320), (323), (325)....14328
        12.40. Connector Composites (325), (326), (327), (328), (329), (....14329
        12.41. Connector Composites (332), (333), (335), (336), (337)....14330
        12.42. Connector Composites (338), (339), (340), (341), (342), (....14331
        12.43. Connector Composites (345), (346), (347), (348), (349), (....14332
        12.44. Connector Composites (355), (356), (357), (358), (359), (....14333
        12.45. Connector Composites (367), (368), (369), (370), (372), (....14334
        12.46. Connector Composites (377), (377A), (377B)....14335
        12.47. Connector Composites (379), (382), (382A)....14336
        12.48. Connector Composites (383), (384), (386), (386A), (386B)....14337
        12.49. Connector Composites (387), (389), (390), (391), (392)....14338
        12.50. Connector Composites (396), (399), (400), (401)....14339
        12.51. Connector Composites (402), (403), (404)....14340
        12.52. Connector Composites (406), (413), (417)....14341
        12.53. Connector Composite (418)....14342
        12.54. Connector Composites (420), (421), (422)....14343
        12.55. Connector Composites (423), (425), (426), (427), (428)....14344
        12.56. Connector Composites (430), (431), (432), (433), (434), (....14345
        12.57. Connector Composites (447), (449), (457)....14346
        12.58. Connector Composites (458), (459), (460), (463), (465), (....14347
        12.59. Connector Composites (467), (468), (469), (473), (480), (....14348
        12.60. Connector Composites (492), (493), (494), (495)....14349
        12.61. Connector Composites (499), (500), (501), (502), (503), (....14350
        12.62. Connector Composites (506), (507), (508), (510), (511), (....14351
        12.63. Connector Composites (555), (557), (558), (569), (570), (....14352
        12.64. Connector Composite (615)....14353
        12.65. Connector Composites (631), (632)....14354
        12.66. Connector Composites (633), (634)....14355
        12.67. Connector Composites (636), (637), (639)....14356
        12.68. Connector Composites (646), (646A), (647), (648), (649), ....14357
        12.69. Connector Composites (661), (662), (667), (675), (683), (....14358
        12.70. Connector Composites (700), (701), (702), (703), (707)....14359
        12.71. Connector Composites (708), (734), (758), (759), (760), (....14360
        12.72. Connector Composites (766), (767), (768), (769), (770), (....14361
        12.73. Connector Composites (775), (776), (777), (778), (789), (....14362
        12.74. Connector Composites (792), (807), (830A), (830B), (917),....14363
        12.75. Connector Composites (926), (958), (959), (960), (960A), ....14364
        12.76. Connector Composites (995), (996), (1000), (1001), (1002)....14365
        12.77. Connector Composites (1014), (1015)....14366
        12.78. Connector Composites (1016), (1017), (1091)....14367
        12.79. Connector Composites (1093), (1094), (1095), (1097), (109....14368
        12.80. Connector Composites (1110M), (1113F), (1117), (1119), (1....14369
        12.81. Connector Composites (1125), (1126), (1128), (1129), (113....14370
        12.82. Connector Composites (1132), (1133), (1134), (1135), (302....14371
        12.83. Connector Composites (3024), (3025), (3026), (3027), (302....14372
        12.84. Connector Composites (3031), (3032), (3033), (3034)....14373
        12.85. Connector Composites (3035), (3038), (3039), (3040)....14374
        12.86. Connector Composites (3043), (3044), (3047), (3084), (308....14375
S08230 - Electrical System Troubleshooting Guide, Supersedes CTS-5300 (July 1999) Service Manual....14376
S082503 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built Before 05_20_2003....15088
  S082503Z.PDF (p.1-140)....15088
  3200 4000 7000 8000 (May 2003) Electrical Troubleshooting (S082503A).pdf (p.141-1320)....15228
    S082503AA.PDF (p.1-140)....15228
    S082503AB.PDF (p.141-340)....15368
    S082503AC.PDF (p.341-444)....15568
    S082503AD.PDF (p.445-628)....15672
    S082503AE.PDF (p.629-830)....15856
    S082503AF.PDF (p.831-964)....16058
    S082503AG.PDF (p.965-1180)....16192
  S082503B.PDF (p.1321-1510)....16408
  S082503C.PDF (p.1511-1612)....16598
  S082503D.PDF (p.1613-1794)....16700
  S082503E.PDF (p.1795-1990)....16882
  S082503F.PDF (p.1991-2124)....17078
  S082503G.PDF (p.2125-2332)....17212
S082503 - Electrical System Troubleshooting Guide Models Built 10_16_2000 to 05_20_2003 (Jan 2008) Service Manual....17420
  S082503Z....17420
  S082503B....17560
  S082503C....17750
  S082503D....17852
  S082503E....18034
  S082503F....18230
  S082503G....18364
S082504 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models 05_20_2003 to 02_28_2007....18572
  S082504Z.PDF (p.1-332)....18572
  S082504B.PDF (p.333-620)....18904
  S082504C.PDF (p.621-824)....19192
  S082504D.PDF (p.825-1172)....19396
S082504 - Electrical System Troubleshooting Guide Models Built 05_20_2003 to 02_28_2007 (Jan 2008) Service Manual....19744
  S082504Z....19744
  S082504B....20076
  S082504C....20364
  S082504D....20568
S08285 - 4200, 4300, 4400 Models Built October 16, 2000 to December 31, 2001 Electrical Circuit Diagrams (Jan 2001)....20916
  S08285A....20916
  S08285B....20974
  S08285C....21023
S082852 - 4000 Series (Jan 2002 to Sep 2002) Wiring Diagrams....21080
  S082852Z.PDF (p.1-63)....21080
  S082852B.PDF (p.64-119)....21143
  S082852C.PDF (p.120-183)....21199
S082852 - 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600 Models Built January 1, 2002 To September 30, 2002 Electrical Circuit Diagrams (Jan 2002) Service Manual....21263
  S082852Z....21263
  S082852B....21326
  S082852C....21382
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built October 1, 2002 to September 15, 2003 Electrical Circuit Diagrams (Oct 2002) Manual....21446
  S082852AA....21446
  S082852AB....21511
  S082852AC....21569
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES Built October 1, 2002 and After ELECTRICAL CIRCUIT DIAGRAMS....21633
  S082852AA.PDF (p.1-65)....21633
  S082852AB.PDF (p.66-123)....21698
  S082852AC.PDF (p.124-187)....21756
S082853 - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built September 16, 2003 to March 10, 2004 Electrical Circuit Diagrams....21820
  S082853Z....21820
  S082853B....21889
  S082853C....21963
S082854 - 4000 Series (2004 to 2005) Wiring Diagrams....22028
S08300 - Body Builder Electrical Data Book for Models Built January 2001 to February 28, 2007 Supersedes PBB-73000B (Aug 2008) Service Manual....22243
  S08300z0805....22243
  S08300b0805....22370
  S08300c0805....22527
S08308 - Diamond Logic PowerPack 3 Dynamic Power System Service _ Troubleshooting Guide (Feb 2006) Service Manual....22679
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes (June 2005) Service Manual....22691
S08315 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, MXT, RXT Models Built Oct. 1, 2005 to Feb. 28, 2007 Electrical Circuit Diagrams....22702
S08322 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600, RXT Models Built March 1, 2007 to March 18, 2008 Electrical Circuit Diagrams....22991
  S08322a....22991
  S08322b....23105
  S08322c....23213
S08322 - 4000 Series (March 2007 to March 2008) Wiring Diagrams....23342
  3200 RXT 4000 7000 8000 (March 2007 to March 2008) Wiring Diagrams (S08322a).pdf (p.1-114)....23342
  S08322b.pdf (p.115-222)....23456
  S08322c.pdf (p.223-351)....23564
S08323A - (2007) 3000 4000 7000 8000 BE CE DuraStar WorkStar TranStar  - Body Builder Data Book....23693
S08324 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, CXT, DuraStar, RXT, TranStar, and WorkStar Models Built After March 01, 2007 Electrical System Troubleshooting Guide....23969
  toc....23973
    SAFETY INFORMATION....23973
      INTRODUCTION....23975
        1. MANUAL INTRODUCTION....23977
        Electronic Gauge Cluster....23979
          1. Description And Operation....23981
            1.1. Overview....23981
            1.2. Operation....23981
            1.3. EGC Diagram....23982
            1.4. Data Link Communication....23982
          2. Feature Codes....23982
          3. Cluster Features....23983
            3.1. Gauges....23983
            3.2. Warning and Indicator Lamps....23989
              Flashing of Diagnostic Lamps ....23989
              Individual Warning Lamps....23989
              In-Gauge Warning Lamps....24006
              Direct Drive Warning Lamps....24006
            3.3. Digital Display....24007
              Display Control....24007
              Display Lighting....24007
              Initial Display Mode....24008
              Informational Display Screens (Quadrant 1)....24008
              Standard Selections....24008
              Optional Selections....24008
              Odometer/Trip Functions....24008
              Hours Functions....24009
              Fuel Economy....24009
              Fuel Used (2010 and beyond Clusters)....24010
              Compass/Outside Temperature (Quadrant 3)....24010
              General Text and Warning Messages (Quadrant 2)....24011
              HVAC Graphics....24015
              Transmission Gear Displays (Quadrant 4)....24015
            3.4. Audible Alarm....24016
              One-time Five-short-beeps Alarm....24016
              Repetitive One-short-beep Alarm....24016
              One-time Ten-short-beeps Alarm ....24017
              One-time Three-long-beeps Alarm....24017
              Repetitive Short Duration Blips ....24017
            3.5. Switches....24017
              Headlight/Park Light Switch....24018
              Panel Dimmer Switch....24018
              Right Side Optional Switches....24018
              Left Side Optional Switches....24018
            3.6. Analog Inputs....24018
              Pressure Sensors....24018
              Outside Temperature....24019
            3.7. Outputs....24019
              Headlight Enable....24019
            3.8. Digital Inputs....24019
            3.9. Panel Dimming and Gauge Backlighting....24019
              Panel Lighting....24019
            3.10. Error Operation....24020
              Lost Communication....24020
              EGC Internal Failure....24020
              Gauge Faults....24020
              Digital Display....24021
            3.11. Full Power, Low Power, and Standby Modes....24021
          4. Cluster Programming....24023
          5. User Programmable Parameters....24023
          6. Caution — Handling the EGC....24024
          7. Diagnostics....24024
            7.1. Gauge Sweep....24024
            7.2. On-Board Diagnostics....24024
            7.3. Off-Board Diagnostics....24024
            7.4. Diamond Logic Builder (DLB)....24025
            7.5. Diagnostic Trouble Codes....24025
            7.6. Displaying Fault Codes....24029
              Definitions:....24030
              Failure Mode Indicators (FMI):....24031
              Source Addresses (SA)....24032
            7.7. Clearing Fault Codes....24033
          8. Troubleshooting....24033
            8.1. EGC Preliminary System Check....24033
            8.2. EGC Power and Data Link Voltage Checks....24035
            8.3. Gauge Troubleshooting....24035
              Gauge Troubleshooting Procedure....24035
              Diagnostic Trouble Codes and Related Voltage Checks for the Sens....24039
            8.4. Warning Lamp Troubleshooting Procedure....24052
            8.5. In-Gauge Warning Lamps....24054
            8.6. Direct Drive Warning Lamps....24055
              Direct Drive Warning Lamp Troubleshooting:....24056
            8.7. EGC Backlighting Inoperative....24056
            8.8. EGC Switches....24057
              Push Button Switch Troubleshooting....24057
              Rocker Switch Troubleshooting....24057
            8.9. Digital Display....24057
              Display Control....24058
            8.10. Audible Alarm....24058
            8.11. Outside Temperature Display Malfunction....24059
            8.12. Lost SAE J1939 Data Link Communication....24060
          9. Body Controller Signals....24061
        Lighting Systems....24063
          1. snowplow auxiliary lighting....24067
            1.1. system description....24067
              Overview....24067
              Operation....24067
            1.2. feature codes....24067
            1.3. user programmable parameters....24068
            1.4. diagnostic trouble codes....24069
            1.5. troubleshooting....24070
              Snow plow lighting preliminary checks....24071
              Auxiliary Lights Relay Tests....24072
          2. back up lights....24073
            2.1. system description....24073
              Overview....24073
              Operation....24073
            2.2. feature code....24074
            2.3. user programmable parameters....24074
            2.4. diagnostic trouble codes....24074
            2.5. troubleshooting....24075
              Back Up Lights Preliminary Checks....24075
              Back Up Lights Test....24076
              Backup Light Relay Tests....24077
              Backup Light Ball Switch Tests....24077
          3. Dome and courtesy lights....24077
            3.1. system description....24077
              Overview....24077
              Operation....24078
            3.2. feature code....24078
            3.3. USER PROGRAMMABLE PARAMETERS....24078
            3.4. diagnostic trouble codes....24079
            3.5. troubleshooting....24080
              Dome and Courtesy Lights Preliminary Checks....24080
              Door Switch Circuit Tests....24081
              Dome Light Circuit Tests....24082
          4. fog lights....24083
            4.1. system description....24083
              Overview....24083
              Operation....24084
            4.2. feature codes....24084
            4.3. user programmable parameters....24084
            4.4. diagnostic trouble codes....24084
            4.5. troubleshooting....24085
              Fog Light System Preliminary Checks....24086
              Fog Light Switch Test....24086
              Fog Light Open Circuit Test....24087
              Fog Light Short Circuit Test....24088
          5. Headlights and DTRL....24088
            5.1. system description....24088
              Overview....24088
              Operation....24088
            5.2. feature codes....24089
            5.3. user programmable parameters....24089
            5.4. diagnostic trouble codes....24090
            5.5. troubleshooting....24091
              Headlight System Preliminary Checks....24092
              Headlight Switch and Headlight Dimmer Tests....24093
              Headlight Open Circuit Test....24094
              Headlight Short Circuit Test....24095
          6. STOP, TURN, AND HAZARDS....24095
            6.1. system description....24095
              Overview....24095
              Operation....24095
            6.2. feature codes....24095
            6.3. user programmable parameters....24097
            6.4. diagnostic trouble codes....24097
            6.5. troubleshooting....24099
              Stop, Turn, and Hazards System Preliminary Checks....24099
              Turn Signal Switch Test....24101
              Hazard Switch Test....24101
              Brake Switch Test....24102
              Output Open Circuit Test....24102
              Output Short Circuit Test....24103
          7. TAIL, MARKER, PARK, AND CLEARANCE LIGHTING....24103
            7.1. system description....24103
              Overview....24103
              Operation....24104
            7.2. feature codes....24104
            7.3. user programmable parameters....24105
            7.4. diagnostic trouble codes....24105
            7.5. troubleshooting....24106
              Tail, Marker, Park, and Clearance Lighting Preliminary Checks....24107
              Headlight Switch Tests....24107
              Interrupt Switch Tests....24108
              Park Light Open Circuit Tests....24109
              Park Light Short Circuit Tests....24109
          8. work lights....24109
            8.1. system description....24109
              Overview....24109
              Operation....24110
            8.2. feature codes....24110
            8.3. user programmable parameters....24111
            8.4. diagnostic trouble codes....24111
            8.5. troubleshooting....24112
              Work Light System Preliminary Checks....24112
              Work Light Switch Test....24113
              Work Light Open Circuit Test....24113
              Work Light Short Circuit Test....24114
        Auxiliary Gauge Switch Pack....24115
          1. Description And Operation....24117
            1.1. Overview....24117
            1.2. Operation....24117
            1.3. AGSP Diagram....24117
            1.4. Data Link Communication....24117
          2. Feature Codes....24118
          3. Features....24118
            3.1. Gauges....24118
            3.2. In-Gauge Warning Lamps....24119
            3.3. Hybrid Display....24119
            3.4. Switches....24120
            3.5. Panel Dimming and Gauge Backlighting....24120
            3.6. Error Operation....24120
            Lost Communication....24121
            Gauge Faults....24121
          4. AGSP Programming....24122
          5. User Programmable Parameters....24122
          6. Caution — Handling the AGSP....24122
          7. Diagnostics....24122
            7.1. Gauge Sweep....24122
            7.2. On-Board Diagnostics....24123
            7.3. Off-Board Diagnostics....24123
            7.4. Diamond Logic Builder (DLB)....24123
            7.5. Diagnostic Trouble Codes....24123
          8. Troubleshooting....24126
            8.1. AGSP Preliminary System Check....24126
            8.2. AGSP Power and Data Link Voltage Checks....24127
            8.3. Gauge Troubleshooting Procedure....24127
            8.4. Troubleshooting Specific Gauges....24129
            8.5. In-Gauge Warning Lamps....24136
            8.6. Panel Dimming and Gauge Backlighting....24137
            8.7. AGSP Switches....24137
            8.8. Lost SAE J1939 Data Link Communication....24137
            9.1. Body Controller Signals....24137
        Cab Features....24139
          1. cigar lighter and power feed....24145
            1.1. System description....24145
              Overview....24145
              Cigar Lighter Operation....24145
              Cigar Lighter Power Source and Two Post Power Source Operation....24145
            1.2. feature codes....24145
            1.3. user programmable parameters....24145
            1.4. diagnostic trouble codes....24145
            1.5. diagnostics....24145
              Cigar Lighter and Power Feed Preliminary Check....24145
              Cigar Lighter Tests....24146
              Cigar Lighter Power Source Test....24147
              Two Post Power Source Test....24147
          2. C.b. Power radio....24149
            2.1. system description....24149
              Overview....24149
              Operation....24149
            2.2. feature codes....24149
            2.3. user programmable parameters....24149
            2.4. diagnostic trouble codes....24149
            2.5. diagnostics....24149
              C.B. Radio Power Source Preliminary Check....24149
              C.B. Power Connector Tests....24150
          3. compass and temperature display....24152
            3.1. system description....24152
              Overview....24152
              Temperature Display Operation....24152
              Compass Display Operation....24152
            3.2. feature codes....24152
            3.3. USER PROGRAMMABLE PARAMETERS....24152
            3.4. Diagnostic Trouble Codes....24152
            3.5. diagnostics....24153
              Compass/Temperature Display Preliminary Check....24154
              Compass/Temperature Display Voltage Checks....24154
          4. power windows and locks....24155
            4.1. system description....24155
              Overview....24155
              Power Window Operation....24155
              Power Door Lock Operation....24155
            4.2. feature codes....24156
            4.3. user programmable parameters....24158
            4.4. diagnostic trouble codes....24158
            4.5. Troubleshooting....24161
              Power Window and Lock Preliminary Check....24162
              Power Door Lock Tests....24163
              Power Window Test....24164
          5. cruise control....24165
            5.1. system description....24165
              Overview....24165
              Operation....24165
            5.2. feature codes....24165
            5.3. user programmable parameters....24166
            5.4. diagnostic trouble codes....24166
            5.5. Troubleshooting....24167
              Cruise Control Preliminary Check....24168
              Cruise Control Switch Tests....24169
          6. Theft deterrent....24171
            6.1. system description....24171
              Overview....24171
              Operation....24171
            6.2. feature codes....24172
            6.3. User programmable parameters....24173
            6.4. diagnostic trouble codes....24174
            6.5. troubleshooting....24175
              Theft Deterrent Preliminary Check....24175
              Theft Deterrent System Test....24175
          7. electric horn....24177
            7.1. system description....24177
              Overview....24177
              Operation....24177
            7.2. feature codes....24177
            7.3. User programmable parameters....24177
            7.4. diagnostic trouble codes....24178
            7.5. troubleshooting....24179
              Electric Horn Preliminary Check....24179
              Electric Horn Test....24180
          8. air horn....24182
            8.1. system description....24182
              Overview....24182
              Operation....24182
            8.2. feature codes....24182
            8.3. User programmable parameters....24182
            8.4. diagnostic trouble codes....24182
            8.5. troubleshooting....24183
              Air Horns Preliminary Check....24183
              Air Horn Test....24184
          9. power mirrors....24185
            9.1. system description....24185
              Overview....24185
              Operation....24185
            9.2. feature codes....24185
            9.3. User programmable parameters....24185
            9.4. diagnostic trouble codes....24185
            9.5. troubleshooting....24185
              Power Mirror Preliminary Check....24186
              Power Mirror Test....24187
          10. Heated Mirror....24189
            10.1. system description....24189
              Overview....24189
              Operation....24189
            10.2. feature codes....24189
            10.3. User programmable parameters....24191
            10.4. diagnostic trouble codes....24191
            10.5. troubleshooting....24192
              Heated Mirror Preliminary Check....24192
              Heated Mirrors Test....24193
              Left Heated Mirror Test....24193
              Right Heated Mirror Test....24194
          11. radio (entertainment), speakers....24195
            11.1. system description....24195
              Overview....24195
              Operation....24195
            11.2. feature codes....24195
            11.3. User programmable parameters....24195
            11.4. diagnostic trouble codes....24195
            11.5. troubleshooting....24195
              Radio Preliminary Check....24196
              Radio Test....24196
          12. Two-way radio....24198
            12.1. system description....24198
              Overview....24198
              Operation....24198
            12.2. feature codes....24198
            12.3. User programmable parameters....24198
            12.4. diagnostic trouble codes....24198
            12.5. troubleshooting....24198
              Two-Way Radio Circuit Tests....24198
          13. Windshield wiper and washer pump....24200
            13.1. system description....24200
              Overview....24200
              Wiper Operation....24200
              Park Operation....24200
              Washer Operation....24200
            13.2. feature codes....24200
            13.3. User programmable parameters....24201
            13.4. diagnostic trouble codes....24202
              NO TITLE....24204
            13.5. troubleshooting....24204
              Wiper and Washer Preliminary Check....24204
              Washer Test....24206
              Wiper Park Test....24206
              Wiper Switch Test....24207
              Wiper Motor Test....24208
          14. Roof auxiliary load and air shield light....24210
            14.1. system description....24210
              Overview....24210
              Roof Auxiliary Load Operation....24210
              Air Shield Light Operation....24210
            14.2. Feature codes....24210
            14.3. User programmable parameters....24210
            14.4. diagnostic trouble code....24210
              Roof Auxiliary Load Feature....24210
              Lighted Air Shield....24211
            14.5. troubleshooting....24211
              Roof Auxiliary Load Preliminary Check....24211
              Roof Auxiliary Load Test....24212
              IP Mounted Roof Auxiliary Load Switch Test....24212
              Lighted Air Shield Preliminary Check....24213
              Lighted Air Shield Test....24214
          15. self contained air seat....24215
            15.1. system description....24215
              Overview....24215
              Operation....24215
            15.2. Feature codes....24215
            15.3. User programmable parameters....24215
            15.4. diagnostic trouble code....24215
            15.5. troubleshooting....24215
              Self Contained Air Seats Preliminary Check....24215
              Self Contained Air Seat Test....24216
          16. Heated seats....24217
            16.1. system description....24217
              Overview....24217
              Operation....24217
            16.2. Feature codes....24217
            16.3. User programmable parameters....24217
            16.4. diagnostic trouble code....24217
            16.5. troubleshooting....24217
              Heated Seats Preliminary Check....24217
              Heated Seat Test....24218
          17. seat belt and seat sensor....24219
            17.1. system description....24219
              Overview....24219
              Operation....24219
            17.2. feature codes....24219
            17.3. User programmable parameters....24219
            17.4. diagnostic trouble code....24220
            17.5. troubleshooting....24220
              Seat Belt Preliminary Check....24220
              Seat Belt Test....24221
          18. brake light switch....24222
            18.1. system description....24222
              Overview....24222
              Operation....24222
            18.2. Feature codes....24222
            18.3. User programmable parameters....24222
            18.4. diagnostic trouble code....24222
            18.5. troubleshooting....24224
              Brake Switch Preliminary Check....24224
              Brake Switch Test....24225
          19. Clutch switch....24226
            19.1. system description....24226
              Overview....24226
              Operation....24226
            19.2. Feature codes....24226
            19.3. User programmable parameters....24226
            19.4. diagnostic trouble code....24226
            19.5. troubleshooting....24227
              Clutch Switch Preliminary Checks....24228
              No Engine Crank Clutch Switch Test....24229
              Cruise Control Clutch Switch Test....24229
          20. load shedding....24230
            20.1. system description....24230
              Overview....24230
              Operation....24230
            20.2. Feature codes....24230
            20.3. User programmable parameters....24230
            20.4. diagnostic trouble code....24230
            20.5. troubleshooting....24231
              Latching Relay Diagnostics....24232
        Chassis Features....24233
          1. trailer turn signal relays....24239
            1.1. System description....24239
              Overview....24239
              Operation....24239
            1.2. feature codes....24239
            1.3. user programmable parameters....24239
            1.4. diagnostic trouble codes....24239
            1.5. troubleshooting....24240
              Trailer Turn Signal Relay System Preliminary Checks....24241
              Left Trailer Turn Signal Inop Test....24242
              Right Trailer Turn Signal Inop Test....24243
          2. trailer auxiliary power circuit....24244
            2.1. System description....24244
              Overview....24244
              Operation....24244
            2.2. feature codes....24244
            2.3. user programmable parameters....24244
            2.4. diagnostic trouble codes....24244
            2.5. troubleshooting....24245
              Trailer Auxiliary Power Circuit Preliminary Checks....24245
              Trailer Auxiliary Circuit Tests....24245
          3. Auto Neutral (Feature Code 0595AYP)....24247
            3.1. Description And Operation....24247
              Overview....24247
              Operation....24247
            3.2. Feature Codes....24248
            3.3. User Programmable Parameters....24248
            3.4. Diagnostics....24249
              Diamond Logic Builder (DLB)....24249
              Diagnostic Trouble Codes....24249
              Displaying Diagnostic Trouble Codes....24250
            3.5. Troubleshooting....24250
              Auto Neutral Preliminary System Check....24250
              Auto Neutral Does Not Engage....24251
              Auto Neutral Does Not Disengage....24252
              Auto Neutral Warning Lamp Inoperative....24253
            3.6. Body Controller Signals....24253
            3.7. Body Controller Functions....24254
              Activate Auto Neutral....24254
              Error Operation....24255
          4. Axle Load Monitor....24256
            4.1. Description And Operation....24256
              Overview....24256
              Operation....24256
            4.2. Feature Codes....24256
            4.3. User Programmable Parameters....24257
            4.4. Diagnostics....24258
              Diamond Logic Builder (DLB)....24258
              Diagnostic Trouble Codes....24258
              Displaying Diagnostic Trouble Codes....24260
            4.5. Troubleshooting....24260
              Axle Load Monitor Preliminary Check....24260
              Axle Pressure Transducer Voltage Checks....24261
            4.6. Body Controller Signals....24261
            4.7. Body Controller Functions....24262
            To activate the axle load monitor feature, the following conditi....24262
          5. REMOTE POWER MODULE....24263
            5.1. Description and Operation....24263
              Overview....24263
              Operation....24263
              RPM Addressing....24264
            5.2. Feature Codes....24264
            5.3. User Programmable Parameters....24264
            5.4. Diagnostics....24265
              Diamond Logic Builder (DLB)....24265
              Diagnostic Trouble Codes....24265
              Displaying Diagnostic Trouble Codes....24268
            5.5. Troubleshooting....24268
              Remote Power Module Preliminary Check....24268
              RPM Power, Ground and Data Link Circuits....24269
            5.6. Body Controller Signals....24270
            5.7. Body Controller Functions....24270
          6. auxiliary power source....24271
            6.1. System description....24271
              Overview....24271
              Operation....24271
            6.2. feature codes....24271
            6.3. user programmable parameters....24271
            6.4. diagnostic trouble codes....24271
            6.5. troubleshooting....24271
              Auxiliary Power Source Preliminary Check....24272
              Aux Power Source Tests....24272
          7. Two-speed axle switch....24274
            7.1. System description....24274
              Overview....24274
              Operation....24274
            7.2. feature codes....24274
            7.3. user programmable parameters....24274
            7.4. diagnostic trouble codes....24274
            7.5. troubleshooting....24275
              Two-Speed Switch Preliminary Check....24275
              Two-Speed Switch Test....24275
          8. Air Dryer and heated drain valve....24276
            8.1. System description....24276
              Overview....24276
              Operation....24276
            8.2. feature codes....24276
            8.3. user programmable parameters....24276
            8.4. diagnostic trouble codes....24276
            8.5. troubleshooting....24276
              Air Dryer and Heated Drain Valve Preliminary Check....24276
              Heated Drain Valve Test....24277
              Air Dryer Test....24277
          9. fuel transfer pump....24279
            9.1. System description....24279
              Overview....24279
              Operation....24279
            9.2. feature codes....24279
            9.3. user programmable parameters....24279
            9.4. diagnostic trouble codes....24281
            9.5. troubleshooting....24281
              Fuel Transfer Pump Preliminary Check....24282
              Fuel Transfer Pump Won’t Run Test....24282
              Fuel Transfer Pump Continuously Runs Test....24284
          10. water in fuel monitor....24285
            10.1. System description....24285
              Overview....24285
              Operation....24285
            10.2. feature codes....24285
            10.3. user programmable parameters....24285
            10.4. diagnostic trouble codes....24285
            10.5. troubleshooting....24286
              Water in Fuel Preliminary Check....24286
              Water Probe Test....24287
          11. electric trailer brake....24288
            11.1. System description....24288
              Overview....24288
              Operation....24288
            11.2. feature codes....24288
            11.3. user programmable parameters....24288
            11.4. diagnostic trouble codes....24288
            11.5. troubleshooting....24289
              Electric Trailer Brake Preliminary Check....24289
              Electric Trailer Brake Test....24290
          12. air solenoid....24292
            12.1. System description....24292
              Overview....24292
              Operation....24292
            12.2. feature codes....24292
            12.3. user programmable parameters....24293
            12.4. diagnostic trouble codes....24294
            12.5. Troubleshooting....24302
              Air Solenoid Preliminary Check....24302
              Air Solenoid Diagnosis....24302
          13. Suspension dump....24304
            13.1. System description....24304
              Overview....24304
              Operation....24304
            13.2. feature code....24304
            13.3. user programmable parameters....24304
            13.4. diagnostic trouble codes....24305
            13.5. Troubleshooting....24306
              Suspension Dump Test....24307
          14. Customer Installed Lift Gate Power Source....24309
            14.1. System description....24309
              Overview....24309
              Operation....24309
            14.2. feature code....24309
            14.3. user programmable parameters....24309
            14.4. diagnostic trouble codes....24310
            14.5. Troubleshooting....24310
              Lift Gate Test....24311
          15. Fifth Wheel Slide, Air Controlled....24312
            15.1. System description....24312
              Overview....24312
              Operation....24312
            15.2. FEATURE CODE....24312
            15.3. user programmable parameters....24312
            15.4. diagnostic trouble codes....24313
            15.5. Troubleshooting....24313
              Fifth Wheel Slide Preliminary Check....24314
              Fifth Wheel Slide Test....24314
          16. Differential Lock Air controlled....24315
            16.1. System description....24315
              Overview....24315
              Operation....24315
            16.2. FEATURE CODE....24316
            16.3. user programmable parameters....24316
            16.4. diagnostic trouble codes....24317
            16.5. Troubleshooting....24318
              Differential Lock Preliminary Check....24319
              (0595ACT) Differential Lock Test....24319
              (0595ACU) Differential Lock Test....24320
          17. Power Divider Lock (PDL) Air Controlled....24321
            17.1. System description....24321
              Overview....24321
              Operation....24321
            17.2. FEATURE CODE....24321
            17.3. user programmable parameters....24322
            17.4. diagnostic trouble codes....24323
            17.5. Troubleshooting....24323
              Power Divider Lock Preliminary Check....24324
              Power Divider Lock Test....24324
          18. Remote start/stop....24325
            18.1. System Description....24325
              Overview....24325
              Operation....24325
            18.2. FEATURE CODE....24325
            18.3. user programmable parameters....24326
            18.4. Diagnostic Trouble Codes....24326
            18.5. Troubleshooting....24327
              Remote Start/Stop Preliminary Check....24327
              Remote Start/Stop System Tests....24329
          19. Power Take Off (PTO)....24331
            19.1. Description and Operation....24331
              Overview....24331
              Operation....24331
            19.2. Feature Codes....24332
            19.3. User Programmable Parameters....24340
            19.4. Diagnostics....24341
              Diamond Logic Builder (DLB)....24341
              Diagnostic Trouble Codes....24341
              Displaying Diagnostic Trouble Codes....24352
            19.5. Troubleshooting....24352
              Power Take Off (PTO) Preliminary Check....24352
            19.6. Body Controller Signals....24354
            19.7. Body Controller Functions....24356
          20. Wheelchair Lift Interlock....24357
            20.1. Description And Operation....24357
              Overview....24357
              Operation....24357
            20.2. Feature Codes....24358
            20.3. User Programmable Parameters....24358
            20.4. Diagnostics....24358
              Diamond Logic Builder (DLB)....24358
              Diagnostic Trouble Codes....24358
              Displaying Diagnostic Trouble Codes....24359
            20.5. Troubleshooting....24359
              Wheelchair Lift Interlock Preliminary System Check....24359
            20.6. Body Controller Signals....24362
            20.7. Body Controller Functions....24363
              Activate Wheelchair Lift Solenoid....24363
              Activate Audible Alarm....24364
        TRANSMISSIONS....24365
          1. Description and Operation....24367
            1.1. Overview....24367
            1.2. Operation....24367
          2. Feature Codes....24369
            2.1. Available Body Controller Configurations....24369
            2.2. User Programmable Parameters....24371
          3. Diagnostics....24372
            3.1. Diamond Logic Builder (DLB)....24372
            3.2. Diagnostic Trouble Codes....24372
            3.3. Displaying Diagnostic Trouble Codes....24373
          4. Troubleshooting....24374
            4.1. Preliminary System Check — All Transmissions....24374
            4.2. Park Position Unlock Solenoid Checks — Eaton T-Handle & All....24379
            4.3. LCT Column Shifter Interlock Checks....24380
            4.4. TCM Power, Ground and Data Link Circuit Checks....24380
            4.5. Shift Selector Power and Ground Circuit Checks....24381
            4.6. Body Controller Signals....24381
            4.7. Body Controller Functions....24382
              Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....24382
              PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....24382
        Multiplexing (Data Links)....24383
          1. multiplexing (data links)....24385
            1.1. Description....24385
              Overview....24385
              Operation....24385
            1.2. troubleshooting....24387
              J1939 Data Link Terminating Resistors....24387
              Body Controller....24388
        Electronic Engines....24389
          1. REMOTE ENGINE SPEED CONTROL MODULE (RESCM)....24391
            1.1. Description and Operation....24391
              Overview....24391
              Operation....24391
            1.2. Feature Codes....24392
            1.3. User Programmable Parameters....24392
            1.4. Diagnostics....24392
              Diamond Logic Builder (DLB)....24392
              Diagnostic Trouble Codes....24392
              Displaying Diagnostic Trouble Codes....24397
            1.5. Troubleshooting....24397
              RESCM Preliminary Check....24397
              RESCM Power, Ground and Data Link Circuits....24398
            1.6. Body Controller Signals....24399
            1.7. Body Controller Functions....24400
          2. Aftertreatment....24401
            2.1. Description And Operation....24401
              Overview....24401
              Operation....24401
            2.2. Aftertreatment Definitions....24402
            2.3. Soot Accumulation Level Indications....24402
            2.4. Feature Related Text Messages in the Gauge Cluster....24403
            2.5. Feature Codes....24404
            2.6. User Programmable Parameters....24405
            2.7. Diagnostics....24405
              Diamond Logic Builder (DLB)....24406
              Diagnostic Trouble Codes....24406
              Displaying Diagnostic Trouble Codes....24409
            2.8. Troubleshooting....24409
              Preliminary System Check — Aftertreatment....24409
              Parked Regeneration Switch Test....24410
              Parked Regeneration Switch Indicator Test....24411
              Inhibit Regeneration Switch Test....24411
              Inhibit Regeneration Switch Indicator Test....24412
              DPF Status Warning Lamp Test....24412
              HEST Warning Lamp Test....24412
              Lamp Check....24413
              Lost Communication and Warning Lamp Diagnostics....24413
            2.9. Body Controller Signals....24413
            2.10. Body Controller Functions....24415
              Parked Regeneration....24415
              Inhibit Regeneration....24416
              Parked Regeneration Switch Indicator....24416
              Inhibit Regeneration Switch Indicator....24417
              DPF Status Warning Lamp....24418
              HEST Warning Lamp....24418
              Audible Alarm....24419
        Switch Packs (J1708 Data Links)....24421
          1. switch packs (j1708 data link)....24423
            1.1. Description....24423
              Overview....24423
              Operation....24423
            1.2. troubleshooting....24423
              Switch Pack Preliminary Check....24424
              Switch Pack Test....24424
        12 Volt Power Distribution and Grounds....24425
          1. 12-Volt power distribution and grounds....24427
            1.1. Description....24427
              Overview....24427
              Operation....24427
            1.2. troubleshooting....24427
              Battery Power Distribution Check....24428
              Accessory Power Distribution Preliminary Check....24428
              Accessory Power Test....24428
              Ignition Power Distribution Preliminary Check....24429
              Ignition Power Test....24430
              Ground Test....24431
        Fans and Engine Accessories....24433
          1. Engine Cooling Fan Control....24435
            1.1. Description And Operation....24435
              Overview....24435
              Operation....24435
            1.2. Feature Codes....24435
            1.3. User Programmable Parameters....24436
            1.4. Diagnostics....24436
              Diagnostic Trouble Codes....24436
              Displaying Diagnostic Trouble Codes....24437
            1.5. Troubleshooting....24437
              Preliminary Check — Engine Cooling Fan....24437
            1.6. Body Controller Signals....24438
            1.7. Body Controller Functions....24440
              Fan Control — General Information....24440
              ON/OFF Fan Control....24440
              Low Air Pressure Engine Fan Override (0595BBB)....24441
              Variable Speed Fan Control (0595AYH)....24442
          2. Snow Valve (Engine Intake) (non Big Bore Engines)....24444
            2.1. Description And Operation....24444
              Overview....24444
              Operation....24444
            2.2. Feature Codes....24444
            2.3. User Programmable Parameters....24444
            2.4. Diagnostics....24445
              Diagnostic Trouble Codes....24445
            2.5. Troubleshooting....24445
              Snow Valve Preliminary Check....24445
              Snow Valve Mechanical Checks....24445
               Snow Valve Module Checks....24446
            2.6. Body Controller Signals....24446
            2.7. Body Controller Functions....24446
          3. Snow Valve (Engine Intake) (Big Bore Engines)....24447
            3.1. Description And Operation....24447
              Overview....24447
              Operation....24447
            3.2. Feature Codes....24448
            3.3. User Programmable Parameters....24448
            3.4. Diagnostics....24448
              Diamond Logic Builder (DLB)....24448
              Diagnostic Trouble Codes....24449
              Displaying Diagnostic Trouble Codes....24449
            3.5. Troubleshooting....24449
              Snow Valve Preliminary Check....24449
              Snow Valve Mechanical Checks....24450
              Snow Valve Switch Test....24451
              Snow Valve Module Checks....24451
            3.6. Body Controller Signals....24453
            3.7. Body Controller Functions....24453
            To activate the feature, the following conditions must be true:....24453
            If the conditions to activate the feature (above) are true, then....24453
            If any of the following conditions occur, then the feature will ....24454
            If any of the conditions to deactivate the feature (above) are t....24454
          4. Exhaust Brake....24455
            4.1. Description And Operation....24455
              Overview....24455
              Operation....24455
            4.2. Feature Codes....24455
            4.3. User Programmable Parameters....24456
            4.4. Diagnostics....24456
              Diamond Logic Builder (DLB)....24456
              Diagnostic Trouble Codes....24456
              Displaying Diagnostic Trouble Codes....24456
            4.5. Troubleshooting....24457
              Exhaust Brake Preliminary Check....24457
               Exhaust Brake Switch Test....24458
            4.6. Body Controller Signals....24458
            4.7. Body Controller Functions....24459
            To activate the exhaust brake feature, the following conditions ....24459
            If the conditions to activate the feature (above) are true, then....24459
        Battery, Charging, and Cranking System....24461
          1. battery....24463
            1.1. Description....24463
              Overview....24463
              Operation....24463
            1.2. diagnostic trouble codes....24464
            1.3. troubleshooting....24464
              NO TITLE....24464
          2. charging system....24465
            2.1. Description....24465
              Overview....24465
              Operation....24465
            2.2. diagnostic trouble codes....24465
            2.3. troubleshooting....24466
          3. ENGINE CRANKING....24466
            3.1. Description....24466
              Overview....24466
              Operation....24466
            3.2. troubleshooting....24467
          4. Power pack 3....24467
            4.1. Description....24467
              Overview....24467
              Operation....24467
            4.2. troubleshooting....24468
  tables....23983
    Table 1Gauge Table....23983
    Table 2Warning and Indicator Lamp Table – Type A....23990
    Table 3Warning and Indicator Lamp Table – Type B....23998
    Table 5General Text and Warning Messages requested by means of a....24011
    Table 6General Text and Warning Messages Generated by the Electr....24012
    Table 18Fuel Level Sensor Voltage Checks....24041
    Table 20Transmission Oil Temperature Sensor Voltage Checks....24043
    Table 22Axle Temperature Sensor Voltage Checks....24045
    Table 24Axle Temperature Sensor Voltage Checks....24047
    Table 26Air Pressure Transducer Voltage Checks....24051
    Table 27Direct Drive Warning Lamp Table....24055
    Table 29Ambient Air Temperature Sensor Test....24060
    Table 30Ambient Air Temperature Sensor Table....24060
    Table 32Feature Codes....24068
    Table 33Diagnostic Trouble Codes....24069
    Table 34Snow plow lighting preliminary checks....24071
    Table 35Auxiliary Lights Relay Tests....24072
    Table 36Diagnostic Trouble Codes....24074
    Table 37Back Up Lights Preliminary Checks....24075
    Table 38Back Up Lights Test....24076
    Table 39Backup Light Relay Tests....24077
    Table 40Backup Light Ball Switch Tests....24077
    Table 41Feature Code....24078
    Table 42Diagnostic Trouble Codes....24080
    Table 43Dome and Courtesy Lights Preliminary Checks....24081
    Table 44Door Switch Short Circuit Tests....24082
    Table 45Door Switch Open Circuit Tests....24082
    Table 46Dome Light Short Circuit Test....24083
    Table 47Dome Light Open Circuit Test....24083
    Table 48Feature Codes....24084
    Table 49Diagnostic Trouble Codes....24085
    Table 50Fog Light System Preliminary Checks....24086
    Table 51Fog Light Switch Test....24087
    Table 52Fog Light Open Circuit Test....24087
    Table 53Fog Light Short Circuit Test....24088
    Table 54Feature Codes....24089
    Table 55Diagnostic Trouble Codes....24090
    Table 56Headlight System Preliminary Checks....24092
    Table 57Headlight Switch and Headlight Dimmer Test....24093
    Table 58Headlight Open Circuit Test....24094
    Table 59Headlight Short Circuit Test....24095
    Table 60Feature Codes....24096
    Table 61Diagnostic Trouble Codes....24098
    Table 62Stop, Turn, and Hazards System Preliminary Checks....24100
    Table 63Turn Signal Switch Test....24101
    Table 64Hazard Switch Test....24101
    Table 65Brake Switch Test....24102
    Table 66Output Open Circuit Test....24102
    Table 67Output Short Circuit Test....24103
    Table 68Feature Codes....24104
    Table 69Diagnostic Trouble Codes....24106
    Table 70Tail, Marker, Park, and Clearance Lighting Preliminary C....24107
    Table 71Headlight Switch Tests....24107
    Table 72Interrupt Switch Tests....24108
    Table 73Park Light Open Circuit Tests....24109
    Table 74Park Light Short Circuit Tests....24109
    Table 75Feature Codes....24110
    Table 76Diagnostic Trouble Codes....24111
    Table 77Work Light System Preliminary Checks....24112
    Table 78Work Light Switch Test....24113
    Table 79Work Light Open Circuit Test....24114
    Table 80Work Light Short Circuit Test....24114
    Table 82Gauge Table....24119
    Table 88Axle Temperature Sensor Voltage Checks....24130
    Table 90Axle Temperature Sensor Voltage Checks....24133
    Table 93Cigar Lighter and Power Feed Preliminary Check....24146
    Table 94Cigar Lighter Tests....24146
    Table 95Cigar Lighter Power Source Tests....24147
    Table 96Two Post Power Source Tests....24147
    Table 97C.B. Radio Power Source Preliminary Check....24149
    Table 98C.B. Radio Power Connector Tests....24150
    Table 99Feature Codes....24152
    Table 100Diagnostic Trouble Codes....24152
    Table 101Compass/Temperature Display Preliminary Check....24154
    Table 102Compass/Temperature Display Voltage Checks....24154
    Table 103Feature Codes....24156
    Table 104Diagnostic Trouble Codes....24158
    Table 105Power Locks Preliminary Check....24162
    Table 106Power Windows Preliminary Check....24162
    Table 107One Door Lock Inop Test....24163
    Table 108All Door Locks Inop Test....24163
    Table 109One Power Window Inop Test....24164
    Table 110All Power Windows Inop Test....24164
    Table 111Feature Codes....24165
    Table 112Diagnostic Trouble Codes....24166
    Table 113Cruise Control Preliminary Check....24168
    Table 114Steering Wheel Mounted Cruise Control Command Switch Te....24169
    Table 115Steering Wheel Mounted Cruise Control Command Switch Te....24170
    Table 116Feature Codes....24172
    Table 117Theft Deterrent Preliminary Check....24175
    Table 118Theft Deterrent System Test....24175
    Table 119Feature Codes....24177
    Table 120Diagnostic Trouble Codes....24179
    Table 121Electric Horn Preliminary Check....24179
    Table 122Electric Horn Test....24180
    Table 123Feature Codes....24182
    Table 124Diagnostic Trouble Codes....24183
    Table 125Air Horns Preliminary Checks....24183
    Table 126Air Horn Test....24184
    Table 127Power Mirror Preliminary Check....24186
    Table 128Power Mirror Tests....24187
    Table 129Feature Codes....24189
    Table 130Diagnostic Trouble codes....24191
    Table 131Heated Mirror Preliminary Check....24192
    Table 132Heated Mirrors Test....24193
    Table 133Left Heated Mirror Test....24193
    Table 134Right Heated Mirror Test....24194
    Table 135Radio Preliminary Check....24196
    Table 136Radio Test....24196
    Table 137Two-Way Radio Circuit Tests....24198
    Table 138Feature Codes....24200
    Table 139Diagnostic Trouble Codes....24202
    Table 140Wiper and Washer Preliminary Check....24204
    Table 141Washer Test....24206
    Table 142Wiper Park Test....24206
    Table 143Wiper Switch Test....24207
    Table 144Wiper Motor Test....24208
    Table 145Feature Codes....24210
    Table 146Lighted Air Shield DTC....24211
    Table 147Roof Auxiliary Load Preliminary Check....24211
    Table 148Roof Auxiliary Load Test....24212
    Table 149IP Mounted Roof Auxiliary Load Switch Test....24212
    Table 150Lighted Air Shield Preliminary Check....24213
    Table 151Lighted Air Shield Test....24214
    Table 152Self Contained Air Seats Preliminary Check....24215
    Table 153Self Contained Air Seat Test....24216
    Table 154Heated Seats Preliminary Check....24217
    Table 155Heated Seat Test....24218
    Table 157Seat Belt Preliminary Check....24220
    Table 1580595BAG Seat Belt Test....24221
    Table 159Feature Codes....24222
    Table 160Diagnostic Trouble Codes....24222
    Table 161Brake Switch Preliminary Check....24224
    Table 162Brake Switch Test....24225
    Table 163Feature Code....24226
    Table 164Diagnostic Trouble Codes....24227
    Table 165Clutch Switch Preliminary Checks....24228
    Table 166No Engine Crank Clutch Switch Test....24229
    Table 167Cruise Control Clutch Switch Test....24229
    Table 168Feature Code....24230
    Table 169Diagnostic Trouble Codes....24231
    Table 170Feature Code....24239
    Table 171Diagnostic Trouble codes....24239
    Table 172Trailer Turn Signal Relay System Preliminary Checks....24241
    Table 173Left Trailer Turn Signal Inop Test....24242
    Table 174Right Trailer Turn Signal Inop Test....24243
    Table 175Feature Codes....24244
    Table 176Diagnostic Trouble Codes....24245
    Table 177Trailer Auxiliary Power Circuit Preliminary Checks....24245
    Table 178Trailer Auxiliary Circuit Tests....24245
    Table 188Axle Pressure Transducer Voltage Checks....24261
    Table 192RPM Checks....24269
    Table 193Feature Codes....24271
    Table 194Auxiliary Power Source Preliminary Check....24272
    Table 195Aux Power Source Tests....24272
    Table 197Diagnostic Trouble Codes....24274
    Table 198Two-Speed Switch Preliminary Check....24275
    Table 199Two-Speed Switch Test....24275
    Table 200Air Dryer and Heated Drain Valve Preliminary Check....24276
    Table 201Heated Drain Valve Test....24277
    Table 202Air Dryer Test....24277
    Table 203Feature Codes....24279
    Table 204Diagnostic Trouble Codes....24281
    Table 205Fuel Transfer Pump Preliminary Check....24282
    Table 206Fuel Transfer Pump Won’t Run Test....24282
    Table 207Fuel Transfer Pump Continuously Runs Test....24284
    Table 208Feature Code....24285
    Table 210Water in Fuel Preliminary Check....24286
    Table 211Water Probe Test....24287
    Table 212Feature Code....24288
    Table 213Diagnostic Trouble Codes....24289
    Table 214Electric Trailer Brake Preliminary Check....24289
    Table 215Electric Trailer Brake Test....24290
    Table 216Feature Code....24292
    Table 217Diagnostic Trouble Codes....24294
    Table 218Air Solenoid Preliminary Check....24302
    Table 219Feature Code....24304
    Table 220Diagnostic Trouble Codes....24305
    Table 221Suspension Dump Preliminary Check....24307
    Table 222Suspension Dump Test....24307
    Table 223Feature Code....24309
    Table 224Diagnostic Trouble Codes....24310
    Table 225Lift Gate Preliminary Check....24311
    Table 226Lift Gate Test....24311
    Table 227Feature Code....24312
    Table 228Diagnostic Trouble Codes....24313
    Table 229Fifth Wheel Slide Preliminary Check....24314
    Table 230Fifth Wheel Slide Test....24314
    Table 231Feature Code....24316
    Table 232Diagnostic Trouble Codes....24317
    Table 233Differential Lock Preliminary Check....24319
    Table 234(0595ACT) Differential Lock Test....24319
    Table 235(0595ACU) Differential Lock Test....24320
    Table 236Feature Code....24322
    Table 237Diagnostic Trouble Codes....24323
    Table 238Power Divider Lock Preliminary Check....24324
    Table 239Power Divider Lock Test....24324
    Table 240Feature Code....24326
    Table 241Diagnostic Trouble Codes....24327
    Table 242Remote Start/Stop Preliminary Check....24327
    Table 243Remote Start/Stop System Tests....24329
    Table 247PTO Hour Meter/ PTO Indicator Checks....24354
    Table 249Additional Signals Used for PTO Operation....24356
    Table 254Wheelchair Lift Interlock Checks....24361
    Table 256Additional Signals Used for Wheelchair Lift Interlock O....24363
    Table 260Park Position Unlock Solenoid Checks — Eaton T-Handle &....24379
    Table 261LCT Column Shifter Interlock Checks....24380
    Table 262TCM Power, Ground and Data Link Circuit Checks....24380
    Table 263Shift Selector Power and Ground Circuit Checks....24381
    Table 269RESCM Checks....24398
    Table 276Parked Regeneration (Particulate_Trap_Regeneration_Forc....24410
    Table 277Inhibit Regeneration (Particulate_Trap_Regeneration_Inh....24411
    Table 279Switch Pack Preliminary Check....24424
    Table 280Switch Pack Test....24424
    Table 281Battery Power Distribution Check....24428
    Table 282Accessory Power Distribution Check....24428
    Table 283Accessory Power Test....24428
    Table 284Ignition Power Distribution Check....24429
    Table 285Ignition Power Test....24430
    Table 286Ground Test....24431
    Table 292 Snow Valve Mechanical Checks....24445
    Table 293 Snow Valve Module Checks....24446
    Table 298 Snow Valve Mechanical Checks....24450
    Table 299 Snow Valve Switch Test....24451
    Table 300 Snow Valve Module Checks....24451
    Table 305 Exhaust Brake Switch Test....24458
    Table 307Diagnostic Trouble codes....24464
    Table 308Diagnostic Trouble codes....24465
S08327 - 2007-2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual....24471
S08333 - 4300 Eaton Hybrid Drive System Built November 2006 through February 2007 Electrical Circuit Diagrams....24604
S08357 - 2011 DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE Model 4400....24615
S08359 - 4400 LHD Euro III Model Built After July, 2011 Electrical Circuit Diagrams (Brazil Market) Circuit Diagrams....24857
S08361 - DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — DuraStar, TerraStar, TranStar, and WorkStar Built May 2010 and Later....25262
  toc....25266
    SAFETY INFORMATION....25266
      MANUAL INTRODUCTION....25268
        1. Manual Introduction....25270
        2. Vehicle Electrical System Overview....25271
        3. Electrical Circuit Diagram Book....25271
          3.1. CIRCUIT DIAGRAMS....25271
            Circuit Diagram Instructions....25272
          3.2. CONNECTOR BODY COMPOSITE....25275
        4. Troubleshooting....25276
          4.1. Verify The Problem....25276
          4.2. Important Steps Before Performing Circuit Tests....25276
          4.3. Review Feature Operation....25277
          4.4. Check the Circuit Diagram....25277
          4.5. Performing Circuit And System Tests....25278
          4.6. Perform The Repair....25278
          4.7. Verify The Repair....25278
        5. Electrical Test Equipment....25278
          5.1. EZ-TECH® Electronic Service Tool (EST)....25278
          5.2. Body Controller Breakout Box (ZTSE4477)....25278
          5.3. FLUKE 88 Digital Multimeter (DMM)....25279
          5.4. MIDTRONICS EXP-1000HD....25280
          5.5. Jumper Wires, Test Leads, And Test Lights....25281
            Jumper Wires....25281
            Test Leads....25282
            Test Lights....25283
          5.6. Ohm's Law Review....25283
          5.7. Voltmeter....25285
            Measuring Voltage....25285
          5.8. Ammeter....25288
            Measuring Amperage....25288
          5.9. Ohmmeter....25290
            Measuring Resistance....25290
            Checking For Open Circuits....25292
            Checking For Short Circuits....25293
        6. Bench Testing Relays....25294
        ELECTRONIC GAUGE CLUSTER....25298
          1. Electronic Gauge Cluster....25300
            1.1. System Description....25300
              Overview....25300
              Operation....25300
            1.2. Feature Codes....25305
            1.3. User Programmable Parameters....25306
            1.4. Diagnostic Trouble Codes....25311
            1.5. Troubleshooting....25319
              Preliminary Checks....25319
              Electronic Gauge Cluster Circuit Test....25321
              EGC Backlight Circuit Test....25323
              EGC Gauge Test....25323
              Warning Lamp Test....25325
              Fuel Level Gauge Circuit Test....25326
              Transmission Oil Temperature Circuit Tests....25327
              Front Rear and Rear Rear Axle Temperature Circuit Tests....25328
              Air Pressure Transducer Circuit Tests....25329
              Park Brake Switch Circuit Test....25332
              Air Restriction Gauge Circuit Test....25333
              Engine Coolant Level Monitor Circuit Test....25333
            1.6. Electronic Gauge Cluster Programming....25334
        SWITCH PACKS (J1708 DATA LINK)....25336
          1. Switch Packs....25338
            1.1. Description....25338
              Overview....25338
              Operation....25338
            1.2. Diagnostic Trouble Codes....25338
            1.3. Troubleshooting....25339
              Switch Pack Preliminary Check....25340
              Switch Pack Circuit Test....25340
              J1708 Data Link Circuit Test....25341
        LIGHTING SYSTEM....25342
          1. Backup Lights....25346
            1.1. System Description....25346
              Overview....25346
              Operation....25346
            1.2. Feature Code....25346
            1.3. user programmable parameters....25347
            1.4. diagnostic trouble codes....25347
            1.5. Troubleshooting....25347
              Backup Lights Preliminary Checks....25348
              Backup Light Circuit Test (Automatic Transmission)....25348
              Backup Light Switch Test (Manual Transmission)....25350
          2. Dome And Courtesy Lights....25351
            2.1. System Description....25351
              Overview....25351
              Operation....25351
            2.2. Feature Code....25352
            2.3. User Programmable Parameters....25352
            2.4. Diagnostic Trouble Codes....25352
            2.5. Troubleshooting ....25353
              Dome and Courtesy Lights Preliminary Checks....25353
              Door Switch Circuit Tests....25354
              Cab Dome Light Circuit Test....25355
              Courtesy Lights Circuit Test....25357
          3. Fog Lights....25357
            3.1. System Description....25357
              Overview....25357
              Operation....25357
            3.2. Feature Codes....25358
            3.3. User Programmable Parameters ....25358
            3.4. Diagnostic Trouble Codes....25358
            3.5. Troubleshooting....25359
              Fog Light System Preliminary Check....25359
              Fog Light Switch Test....25360
              Fog Light Circuit Test....25361
          4. Headlights And Daytime Running Lights (DTRL)....25362
            4.1. system description....25362
              Overview....25363
              Operation....25363
            4.2. Feature Codes....25363
            4.3. User Programmable Parameters....25363
            4.4. Diagnostic Trouble Codes....25363
            4.5. Troubleshooting....25365
              Headlight System Preliminary Check....25366
              Headlight Switch Test....25367
              Turn Signal Switch Circuit Test....25368
              Right Headlight Circuit Test....25369
              Left Headlight Circuit Test....25371
          5. Stop, Turn, And Hazard Lights....25371
            5.1. System Description....25371
              Overview....25371
              Operation....25372
            5.2. Feature Codes....25372
            5.3. User Programmable Parameters....25372
            5.4. Diagnostic Trouble Codes....25372
            5.5. Troubleshooting....25375
              Stop, Turn, and Hazards System Preliminary Check....25375
              Turn Signal Switch Circuit Test....25376
              Brake Switch Circuit Test....25378
              Left Front Turn Signal Circuit Test....25380
              Right Front Turn Signal Circuit Test....25380
              Left Rear Turn Signal Circuit Test....25381
              Right Rear Turn Signal Circuit Test....25382
          6. Tail, Marker, Park, And Clearance Lighting....25382
            6.1. System Description....25382
              Overview....25382
              Operation....25383
            6.2. Feature Codes....25383
            6.3. User Programmable Parameters....25383
            6.4. Diagnostic Trouble Codes....25383
            6.5. Troubleshooting....25384
              Tail, Marker, Park, and Clearance Lighting Preliminary Check....25384
              Headlight Switch Test....25384
              Tail Light Circuit Test....25386
              Park, Marker, Clearance, and Identification Lights Circuit Test....25386
          7. Work Light....25387
            7.1. System Description....25387
              Overview....25387
              Operation....25387
            7.2. Feature Codes....25387
            7.3. User Programmable Parameters....25387
            7.4. Diagnostic Trouble Codes....25388
            7.5. Troubleshooting....25388
              Work Light System Preliminary Check....25389
              Work Light Switch Test....25389
              Work Light Circuit Tests....25390
          8. Roof Auxiliary Load And Air Shield Light....25391
            8.1. System Description....25391
              Overview....25391
              Roof Auxiliary Load Operation....25391
              Air Shield Light Operation....25391
            8.2. Feature Codes....25391
            8.3. User Programmable Parameters....25392
            8.4. Diagnostic Trouble CodeS....25392
              Roof Auxiliary Load ....25392
              Lighted Air Shield....25392
            8.5. Troubleshooting....25392
              Roof Auxiliary Load Preliminary Check....25392
              Lighted Air Shield Preliminary Check....25393
              Roof Auxiliary Load Switch Test....25394
              Roof Auxiliary Load Circuit Test....25395
              Lighted Air Shield Circuit Test....25395
          9. Trailer Lighting....25396
            9.1. System Description....25396
              Overview....25396
              Operation....25396
            9.2. Feature Codes....25396
            9.3. User Programmable Parameters....25396
            9.4. Diagnostic Trouble CodeS....25396
            9.5. Troubleshooting....25398
              Trailer Lights Preliminary Check....25398
              Trailer Socket Circuit Test....25398
              Trailer Left Turn Relay Circuit Test....25400
              Trailer Right Turn Relay Circuit Test....25401
              Trailer Marker Light Relay Circuit Test....25402
              Trailer Tail Light Relay Circuit Test....25403
              Trailer Stop Light Relay Circuit Test....25404
              Trailer ABS ECU Relay Circuit Test....25405
          10. Auxiliary Snowplow Lighting....25405
            10.1. System Description....25405
              Overview....25405
              Operation....25405
            10.2. Feature Code....25406
            10.3. user programmable parameters....25406
            10.4. diagnostic trouble codes....25406
            10.5. Troubleshooting....25407
              Auxiliary Snowplow Lights Preliminary Checks....25407
              Snowplow Switch Test....25408
              Snowplow Lights Circuit Test....25408
        CAB FEATURES....25410
          1. Cigar Lighter And Power Feed....25416
            1.1. System Description....25416
              Overview....25416
              Cigar Lighter Operation....25416
              Cigar Lighter Power Source and Two-Post Power Source Operation....25416
            1.2. Feature Codes....25416
            1.3. User Programmable Parameters....25416
            1.4. Diagnostic Trouble Codes....25416
            1.5. Troubleshooting....25416
              Cigar Lighter and Power Feed Preliminary Check....25416
              Cigar Lighter Circuit Test....25417
              Two-Post Power Source Circuit Test....25417
          2. CB Power Radio....25418
            2.1. System Description....25418
              Overview....25418
              Operation....25418
            2.2. Feature Codes....25418
            2.3. User Programmable Parameters....25418
            2.4. Diagnostic Trouble Codes....25418
            2.5. Troubleshooting....25418
              CB Radio Power Source Preliminary Check....25419
              CB Radio Circuit Test....25419
          3. Compass And Temperature Display....25419
            3.1. System Description....25419
              Overview....25419
              Temperature Display Operation....25420
              Compass Display Operation....25420
            3.2. Feature Codes....25420
            3.3. User Programmable Parameters....25420
            3.4. Diagnostic Trouble Codes....25420
            3.5. Troubleshooting....25422
              Compass and Temperature Display Preliminary Check....25422
              Compass / Temperature Display Circuit Tests....25422
              Compass Calibration....25424
              Ambient Temperature Sensor Circuit Test....25425
          4. Power Windows And Locks....25426
            4.1. System Description....25426
              Overview....25426
              Power Window Operation....25426
              Power Door Lock Operation....25427
            4.2. Feature Codes....25427
            4.3. User Programmable Parameters....25427
            4.4. Diagnostic Trouble Codes....25428
            4.5. Troubleshooting....25430
              Power Window and Lock Preliminary Check....25431
              Locks and Windows Inoperative Circuit Test....25431
              Power Window Circuit Test....25432
              Power Door Lock Circuit Test....25433
          5. Electric Horn....25433
            5.1. System Description....25433
              Overview....25433
              Operation....25433
            5.2. Feature Codes....25433
            5.3. User Programmable Parameters....25433
            5.4. Diagnostic Trouble Codes....25435
            5.5. Troubleshooting....25435
              Electric Horn Preliminary Check....25435
              Electric Horn Circuit Test....25436
          6. Air Horn....25437
            6.1. System Description....25437
              Overview....25437
              Operation....25437
            6.2. Feature Codes....25437
            6.3. User Programmable Parameters....25437
            6.4. Diagnostic Trouble Codes....25437
            6.5. Troubleshooting....25438
              Air Horn Preliminary Check....25438
              Air Horn Circuit Test....25439
          7. Power Mirrors....25439
            7.1. System Description....25439
              Overview....25439
              Operation....25439
            7.2. Feature Codes....25440
            7.3. User Programmable Parameters....25440
            7.4. Diagnostic Trouble Codes....25440
            7.5. Troubleshooting....25440
              Power Mirror Preliminary Check....25441
              Driver Power Mirror Circuit Test....25441
              Passenger Power Mirror Circuit Test....25442
          8. Heated Mirror....25443
            8.1. System Description....25443
              Overview....25443
              Operation....25443
            8.2. Feature Codes....25443
            8.3. User Programmable Parameters....25443
            8.4. Diagnostic Trouble Codes....25443
            8.5. Troubleshooting....25444
              Heated Mirror Preliminary Check....25444
              Heated Mirror Switch Test....25445
              Driver Heated Mirror Circuit Test....25445
              Passenger Heated Mirror Circuit Test....25446
              Heated Windshield Circuit Test....25446
          9. Radio (Entertainment), Speakers....25448
            9.1. System Description....25448
              Overview....25448
              Operation....25449
            9.2. Feature Codes....25449
            9.3. User Programmable Parameters....25449
            9.4. Diagnostic Trouble Codes....25449
            9.5. Troubleshooting....25449
              Radio Preliminary Check....25449
              Radio Circuit Test (16 Way Connector)....25450
              Radio Circuit Test (12 Way Connector)....25450
              Speaker Circuit Test (16 Way Connector)....25450
              Speaker Circuit Test....25451
          10. Two-Way Radio....25452
            10.1. System Description....25452
              Overview....25452
              Operation....25452
            10.2. Feature Codes....25453
            10.3. User Programmable Parameters....25453
            10.4. diagnostic trouble codes....25453
            10.5. Troubleshooting....25453
              Two-Way Radio Circuit Test....25453
          11. Windshield Wiper And Washer Pump....25453
            11.1. System Description....25453
              Overview....25453
              Wiper Operation....25454
              Park Operation....25454
              Washer Operation....25454
            11.2. Feature Codes....25454
            11.3. User Programmable Parameters....25454
            11.4. Diagnostic Trouble Codes....25456
            11.5. Troubleshooting....25457
              Wiper and Washer Preliminary Check....25457
              Washer Pump Circuit Test....25458
              Wiper Switch Circuit Test....25459
              Wiper Motor Circuit Test....25460
          12. Park Brake And Brake Switch....25460
            12.1. System Description....25460
              Overview....25461
              Operation....25461
            12.2. Feature Codes....25461
            12.3. User Programmable Parameters....25461
            12.4. Diagnostic Trouble CodeS....25462
            12.5. Troubleshooting....25463
              Brake Switch Preliminary Check....25463
              Brake Switch Test....25464
              Park Brake Switch Test....25465
          13. Clutch Switch....25467
            13.1. System Description....25467
              Overview....25467
              Operation....25467
            13.2. Feature Codes....25467
            13.3. User Programmable Parameters....25468
            13.4. Diagnostic Trouble CodeS....25468
            13.5. Troubleshooting....25469
              Clutch Switch Preliminary Checks....25469
              Engine Crank Clutch Switch Test....25470
              Cruise Control Clutch Switch Test....25472
          14. Load Shedding....25472
            14.1. System Description....25472
              Overview....25473
              Operation....25473
            14.2. Feature Codes....25473
            14.3. User Programmable Parameters....25473
            14.4. Diagnostic Trouble CodeS....25473
            14.5. Troubleshooting....25474
              Latching Relay Circuit Test....25474
          15. Vehicle Data Recorder....25475
            15.1. System Description....25475
              Overview....25475
              Operation....25476
            15.2. Feature Code....25476
            15.3. User Programmable Parameters....25476
            15.4. Diagnostic Trouble Codes....25476
            15.5. Troubleshooting....25476
              Vehicle Data Recorder Preliminary Check....25476
              Vehicle Data Recorder Circuit Test....25477
              VDR Brake Pressure Switch Circuit Test....25478
              VDR Headlight Input Relay Circuit Test....25479
          16. Theft Deterrent System....25480
            16.1. System Description....25480
              Overview....25480
              Operation....25480
            16.2. FEATURE CODE....25480
            16.3. user programmable parameters....25480
            16.4. diagnostic trouble codes....25480
            16.5. Troubleshooting....25481
              Theft Deterrent Preliminary Check....25482
              Theft Deterrent System Test....25482
          17. Seat Belt And Seat Sensor....25483
            17.1. System Description....25483
              Overview....25483
              Operation....25484
            17.2. Feature Code....25484
            17.3. User Programmable Parameters....25484
            17.4. Diagnostic Trouble Codes....25485
            17.5. Troubleshooting....25485
              Seat Belt Preliminary Check....25485
              Seat Belt Indicator Circuit Test....25486
          18. Self-Contained Air Seat....25487
            18.1. System Description....25487
              Overview....25487
              Operation....25487
            18.2. Feature Code....25487
            18.3. User Programmable Parameters....25487
            18.4. Diagnostic Trouble Codes....25487
            18.5. Troubleshooting....25487
              Driver and Passenger Self-Contained Air Seats Preliminary Check....25487
              Driver and Passenger Self-Contained Air Seat Test....25488
          19. Heated Seats....25489
            19.1. System Description....25489
              Overview....25489
              Operation....25489
            19.2. Feature Codes....25489
            19.3. User Programmable Parameters....25489
            19.4. Diagnostic Trouble CodeS....25489
            19.5. Troubleshooting....25489
              Driver and Passenger Heated Seats Preliminary Check....25489
              Driver and Passenger Heated Seat Test....25489
        CHASSIS FEATURES....25492
          1. Heated Air Dryer and drain valve....25496
            1.1. System Description....25496
              Overview....25496
              Operation....25496
            1.2. Feature Codes....25496
            1.3. User Programmable Parameters....25496
            1.4. diagnostic trouble codes....25496
            1.5. Troubleshooting....25496
              Air Dryer and Heated Drain Valve Preliminary Check....25496
              Heated Drain Valve Circuit Test....25497
              Air Dryer Circuit Test....25498
          2. Air Solenoid....25498
            2.1. System Description....25498
              Overview....25498
              Operation....25498
            2.2. Feature Codes....25499
            2.3. User Programmable Parameters....25499
            2.4. Diagnostic Trouble Codes....25499
            2.5. Troubleshooting....25504
              Air Solenoid Preliminary Check....25505
              Air Solenoid Circuit Test....25505
          3. Suspension Dump....25506
            3.1. System Description....25506
              Overview....25506
              Operation....25506
            3.2. Feature Code....25507
            3.3. User Programmable Parameters....25507
            3.4. Diagnostic Trouble Codes....25508
            3.5. Troubleshooting....25509
              Suspension Dump Preliminary Check....25509
              Suspension Dump Test....25510
          4. Differential Lock....25511
            4.1. System description....25511
              Overview....25511
              Operation....25511
            4.2. Feature Code....25512
            4.3. User Programmable Parameters....25512
            4.4. Diagnostic Trouble Codes....25513
            4.5. Troubleshooting....25514
              Differential Lock Preliminary Check....25515
              Differential Lock Test....25515
          5. Power Divider Lock....25516
            5.1. System Description....25516
              Overview....25516
              Operation....25516
            5.2. FEATURE CODE....25517
            5.3. User Programmable Parameters....25517
            5.4. Diagnostic Trouble Codes....25517
            5.5. Troubleshooting....25518
              Power Divider Lock Preliminary Check....25519
              Power Divider Lock Test....25519
          6. Power Take Off....25520
            6.1. System Description....25520
              Overview....25520
              Operation....25520
            6.2. Feature Code....25520
            6.3. User Programmable Parameters....25520
            6.4. Diagnostic Trouble Codes....25521
            6.5. Troubleshooting....25522
              Power Take Off Preliminary Check....25523
              Power Take Off Circuit Test....25523
          7. Anti-Lock Braking System ....25524
            7.1. System Description....25524
              Overview....25524
              Operation....25524
              Communication....25525
            7.2. Feature Code....25525
            7.3. User Programmable Parameters....25526
            7.4. Diagnostic Trouble Codes....25526
            7.5. Troubleshooting....25527
              Anti-Lock Braking System Preliminary Check....25527
              Bendix® ABS Circuit Tests....25528
              Wabco® ABS Module Circuit Test....25531
          8. Fifth Wheel Slide and jaw lock release....25532
            8.1. System Description....25532
              Overview....25532
              Operation....25533
            8.2. Feature Code....25533
            8.3. User Programmable Parameters....25533
            8.4. Diagnostic Trouble Codes....25534
            8.5. Troubleshooting....25535
              Fifth Wheel Slide Preliminary Check....25535
              Fifth Wheel Slide Circuit Test....25535
              Fifth Wheel Jaw Lock Release Circuit Test....25536
          9. Fuel Heater....25536
            9.1. System Description....25536
              Overview....25537
              Operation....25537
            9.2. Feature Code....25537
            9.3. User Programmable Parameters....25537
            9.4. Diagnostic Trouble Codes....25537
            9.5. Troubleshooting....25537
              Fuel Heater Preliminary Check....25537
              Fuel Heater Circuit Test ....25538
          10. Remote Power Module....25538
            10.1. System Description....25538
              Overview....25539
              Operation....25539
            10.2. Feature Code....25539
            10.3. User Programmable Parameters....25540
            10.4. Diagnostic Trouble Codes....25540
            10.5. Troubleshooting....25543
              RPM Preliminary Check....25544
              RPM Circuit Test....25544
          11. remote start / stop....25546
            11.1. System description....25546
              Overview....25546
              Operation....25547
            11.2. FEATURE CODE....25547
            11.3. user programmable parameters....25548
            11.4. diagnostic trouble codes....25548
            11.5. Troubleshooting....25548
              Remote Start / Stop Preliminary Check....25549
              Remote Start / Stop Test....25549
          12. Two-speed axle ....25551
            12.1. System description....25551
              Overview....25551
              Operation....25551
            12.2. feature codes....25551
            12.3. user programmable parameters....25551
            12.4. diagnostic trouble codes....25551
            12.5. troubleshooting....25552
              Two-Speed Switch Preliminary Check....25552
              Two-Speed Switch Test....25552
          13. Customer installed lift gate power source....25553
            13.1. System description....25553
              Overview....25553
              Operation....25553
            13.2. FEATURE CODE....25553
            13.3. user programmable parameters....25554
            13.4. diagnostic trouble codes....25554
            13.5. Troubleshooting....25555
              Lift Gate Preliminary Check....25555
              Lift Gate Circuit Test ....25556
          14. Auto neutral ....25556
            14.1. System description....25556
              Overview....25556
              Operation....25556
            14.2. FEATURE CODE....25557
            14.3. user programmable parameters....25557
            14.4. diagnostic trouble codes....25557
            14.5. Troubleshooting....25557
              Auto Neutral Preliminary Check....25558
              Auto Neutral Switch Test ....25558
              Auto Neutral Circuit Test....25558
          15. Axle Load Monitor....25560
            15.1. System Description....25560
              Overview....25560
              Operation....25560
            15.2. Feature Code....25560
            15.3. User Programmable Parameters....25561
            15.4. Diagnostic Trouble Codes....25562
            15.5. Troubleshooting....25563
              Axle Load Monitor Preliminary Check....25563
              Axle Pressure Transducer Circuit Test....25563
          16. water-in-fuel monitor ....25564
            16.1. System Description....25564
              Overview....25564
              Operation....25564
            16.2. Feature Code....25564
            16.3. User Programmable Parameters....25564
            16.4. Diagnostic Trouble Codes....25564
            16.5. Troubleshooting....25565
              Water-In-Fuel Monitor Preliminary Check....25565
              Water Probe Circuit Test....25566
        TRANSMISSIONS....25568
          1. Transmission....25570
            1.1. System Description....25570
              Overview....25570
              Operation....25570
            1.2. Feature Code....25571
            1.3. user programmable parameters....25571
            1.4. Diagnostic Trouble Codes....25571
            1.5. Troubleshooting....25573
              Transmission Preliminary Check....25573
              Eaton UltraShift®® TCM Circuit Test....25574
              Eaton UltraShift® Selector Circuit Test....25577
              Eaton T-Handle Shifter Circuit Test....25580
              Eaton Hybrid TCM Circuit Test....25580
              Allison TCU Circuit Test with IBB Engine....25582
              Allison Shift Selector with IBB Engine ....25584
              Allison TCU Circuit Test with I6/V8 Engine....25586
              Allison Shifter with I6/V8 Engine....25587
              Shifter Ignition Relay Circuit Test....25588
              Park Position Unlock Solenoid Test....25590
            1.6. Body Controller Signals....25590
              Body Controller Signals....25591
        MULTIPLEXING (DATA LINKS)....25592
          1. Multiplexing (Data Links)....25594
            1.1. Description....25594
              Overview....25594
              Operation....25594
            1.2. Troubleshooting....25595
              J1939 Data Link Terminating Resistors....25595
              Body Controller....25596
              J1939 Data Link Circuit Test....25596
              J1708 Data Link Circuit Test....25597
        12-VOLT POWER DISTRIBUTION AND GROUND....25598
          1. 12-Volt Power Distribution and Grounds....25600
            1.1. Description....25600
              Overview....25600
              Operation....25600
            1.2. Troubleshooting....25600
              Battery Power Distribution Check....25601
              Accessory Power Distribution Preliminary Check....25601
              Accessory Power Circuit Test....25602
              Body Controller Accessory Feed Input Circuit Test....25603
              Ignition Power Distribution Preliminary Check....25604
              Ignition Power Circuit Test....25604
              Ground Circuit Test....25606
        FANS AND ENGINE ACCESSORIES....25608
          1. Fan System....25610
            1.1. System Description....25610
              Overview....25610
              Operation....25610
            1.2. Feature Code....25610
            1.3. User Programmable Parameters....25611
            1.4. Diagnostic Trouble Codes....25611
            1.5. Troubleshooting....25611
              Fan System Preliminary Check....25612
              Fan Override Switch Test....25612
          2. Compression / Exhaust Brake....25613
            2.1. System Description....25613
              Overview....25613
              Operation....25613
            2.2. Feature Code....25613
            2.3. User Programmable Parameters....25614
            2.4. Diagnostic Trouble Codes....25614
            2.5. Troubleshooting....25614
              Compression / Exhaust Brake Preliminary Check....25615
              Compression / Exhaust Brake Switch Test....25615
          3. Aftertreatment ....25615
            3.1. System Description....25615
              Overview....25615
              Operation....25616
            3.2. Feature Code....25618
            3.3. User Programmable Parameters....25618
            3.4. Diagnostic Trouble Codes....25618
            3.5. Troubleshooting....25619
              Aftertreatment Preliminary Check....25620
              Inhibit Regeneration Switch Test....25620
              Parked Regeneration Switch Test....25621
              Warning Lamp Test....25621
          4. Cruise Control....25622
            4.1. system description....25622
              Overview....25622
              Operation....25622
            4.2. feature codes....25623
            4.3. User Programmable Parameters....25623
            4.4. diagnostic trouble codes....25623
            4.5. Troubleshooting....25624
              Cruise Control Preliminary Check....25625
              Cruise Control Switch Test....25626
          5. Snow Valve....25627
            5.1. System Description....25627
              Overview....25627
              Operation....25627
            5.2. Feature Code....25628
            5.3. User Programmable Parameters....25628
            5.4. Diagnostic Trouble Codes....25628
            5.5. Troubleshooting....25628
              Snow Valve Preliminary Check....25628
              Snow Valve Module Circuit Test....25629
        BATTERY, CHARGING, AND CRANKING SYSTEM....25630
          1. Battery System....25632
            1.1. Description....25632
              Overview....25632
              Operation....25632
            1.2. Diagnostic Trouble Codes....25633
            1.3. Troubleshooting....25633
              Battery Test....25633
              Battery Test Results....25634
              Cable Drop Test....25634
              Battery Pack Test....25634
              Battery Pack Test Results....25634
          2. Charging System....25635
            2.1. Description....25635
              Overview....25635
              Operation....25635
            2.2. Diagnostic Trouble Codes....25635
            2.3. Troubleshooting....25636
              Charging System Test....25636
              Charging System Test Results....25636
          3. Cranking System....25637
            3.1. Description....25637
              Overview....25637
              Operation....25637
            3.2. Troubleshooting....25638
              Starting System Test....25638
              Starting System Test Results....25638
          4. Powerpack 3....25638
            4.1. Description....25638
              Overview....25639
              Operation....25639
            4.2. Troubleshooting....25639
        VEHICLE AND DRIVER INFORMATION DISPLAY....25640
          1. vehicle information display....25642
            1.1. System description....25642
              Overview....25642
              Operation....25642
            1.2. FEATURE CODE....25642
            1.3. user programmable parameters....25643
            1.4. diagnostic trouble codes....25643
            1.5. Troubleshooting....25643
              Vehicle Information Display Preliminary Check....25643
              Vehicle Information Display Circuit Test....25643
          2. Driver information display....25644
            2.1. System description....25644
              Overview....25644
              Operation....25645
            2.2. FEATURE CODE....25645
            2.3. user programmable parameters....25645
            2.4. diagnostic trouble codes....25645
            2.5. Troubleshooting....25645
              Driver Information Display Preliminary Check....25646
              Driver Information Display Circuit Test....25646
  tables....25283
    Table 1Ohm's Law....25283
    Table 2Relay Bench Test....25296
    Table 3Gauges and Signal Paths....25301
    Table 4Warning Lamp and Signal Path....25302
    Table 5Audible Alarms....25304
    Table 6Electronic Gauge Cluster Feature Codes....25305
    Table 7Diagnostic Trouble Codes....25311
    Table 8EGC Preliminary Checks....25319
    Table 9Electronic Gauge Cluster Circuit Test....25321
    Table 10EGC Backlighting Circuit Test....25323
    Table 11EGC Gauge Test....25324
    Table 12Warning Lamp Test....25325
    Table 13Fuel Level Gauge Circuit Test....25326
    Table 14Transmission Oil Temperature Circuit Test....25327
    Table 15Rear Rear Axle Temperature Circuit Test....25328
    Table 16Front Rear Axle Temperature Circuit Test....25329
    Table 17Air Pressure Transducer Circuit Test....25330
    Table 18Park Brake Switch Circuit Test....25332
    Table 19 Air Restriction Gauge Circuit Test....25333
    Table 20Low Coolant Sensor Circuit Test....25333
    Table 21Diagnostic Trouble Codes....25338
    Table 22Switch Pack Preliminary Check....25340
    Table 23Switch Pack Circuit Test....25340
    Table 24J1708 Data Link Circuit Test....25341
    Table 25Feature Code....25346
    Table 26Diagnostic Trouble Codes....25347
    Table 27Backup Lights Preliminary Checks....25348
    Table 28 Backup Light Circuit Test....25348
    Table 29Backup Light Switch Test....25350
    Table 30Feature Code....25352
    Table 31Diagnostic Trouble Codes....25352
    Table 32Dome and Courtesy Lights Preliminary Checks....25353
    Table 33Door Switch Circuit Test....25354
    Table 34Cab Dome Light Circuit Test....25355
    Table 35Courtesy Lights Circuit Test....25357
    Table 36Feature Codes....25358
    Table 37Diagnostic Trouble Codes....25358
    Table 38Fog Light System Preliminary Check....25359
    Table 39Fog Light Switch Test....25360
    Table 40Fog Light Circuit Test....25361
    Table 41Feature Codes....25363
    Table 42Diagnostic Trouble Codes....25364
    Table 43Headlight System Preliminary Check....25366
    Table 44Headlight Switch Test....25367
    Table 45Turn Signal Switch Circuit Test....25368
    Table 46Right Headlight Circuit Test....25369
    Table 47Left Headlight Circuit Test....25371
    Table 48Feature Codes....25372
    Table 49Diagnostic Trouble Codes....25372
    Table 50Stop, Turn, and Hazards System Preliminary Check....25375
    Table 51Turn Signal Switch Circuit Test....25376
    Table 52Brake Switch Circuit Test....25378
    Table 53Left Front Turn Signal Circuit Test....25380
    Table 54Right Front Turn Signal Circuit Test....25381
    Table 55Left Rear Turn Signal Circuit Test....25381
    Table 56Right Rear Turn Signal Circuit Test....25382
    Table 57Feature Codes....25383
    Table 58Diagnostic Trouble Codes....25383
    Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....25384
    Table 60Headlight Switch Test....25385
    Table 61Tail Light Circuit Test....25386
    Table 62Park, Marker, Clearance, and Identification Lights Circu....25386
    Table 63Feature Codes....25387
    Table 64Diagnostic Trouble Codes....25388
    Table 65Work Light System Preliminary Check....25389
    Table 66Work Light Switch Test....25389
    Table 67Work Light Circuit Test....25390
    Table 68Feature Codes....25391
    Table 69Lighted Air Shield DTC....25392
    Table 70Roof Auxiliary Load Preliminary Check....25392
    Table 71Lighted Air Shield Preliminary Check....25393
    Table 72Roof Auxiliary Load Switch Test....25394
    Table 73Roof Auxiliary Load Circuit Test....25395
    Table 74Lighted Air Shield Circuit Test....25395
    Table 75Feature Codes....25396
    Table 76Diagnostic Trouble Codes....25397
    Table 77Trailer Lights Preliminary Check....25398
    Table 78Trailer Socket Circuit Test....25398
    Table 79Trailer Left Turn Relay Circuit Test....25400
    Table 80Trailer Right Turn Relay Circuit Test....25401
    Table 81Trailer Marker Light Relay Circuit Test....25402
    Table 82Trailer Tail Light Relay Circuit Test....25403
    Table 83Trailer Stop Light Relay Circuit Test....25404
    Table 84Trailer ABS ECU Relay Circuit Test....25405
    Table 85Feature Code....25406
    Table 86Diagnostic Trouble Codes....25406
    Table 87Auxiliary Snowplow Lights Preliminary Checks....25407
    Table 88 Snowplow Switch Test....25408
    Table 89Snowplow Lights Circuit Test....25408
    Table 90Cigar Lighter and Power Feed Preliminary Check....25417
    Table 91Cigar Lighter Circuit Test....25417
    Table 92Two-Post Power Source Circuit Test....25417
    Table 93CB Radio Power Source Preliminary Check....25419
    Table 94CB Radio Circuit Test....25419
    Table 95Feature Codes....25420
    Table 96Diagnostic Trouble Codes....25420
    Table 97Compass and Temperature Display Preliminary Check....25422
    Table 98Compass Display Circuit Test....25423
    Table 99Ambient Temperature Sensor Circuit Test....25426
    Table 100Feature Codes....25427
    Table 101Diagnostic Trouble Codes....25428
    Table 102Power Locks Preliminary Check....25431
    Table 103Power Windows Preliminary Check....25431
    Table 104Locks and Windows Inoperative Circuit Test....25431
    Table 105Power Window Circuit Test....25432
    Table 106Power Door Lock Circuit Test....25433
    Table 107Feature Codes....25433
    Table 108Diagnostic Trouble Codes....25435
    Table 109Electric Horn Preliminary Check....25435
    Table 110Electric Horn Circuit Test....25436
    Table 111Feature Codes....25437
    Table 112Diagnostic Trouble Codes....25438
    Table 113Air Horn Preliminary Checks....25438
    Table 114Air Horn Circuit Test....25439
    Table 115Power Mirror Preliminary Check....25441
    Table 116Driver Power Mirror Circuit Test....25441
    Table 117Passenger Power Mirror Circuit Test....25442
    Table 118Feature Codes....25443
    Table 119Diagnostic Trouble codes....25444
    Table 120Heated Mirror Preliminary Check....25444
    Table 121Heated Mirror Switch Test....25445
    Table 122Driver Heated Mirror Circuit Test....25445
    Table 123Passenger Heated Mirror Circuit Test....25446
    Table 124Heated Windshield Circuit Test....25447
    Table 125Radio Preliminary Check....25449
    Table 126Radio Circuit Test (16 Way Connector)....25450
    Table 127Radio Circuit Test (12 Way Connector)....25450
    Table 128Speaker Circuit Test (16 Way Connector)....25451
    Table 129Speaker Circuit Test (12 Way Connector)....25452
    Table 130Two-Way Radio Circuit Test....25453
    Table 131Feature Codes....25454
    Table 132Diagnostic Trouble Codes....25456
    Table 133Wiper and Washer Preliminary Check....25457
    Table 134Washer Pump Circuit Test....25458
    Table 135Wiper Switch Circuit Test....25459
    Table 136Wiper Motor Circuit Test....25460
    Table 137Feature Codes....25461
    Table 138Diagnostic Trouble Codes....25462
    Table 139Brake Switch Preliminary Check....25463
    Table 140Brake Switch Circuit Test....25464
    Table 141Park Brake Switch Circuit Test....25465
    Table 142Feature Code....25468
    Table 143Diagnostic Trouble Codes....25468
    Table 144Clutch Switch Preliminary Checks....25469
    Table 145Engine Crank Clutch Switch Test....25470
    Table 146Cruise Control Clutch Switch Test....25472
    Table 147Feature Code....25473
    Table 148Diagnostic Trouble Codes....25474
    Table 149Latching Relay Circuit Test....25475
    Table 150Vehicle Data Recorder Preliminary Check....25476
    Table 151 Vehicle Data Recorder Circuit Test....25477
    Table 152VDR Brake Pressure Switch Circuit Test....25478
    Table 153VDR Headlight Input Relay Circuit Test....25479
    Table 154Feature Code....25480
    Table 155Diagnostic Trouble Codes....25481
    Table 156Theft Deterrent Preliminary Check....25482
    Table 157Theft Deterrent System Test....25482
    Table 158Feature Code....25484
    Table 159Seat Belt Preliminary Check....25485
    Table 160Seat Belt Indicator Circuit Test....25486
    Table 161Driver and Passenger Self-Contained Air Seats Prelimina....25487
    Table 162Driver and Passenger Self-Contained Air Seat Test....25488
    Table 163Driver and Passenger Heated Seats Preliminary Check....25489
    Table 164Driver and Passenger Heated Seat Test....25490
    Table 165Air Dryer and Heated Drain Valve Preliminary Check....25496
    Table 166Heated Drain Valve Circuit Test....25497
    Table 167Air Dryer Circuit Test....25498
    Table 168Feature Codes....25499
    Table 169Diagnostic Trouble Codes....25499
    Table 170Air Solenoid Preliminary Check....25505
    Table 171Air Solenoid Circuit Test....25506
    Table 172Feature Code....25507
    Table 173Diagnostic Trouble Codes....25508
    Table 174Suspension Dump Preliminary Check....25510
    Table 175Suspension Dump Test....25510
    Table 176Feature Codes....25512
    Table 177Diagnostic Trouble Codes....25513
    Table 178Differential Lock Preliminary Check....25515
    Table 179Differential Lock Test....25515
    Table 180Feature Code....25517
    Table 181Diagnostic Trouble Codes....25518
    Table 182Power Divider Lock Preliminary Check....25519
    Table 183Power Divider Lock Test....25519
    Table 184Feature Code....25520
    Table 185Diagnostic Trouble Codes....25521
    Table 186Power Take Off Preliminary Check....25523
    Table 187Power Take Off Circuit Test....25523
    Table 188Feature Code....25525
    Table 189Diagnostic Trouble Codes....25527
    Table 190Anti-Lock Braking System Preliminary Check....25527
    Table 191Bendix® ABS Module Circuit Test....25528
    Table 192Bendix® Steering Wheel Sensor Circuit Test....25530
    Table 193Bendix® Yaw Sensor Circuit Test....25530
    Table 194Wabco® ABS Module Circuit Test....25531
    Table 195Feature Code....25533
    Table 196Diagnostic Trouble Codes....25534
    Table 197Fifth Wheel Slide Preliminary Check....25535
    Table 198Fifth Wheel Slide Circuit Test....25535
    Table 199Fifth Wheel Jaw Lock Release Circuit Test....25536
    Table 200Fuel Heater Preliminary Check....25537
    Table 201Fuel Heater Circuit Test ....25538
    Table 202Diagnostic Trouble Codes....25540
    Table 203RPM Preliminary Check....25544
    Table 204RPM Circuit Test....25544
    Table 205Feature Code....25547
    Table 206Diagnostic Trouble Codes....25548
    Table 207Remote Start / Stop Preliminary Check....25549
    Table 208Remote Start / Stop Test....25549
    Table 209Feature Codes....25551
    Table 210Diagnostic Trouble Codes....25551
    Table 211Two-Speed Switch Preliminary Check....25552
    Table 212Two-Speed Switch Test....25552
    Table 213Feature Code....25553
    Table 214Diagnostic Trouble Codes....25554
    Table 215Lift Gate Preliminary Check....25555
    Table 216Lift Gate Test ....25556
    Table 217Feature Code....25557
    Table 218Diagnostic Trouble Codes....25557
    Table 219Auto Neutral Preliminary Check....25558
    Table 220Auto Neutral Switch Test ....25558
    Table 221Auto Neutral Circuit Test ....25558
    Table 222Feature Code....25560
    Table 223Diagnostic Trouble Codes....25562
    Table 224Axle Load Monitor Preliminary Check....25563
    Table 225Axle Pressure Transducer Circuit Test....25563
    Table 226Diagnostic Trouble Codes....25565
    Table 227Water-In-Fuel Monitor Preliminary Check....25565
    Table 228Water Probe Circuit Test....25566
    Table 229Feature Code....25571
    Table 230Diagnostic Trouble Codes....25572
    Table 231Transmission Preliminary Check....25573
    Table 232Eaton UltraShift® TCM Circuit Test....25575
    Table 233Eaton UltraShift® Selector Circuit Test....25577
    Table 234Eaton UltraShift® Selector Lighting Circuit Test ....25579
    Table 235Eaton T-Handle Shifter Circuit Test....25580
    Table 236Eaton T-Handle Shifter Lighting Circuit Test....25580
    Table 237Eaton Hybrid TCM Circuit Test....25581
    Table 238Allison TCU Circuit Test with IBB Engine....25583
    Table 239Allison Shift Selector Circuit Test....25584
    Table 240Allison Shift Selector Lighting Circuit Test....25586
    Table 241Allison TCU Circuit Test with I6/V8 Engine....25586
    Table 242Allison Column Mounted Shifter ....25587
    Table 243Allison T-Handle Shifter ....25588
    Table 244Shifter Ignition Relay Circuit Test....25589
    Table 245Park Position Unlock Solenoid Test....25590
    Table 246Body Controller Signals....25591
    Table 247J1939 Data Link Circuit Test....25597
    Table 248J1708 Data Link Circuit Test....25597
    Table 249Battery Power Distribution Preliminary Check....25601
    Table 250Accessory Power Distribution Check....25601
    Table 251Accessory Power Circuit Test....25602
    Table 252Body Controller Accessory Feed Input Circuit Test....25603
    Table 253Ignition Power Distribution Check....25604
    Table 254Ignition Power Circuit Test....25604
    Table 255Ground Circuit Test....25606
    Table 256Feature Code....25611
    Table 257Diagnostic Trouble Codes....25611
    Table 258Fan System Preliminary Check....25612
    Table 259Fan Override Switch Test....25612
    Table 260Feature Code....25613
    Table 261Diagnostic Trouble Codes....25614
    Table 262Compression / Exhaust Brake Preliminary Check....25615
    Table 263Compression Brake Switch Test....25615
    Table 264Soot Accumulation Level Indications....25617
    Table 265Feature Code....25618
    Table 266Diagnostic Trouble Codes....25618
    Table 267Aftertreatment Preliminary Check....25620
    Table 268Inhibit Regeneration Switch Test....25620
    Table 269Parked Regeneration Switch Test....25621
    Table 270Warning Lamp Test....25621
    Table 271Feature Code....25623
    Table 272Diagnostic Trouble Codes....25624
    Table 273Cruise Control Preliminary Check....25625
    Table 274Cruise Control Switch Test....25626
    Table 275Feature Code....25628
    Table 276Snow Valve Preliminary Check....25628
    Table 277Snow Valve Module Circuit Test....25629
    Table 278Diagnostic Trouble Codes....25633
    Table 279Diagnostic Trouble Codes....25635
    Table 280Feature Code....25643
    Table 281Vehicle Information Display Preliminary Check....25643
    Table 282Vehicle Information Display Circuit Test....25643
    Table 283Feature Code....25645
    Table 284Driver Information Display Preliminary Check....25646
    Table 285Driver Information Display Circuit Test....25646
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Manual....25650
  toc....25654
    SAFETY INFORMATION....25654
      MANUAL INTRODUCTION....25656
        1. Manual Introduction....25658
        2. Vehicle Electrical System Overview....25659
        3. Electrical Circuit Diagram Book....25659
          3.1. CIRCUIT DIAGRAMS....25659
            Circuit Diagram Instructions....25660
          3.2. CONNECTOR BODY COMPOSITE....25663
        4. Troubleshooting....25664
          4.1. Verify The Problem....25664
          4.2. Important Steps Before Performing Circuit Tests....25664
          4.3. Review Feature Operation....25665
          4.4. Check the Circuit Diagram....25665
          4.5. Performing Circuit And System Tests....25666
          4.6. Perform The Repair....25666
          4.7. Verify The Repair....25666
        5. Electrical Test Equipment....25666
          5.1. EZ-TECH® Electronic Service Tool (EST)....25666
          5.2. Body Controller Breakout Box (ZTSE4477)....25666
          5.3. FLUKE 88 Digital Multimeter (DMM)....25667
          5.4. MIDTRONICS EXP-1000HD....25668
          5.5. Jumper Wires, Test Leads, And Test Lights....25669
            Jumper Wires....25669
            Test Leads....25670
            Test Lights....25671
          5.6. Ohm's Law Review....25671
          5.7. Voltmeter....25673
            Measuring Voltage....25673
          5.8. Ammeter....25676
            Measuring Amperage....25676
          5.9. Ohmmeter....25678
            Measuring Resistance....25678
            Checking For Open Circuits....25680
            Checking For Short Circuits....25681
        6. Bench Testing Relays....25682
        ELECTRONIC GAUGE CLUSTER....25686
          1. Electronic Gauge Cluster....25688
            1.1. System Description....25688
              Overview....25688
              Operation....25688
            1.2. Feature Codes....25693
            1.3. User Programmable Parameters....25694
            1.4. Diagnostic Trouble Codes....25699
            1.5. Troubleshooting....25707
              Preliminary Checks....25707
              Electronic Gauge Cluster Circuit Test....25709
              EGC Backlight Circuit Test....25711
              EGC Gauge Test....25711
              Warning Lamp Test....25713
              Fuel Level Gauge Circuit Test....25714
              Transmission Oil Temperature Circuit Tests....25715
              Front Rear and Rear Rear Axle Temperature Circuit Tests....25716
              Air Pressure Transducer Circuit Tests....25717
              Park Brake Switch Circuit Test....25720
              Air Restriction Gauge Circuit Test....25721
              Engine Coolant Level Monitor Circuit Test....25721
            1.6. Electronic Gauge Cluster Programming....25722
        SWITCH PACKS (J1708 DATA LINK)....25724
          1. Switch Packs....25726
            1.1. Description....25726
              Overview....25726
              Operation....25726
            1.2. Diagnostic Trouble Codes....25726
            1.3. Troubleshooting....25727
              Switch Pack Preliminary Check....25728
              Switch Pack Circuit Test....25728
              J1708 Data Link Circuit Test....25729
        LIGHTING SYSTEM....25730
          1. Backup Lights....25734
            1.1. System Description....25734
              Overview....25734
              Operation....25734
            1.2. Feature Code....25734
            1.3. user programmable parameters....25735
            1.4. diagnostic trouble codes....25735
            1.5. Troubleshooting....25735
              Backup Lights Preliminary Checks....25736
              Backup Light Circuit Test (Automatic Transmission)....25736
              Backup Light Switch Test (Manual Transmission)....25738
          2. Dome And Courtesy Lights....25739
            2.1. System Description....25739
              Overview....25739
              Operation....25739
            2.2. Feature Code....25740
            2.3. User Programmable Parameters....25740
            2.4. Diagnostic Trouble Codes....25740
            2.5. Troubleshooting ....25741
              Dome and Courtesy Lights Preliminary Checks....25741
              Door Switch Circuit Tests....25742
              Cab Dome Light Circuit Test....25743
              Courtesy Lights Circuit Test....25745
          3. Fog Lights....25745
            3.1. System Description....25745
              Overview....25745
              Operation....25745
            3.2. Feature Codes....25746
            3.3. User Programmable Parameters ....25746
            3.4. Diagnostic Trouble Codes....25746
            3.5. Troubleshooting....25747
              Fog Light System Preliminary Check....25747
              Fog Light Switch Test....25748
              Fog Light Circuit Test....25749
          4. Headlights And Daytime Running Lights (DTRL)....25750
            4.1. system description....25750
              Overview....25751
              Operation....25751
            4.2. Feature Codes....25751
            4.3. User Programmable Parameters....25751
            4.4. Diagnostic Trouble Codes....25751
            4.5. Troubleshooting....25753
              Headlight System Preliminary Check....25754
              Headlight Switch Test....25755
              Turn Signal Switch Circuit Test....25756
              Right Headlight Circuit Test....25757
              Left Headlight Circuit Test....25759
          5. Stop, Turn, And Hazard Lights....25759
            5.1. System Description....25759
              Overview....25759
              Operation....25760
            5.2. Feature Codes....25760
            5.3. User Programmable Parameters....25760
            5.4. Diagnostic Trouble Codes....25760
            5.5. Troubleshooting....25763
              Stop, Turn, and Hazards System Preliminary Check....25763
              Turn Signal Switch Circuit Test....25764
              Brake Switch Circuit Test....25766
              Left Front Turn Signal Circuit Test....25768
              Right Front Turn Signal Circuit Test....25768
              Left Rear Turn Signal Circuit Test....25769
              Right Rear Turn Signal Circuit Test....25770
          6. Tail, Marker, Park, And Clearance Lighting....25770
            6.1. System Description....25770
              Overview....25770
              Operation....25771
            6.2. Feature Codes....25771
            6.3. User Programmable Parameters....25771
            6.4. Diagnostic Trouble Codes....25771
            6.5. Troubleshooting....25772
              Tail, Marker, Park, and Clearance Lighting Preliminary Check....25772
              Headlight Switch Test....25772
              Tail Light Circuit Test....25774
              Park, Marker, Clearance, and Identification Lights Circuit Test....25774
          7. Work Light....25775
            7.1. System Description....25775
              Overview....25775
              Operation....25775
            7.2. Feature Codes....25775
            7.3. User Programmable Parameters....25775
            7.4. Diagnostic Trouble Codes....25776
            7.5. Troubleshooting....25776
              Work Light System Preliminary Check....25777
              Work Light Switch Test....25777
              Work Light Circuit Tests....25778
          8. Roof Auxiliary Load And Air Shield Light....25779
            8.1. System Description....25779
              Overview....25779
              Roof Auxiliary Load Operation....25779
              Air Shield Light Operation....25779
            8.2. Feature Codes....25779
            8.3. User Programmable Parameters....25780
            8.4. Diagnostic Trouble CodeS....25780
              Roof Auxiliary Load ....25780
              Lighted Air Shield....25780
            8.5. Troubleshooting....25780
              Roof Auxiliary Load Preliminary Check....25780
              Lighted Air Shield Preliminary Check....25781
              Roof Auxiliary Load Switch Test....25782
              Roof Auxiliary Load Circuit Test....25783
              Lighted Air Shield Circuit Test....25783
          9. Trailer Lighting....25784
            9.1. System Description....25784
              Overview....25784
              Operation....25784
            9.2. Feature Codes....25784
            9.3. User Programmable Parameters....25784
            9.4. Diagnostic Trouble CodeS....25784
            9.5. Troubleshooting....25786
              Trailer Lights Preliminary Check....25786
              Trailer Socket Circuit Test....25786
              Trailer Left Turn Relay Circuit Test....25788
              Trailer Right Turn Relay Circuit Test....25789
              Trailer Marker Light Relay Circuit Test....25790
              Trailer Tail Light Relay Circuit Test....25791
              Trailer Stop Light Relay Circuit Test....25792
              Trailer ABS ECU Relay Circuit Test....25793
          10. Auxiliary Snowplow Lighting....25793
            10.1. System Description....25793
              Overview....25793
              Operation....25793
            10.2. Feature Code....25794
            10.3. user programmable parameters....25794
            10.4. diagnostic trouble codes....25794
            10.5. Troubleshooting....25795
              Auxiliary Snowplow Lights Preliminary Checks....25795
              Snowplow Switch Test....25796
              Snowplow Lights Circuit Test....25796
        CAB FEATURES....25798
          1. Cigar Lighter And Power Feed....25804
            1.1. System Description....25804
              Overview....25804
              Cigar Lighter Operation....25804
              Cigar Lighter Power Source and Two-Post Power Source Operation....25804
            1.2. Feature Codes....25804
            1.3. User Programmable Parameters....25804
            1.4. Diagnostic Trouble Codes....25804
            1.5. Troubleshooting....25804
              Cigar Lighter and Power Feed Preliminary Check....25804
              Cigar Lighter Circuit Test....25805
              Two-Post Power Source Circuit Test....25805
          2. CB Power Radio....25806
            2.1. System Description....25806
              Overview....25806
              Operation....25806
            2.2. Feature Codes....25806
            2.3. User Programmable Parameters....25806
            2.4. Diagnostic Trouble Codes....25806
            2.5. Troubleshooting....25806
              CB Radio Power Source Preliminary Check....25807
              CB Radio Circuit Test....25807
          3. Compass And Temperature Display....25807
            3.1. System Description....25807
              Overview....25807
              Temperature Display Operation....25808
              Compass Display Operation....25808
            3.2. Feature Codes....25808
            3.3. User Programmable Parameters....25808
            3.4. Diagnostic Trouble Codes....25808
            3.5. Troubleshooting....25810
              Compass and Temperature Display Preliminary Check....25810
              Compass / Temperature Display Circuit Tests....25810
              Compass Calibration....25812
              Ambient Temperature Sensor Circuit Test....25813
          4. Power Windows And Locks....25814
            4.1. System Description....25814
              Overview....25814
              Power Window Operation....25814
              Power Door Lock Operation....25815
            4.2. Feature Codes....25815
            4.3. User Programmable Parameters....25815
            4.4. Diagnostic Trouble Codes....25816
            4.5. Troubleshooting....25818
              Power Window and Lock Preliminary Check....25819
              Locks and Windows Inoperative Circuit Test....25819
              Power Window Circuit Test....25820
              Power Door Lock Circuit Test....25821
          5. Electric Horn....25821
            5.1. System Description....25821
              Overview....25821
              Operation....25821
            5.2. Feature Codes....25821
            5.3. User Programmable Parameters....25821
            5.4. Diagnostic Trouble Codes....25823
            5.5. Troubleshooting....25823
              Electric Horn Preliminary Check....25823
              Electric Horn Circuit Test....25824
          6. Air Horn....25825
            6.1. System Description....25825
              Overview....25825
              Operation....25825
            6.2. Feature Codes....25825
            6.3. User Programmable Parameters....25825
            6.4. Diagnostic Trouble Codes....25825
            6.5. Troubleshooting....25826
              Air Horn Preliminary Check....25826
              Air Horn Circuit Test....25827
          7. Power Mirrors....25827
            7.1. System Description....25827
              Overview....25827
              Operation....25827
            7.2. Feature Codes....25828
            7.3. User Programmable Parameters....25828
            7.4. Diagnostic Trouble Codes....25828
            7.5. Troubleshooting....25828
              Power Mirror Preliminary Check....25829
              Driver Power Mirror Circuit Test....25829
              Passenger Power Mirror Circuit Test....25830
          8. Heated Mirror....25831
            8.1. System Description....25831
              Overview....25831
              Operation....25831
            8.2. Feature Codes....25831
            8.3. User Programmable Parameters....25831
            8.4. Diagnostic Trouble Codes....25831
            8.5. Troubleshooting....25832
              Heated Mirror Preliminary Check....25832
              Heated Mirror Switch Test....25833
              Driver Heated Mirror Circuit Test....25833
              Passenger Heated Mirror Circuit Test....25834
              Heated Windshield Circuit Test....25834
          9. Radio (Entertainment), Speakers....25836
            9.1. System Description....25836
              Overview....25836
              Operation....25837
            9.2. Feature Codes....25837
            9.3. User Programmable Parameters....25837
            9.4. Diagnostic Trouble Codes....25837
            9.5. Troubleshooting....25837
              Radio Preliminary Check....25837
              Radio Circuit Test (16 Way Connector)....25838
              Radio Circuit Test (12 Way Connector)....25838
              Speaker Circuit Test (16 Way Connector)....25838
              Speaker Circuit Test....25839
          10. Two-Way Radio....25840
            10.1. System Description....25840
              Overview....25840
              Operation....25840
            10.2. Feature Codes....25841
            10.3. User Programmable Parameters....25841
            10.4. diagnostic trouble codes....25841
            10.5. Troubleshooting....25841
              Two-Way Radio Circuit Test....25841
          11. Windshield Wiper And Washer Pump....25841
            11.1. System Description....25841
              Overview....25841
              Wiper Operation....25842
              Park Operation....25842
              Washer Operation....25842
            11.2. Feature Codes....25842
            11.3. User Programmable Parameters....25842
            11.4. Diagnostic Trouble Codes....25844
            11.5. Troubleshooting....25845
              Wiper and Washer Preliminary Check....25845
              Washer Pump Circuit Test....25846
              Wiper Switch Circuit Test....25847
              Wiper Motor Circuit Test....25848
          12. Park Brake And Brake Switch....25848
            12.1. System Description....25848
              Overview....25849
              Operation....25849
            12.2. Feature Codes....25849
            12.3. User Programmable Parameters....25849
            12.4. Diagnostic Trouble CodeS....25850
            12.5. Troubleshooting....25851
              Brake Switch Preliminary Check....25851
              Brake Switch Test....25852
              Park Brake Switch Test....25853
          13. Clutch Switch....25855
            13.1. System Description....25855
              Overview....25855
              Operation....25855
            13.2. Feature Codes....25855
            13.3. User Programmable Parameters....25856
            13.4. Diagnostic Trouble CodeS....25856
            13.5. Troubleshooting....25857
              Clutch Switch Preliminary Checks....25857
              Engine Crank Clutch Switch Test....25858
              Cruise Control Clutch Switch Test....25860
          14. Load Shedding....25860
            14.1. System Description....25860
              Overview....25861
              Operation....25861
            14.2. Feature Codes....25861
            14.3. User Programmable Parameters....25861
            14.4. Diagnostic Trouble CodeS....25861
            14.5. Troubleshooting....25862
              Latching Relay Circuit Test....25862
          15. Vehicle Data Recorder....25863
            15.1. System Description....25863
              Overview....25863
              Operation....25864
            15.2. Feature Code....25864
            15.3. User Programmable Parameters....25864
            15.4. Diagnostic Trouble Codes....25864
            15.5. Troubleshooting....25864
              Vehicle Data Recorder Preliminary Check....25864
              Vehicle Data Recorder Circuit Test....25865
              VDR Brake Pressure Switch Circuit Test....25866
              VDR Headlight Input Relay Circuit Test....25867
          16. Theft Deterrent System....25868
            16.1. System Description....25868
              Overview....25868
              Operation....25868
            16.2. FEATURE CODE....25868
            16.3. user programmable parameters....25868
            16.4. diagnostic trouble codes....25868
            16.5. Troubleshooting....25869
              Theft Deterrent Preliminary Check....25870
              Theft Deterrent System Test....25870
          17. Seat Belt And Seat Sensor....25871
            17.1. System Description....25871
              Overview....25871
              Operation....25872
            17.2. Feature Code....25872
            17.3. User Programmable Parameters....25872
            17.4. Diagnostic Trouble Codes....25873
            17.5. Troubleshooting....25873
              Seat Belt Preliminary Check....25873
              Seat Belt Indicator Circuit Test....25874
          18. Self-Contained Air Seat....25875
            18.1. System Description....25875
              Overview....25875
              Operation....25875
            18.2. Feature Code....25875
            18.3. User Programmable Parameters....25875
            18.4. Diagnostic Trouble Codes....25875
            18.5. Troubleshooting....25875
              Driver and Passenger Self-Contained Air Seats Preliminary Check....25875
              Driver and Passenger Self-Contained Air Seat Test....25876
          19. Heated Seats....25877
            19.1. System Description....25877
              Overview....25877
              Operation....25877
            19.2. Feature Codes....25877
            19.3. User Programmable Parameters....25877
            19.4. Diagnostic Trouble CodeS....25877
            19.5. Troubleshooting....25877
              Driver and Passenger Heated Seats Preliminary Check....25877
              Driver and Passenger Heated Seat Test....25877
        CHASSIS FEATURES....25880
          1. Heated Air Dryer and drain valve....25884
            1.1. System Description....25884
              Overview....25884
              Operation....25884
            1.2. Feature Codes....25884
            1.3. User Programmable Parameters....25884
            1.4. diagnostic trouble codes....25884
            1.5. Troubleshooting....25884
              Air Dryer and Heated Drain Valve Preliminary Check....25884
              Heated Drain Valve Circuit Test....25885
              Air Dryer Circuit Test....25886
          2. Air Solenoid....25886
            2.1. System Description....25886
              Overview....25886
              Operation....25886
            2.2. Feature Codes....25887
            2.3. User Programmable Parameters....25887
            2.4. Diagnostic Trouble Codes....25887
            2.5. Troubleshooting....25892
              Air Solenoid Preliminary Check....25893
              Air Solenoid Circuit Test....25893
          3. Suspension Dump....25894
            3.1. System Description....25894
              Overview....25894
              Operation....25894
            3.2. Feature Code....25895
            3.3. User Programmable Parameters....25895
            3.4. Diagnostic Trouble Codes....25896
            3.5. Troubleshooting....25897
              Suspension Dump Preliminary Check....25897
              Suspension Dump Test....25898
          4. Differential Lock....25899
            4.1. System description....25899
              Overview....25899
              Operation....25899
            4.2. Feature Code....25900
            4.3. User Programmable Parameters....25900
            4.4. Diagnostic Trouble Codes....25901
            4.5. Troubleshooting....25902
              Differential Lock Preliminary Check....25903
              Differential Lock Test....25903
          5. Power Divider Lock....25904
            5.1. System Description....25904
              Overview....25904
              Operation....25904
            5.2. FEATURE CODE....25905
            5.3. User Programmable Parameters....25905
            5.4. Diagnostic Trouble Codes....25905
            5.5. Troubleshooting....25906
              Power Divider Lock Preliminary Check....25907
              Power Divider Lock Test....25907
          6. Power Take Off....25908
            6.1. System Description....25908
              Overview....25908
              Operation....25908
            6.2. Feature Code....25908
            6.3. User Programmable Parameters....25908
            6.4. Diagnostic Trouble Codes....25909
            6.5. Troubleshooting....25910
              Power Take Off Preliminary Check....25911
              Power Take Off Circuit Test....25911
          7. Anti-Lock Braking System ....25912
            7.1. System Description....25912
              Overview....25912
              Operation....25912
              Communication....25913
            7.2. Feature Code....25913
            7.3. User Programmable Parameters....25914
            7.4. Diagnostic Trouble Codes....25914
            7.5. Troubleshooting....25915
              Anti-Lock Braking System Preliminary Check....25915
              Bendix® ABS Circuit Tests....25916
              Wabco® ABS Module Circuit Test....25919
          8. Fifth Wheel Slide and jaw lock release....25920
            8.1. System Description....25920
              Overview....25920
              Operation....25921
            8.2. Feature Code....25921
            8.3. User Programmable Parameters....25921
            8.4. Diagnostic Trouble Codes....25922
            8.5. Troubleshooting....25923
              Fifth Wheel Slide Preliminary Check....25923
              Fifth Wheel Slide Circuit Test....25923
              Fifth Wheel Jaw Lock Release Circuit Test....25924
          9. Fuel Heater....25924
            9.1. System Description....25924
              Overview....25925
              Operation....25925
            9.2. Feature Code....25925
            9.3. User Programmable Parameters....25925
            9.4. Diagnostic Trouble Codes....25925
            9.5. Troubleshooting....25925
              Fuel Heater Preliminary Check....25925
              Fuel Heater Circuit Test ....25926
          10. Remote Power Module....25926
            10.1. System Description....25926
              Overview....25927
              Operation....25927
            10.2. Feature Code....25927
            10.3. User Programmable Parameters....25928
            10.4. Diagnostic Trouble Codes....25928
            10.5. Troubleshooting....25931
              RPM Preliminary Check....25932
              RPM Circuit Test....25932
          11. remote start / stop....25934
            11.1. System description....25934
              Overview....25934
              Operation....25935
            11.2. FEATURE CODE....25935
            11.3. user programmable parameters....25936
            11.4. diagnostic trouble codes....25936
            11.5. Troubleshooting....25936
              Remote Start / Stop Preliminary Check....25937
              Remote Start / Stop Test....25937
          12. Two-speed axle ....25939
            12.1. System description....25939
              Overview....25939
              Operation....25939
            12.2. feature codes....25939
            12.3. user programmable parameters....25939
            12.4. diagnostic trouble codes....25939
            12.5. troubleshooting....25940
              Two-Speed Switch Preliminary Check....25940
              Two-Speed Switch Test....25940
          13. Customer installed lift gate power source....25941
            13.1. System description....25941
              Overview....25941
              Operation....25941
            13.2. FEATURE CODE....25941
            13.3. user programmable parameters....25942
            13.4. diagnostic trouble codes....25942
            13.5. Troubleshooting....25943
              Lift Gate Preliminary Check....25943
              Lift Gate Circuit Test ....25944
          14. Auto neutral ....25944
            14.1. System description....25944
              Overview....25944
              Operation....25944
            14.2. FEATURE CODE....25945
            14.3. user programmable parameters....25945
            14.4. diagnostic trouble codes....25945
            14.5. Troubleshooting....25945
              Auto Neutral Preliminary Check....25946
              Auto Neutral Switch Test ....25946
              Auto Neutral Circuit Test....25946
          15. Axle Load Monitor....25948
            15.1. System Description....25948
              Overview....25948
              Operation....25948
            15.2. Feature Code....25948
            15.3. User Programmable Parameters....25949
            15.4. Diagnostic Trouble Codes....25950
            15.5. Troubleshooting....25951
              Axle Load Monitor Preliminary Check....25951
              Axle Pressure Transducer Circuit Test....25951
          16. water-in-fuel monitor ....25952
            16.1. System Description....25952
              Overview....25952
              Operation....25952
            16.2. Feature Code....25952
            16.3. User Programmable Parameters....25952
            16.4. Diagnostic Trouble Codes....25952
            16.5. Troubleshooting....25953
              Water-In-Fuel Monitor Preliminary Check....25953
              Water Probe Circuit Test....25954
        TRANSMISSIONS....25956
          1. Transmission....25958
            1.1. System Description....25958
              Overview....25958
              Operation....25958
            1.2. Feature Code....25959
            1.3. user programmable parameters....25959
            1.4. Diagnostic Trouble Codes....25959
            1.5. Troubleshooting....25961
              Transmission Preliminary Check....25961
              Eaton UltraShift®® TCM Circuit Test....25962
              Eaton UltraShift® Selector Circuit Test....25965
              Eaton T-Handle Shifter Circuit Test....25968
              Eaton Hybrid TCM Circuit Test....25968
              Allison TCU Circuit Test with IBB Engine....25970
              Allison Shift Selector with IBB Engine ....25972
              Allison TCU Circuit Test with I6/V8 Engine....25974
              Allison Shifter with I6/V8 Engine....25975
              Shifter Ignition Relay Circuit Test....25976
              Park Position Unlock Solenoid Test....25978
            1.6. Body Controller Signals....25978
              Body Controller Signals....25979
        MULTIPLEXING (DATA LINKS)....25980
          1. Multiplexing (Data Links)....25982
            1.1. Description....25982
              Overview....25982
              Operation....25982
            1.2. Troubleshooting....25983
              J1939 Data Link Terminating Resistors....25983
              Body Controller....25984
              J1939 Data Link Circuit Test....25984
              J1708 Data Link Circuit Test....25985
        12-VOLT POWER DISTRIBUTION AND GROUND....25986
          1. 12-Volt Power Distribution and Grounds....25988
            1.1. Description....25988
              Overview....25988
              Operation....25988
            1.2. Troubleshooting....25988
              Battery Power Distribution Check....25989
              Accessory Power Distribution Preliminary Check....25989
              Accessory Power Circuit Test....25990
              Body Controller Accessory Feed Input Circuit Test....25991
              Ignition Power Distribution Preliminary Check....25992
              Ignition Power Circuit Test....25992
              Ground Circuit Test....25994
        FANS AND ENGINE ACCESSORIES....25996
          1. Fan System....25998
            1.1. System Description....25998
              Overview....25998
              Operation....25998
            1.2. Feature Code....25998
            1.3. User Programmable Parameters....25999
            1.4. Diagnostic Trouble Codes....25999
            1.5. Troubleshooting....25999
              Fan System Preliminary Check....26000
              Fan Override Switch Test....26000
          2. Compression / Exhaust Brake....26001
            2.1. System Description....26001
              Overview....26001
              Operation....26001
            2.2. Feature Code....26001
            2.3. User Programmable Parameters....26002
            2.4. Diagnostic Trouble Codes....26002
            2.5. Troubleshooting....26002
              Compression / Exhaust Brake Preliminary Check....26003
              Compression / Exhaust Brake Switch Test....26003
          3. Aftertreatment ....26003
            3.1. System Description....26003
              Overview....26003
              Operation....26004
            3.2. Feature Code....26006
            3.3. User Programmable Parameters....26006
            3.4. Diagnostic Trouble Codes....26006
            3.5. Troubleshooting....26007
              Aftertreatment Preliminary Check....26008
              Inhibit Regeneration Switch Test....26008
              Parked Regeneration Switch Test....26009
              Warning Lamp Test....26009
          4. Cruise Control....26010
            4.1. system description....26010
              Overview....26010
              Operation....26010
            4.2. feature codes....26011
            4.3. User Programmable Parameters....26011
            4.4. diagnostic trouble codes....26011
            4.5. Troubleshooting....26012
              Cruise Control Preliminary Check....26013
              Cruise Control Switch Test....26014
          5. Snow Valve....26015
            5.1. System Description....26015
              Overview....26015
              Operation....26015
            5.2. Feature Code....26016
            5.3. User Programmable Parameters....26016
            5.4. Diagnostic Trouble Codes....26016
            5.5. Troubleshooting....26016
              Snow Valve Preliminary Check....26016
              Snow Valve Module Circuit Test....26017
        BATTERY, CHARGING, AND CRANKING SYSTEM....26018
          1. Battery System....26020
            1.1. Description....26020
              Overview....26020
              Operation....26020
            1.2. Diagnostic Trouble Codes....26021
            1.3. Troubleshooting....26021
              Battery Test....26021
              Battery Test Results....26022
              Cable Drop Test....26022
              Battery Pack Test....26022
              Battery Pack Test Results....26022
          2. Charging System....26023
            2.1. Description....26023
              Overview....26023
              Operation....26023
            2.2. Diagnostic Trouble Codes....26023
            2.3. Troubleshooting....26024
              Charging System Test....26024
              Charging System Test Results....26024
          3. Cranking System....26025
            3.1. Description....26025
              Overview....26025
              Operation....26025
            3.2. Troubleshooting....26026
              Starting System Test....26026
              Starting System Test Results....26026
          4. Powerpack 3....26026
            4.1. Description....26026
              Overview....26027
              Operation....26027
            4.2. Troubleshooting....26027
        VEHICLE AND DRIVER INFORMATION DISPLAY....26028
          1. vehicle information display....26030
            1.1. System description....26030
              Overview....26030
              Operation....26030
            1.2. FEATURE CODE....26030
            1.3. user programmable parameters....26031
            1.4. diagnostic trouble codes....26031
            1.5. Troubleshooting....26031
              Vehicle Information Display Preliminary Check....26031
              Vehicle Information Display Circuit Test....26031
          2. Driver information display....26032
            2.1. System description....26032
              Overview....26032
              Operation....26033
            2.2. FEATURE CODE....26033
            2.3. user programmable parameters....26033
            2.4. diagnostic trouble codes....26033
            2.5. Troubleshooting....26033
              Driver Information Display Preliminary Check....26034
              Driver Information Display Circuit Test....26034
  tables....25671
    Table 1Ohm's Law....25671
    Table 2Relay Bench Test....25684
    Table 3Gauges and Signal Paths....25689
    Table 4Warning Lamp and Signal Path....25690
    Table 5Audible Alarms....25692
    Table 6Electronic Gauge Cluster Feature Codes....25693
    Table 7Diagnostic Trouble Codes....25699
    Table 8EGC Preliminary Checks....25707
    Table 9Electronic Gauge Cluster Circuit Test....25709
    Table 10EGC Backlighting Circuit Test....25711
    Table 11EGC Gauge Test....25712
    Table 12Warning Lamp Test....25713
    Table 13Fuel Level Gauge Circuit Test....25714
    Table 14Transmission Oil Temperature Circuit Test....25715
    Table 15Rear Rear Axle Temperature Circuit Test....25716
    Table 16Front Rear Axle Temperature Circuit Test....25717
    Table 17Air Pressure Transducer Circuit Test....25718
    Table 18Park Brake Switch Circuit Test....25720
    Table 19 Air Restriction Gauge Circuit Test....25721
    Table 20Low Coolant Sensor Circuit Test....25721
    Table 21Diagnostic Trouble Codes....25726
    Table 22Switch Pack Preliminary Check....25728
    Table 23Switch Pack Circuit Test....25728
    Table 24J1708 Data Link Circuit Test....25729
    Table 25Feature Code....25734
    Table 26Diagnostic Trouble Codes....25735
    Table 27Backup Lights Preliminary Checks....25736
    Table 28 Backup Light Circuit Test....25736
    Table 29Backup Light Switch Test....25738
    Table 30Feature Code....25740
    Table 31Diagnostic Trouble Codes....25740
    Table 32Dome and Courtesy Lights Preliminary Checks....25741
    Table 33Door Switch Circuit Test....25742
    Table 34Cab Dome Light Circuit Test....25743
    Table 35Courtesy Lights Circuit Test....25745
    Table 36Feature Codes....25746
    Table 37Diagnostic Trouble Codes....25746
    Table 38Fog Light System Preliminary Check....25747
    Table 39Fog Light Switch Test....25748
    Table 40Fog Light Circuit Test....25749
    Table 41Feature Codes....25751
    Table 42Diagnostic Trouble Codes....25752
    Table 43Headlight System Preliminary Check....25754
    Table 44Headlight Switch Test....25755
    Table 45Turn Signal Switch Circuit Test....25756
    Table 46Right Headlight Circuit Test....25757
    Table 47Left Headlight Circuit Test....25759
    Table 48Feature Codes....25760
    Table 49Diagnostic Trouble Codes....25760
    Table 50Stop, Turn, and Hazards System Preliminary Check....25763
    Table 51Turn Signal Switch Circuit Test....25764
    Table 52Brake Switch Circuit Test....25766
    Table 53Left Front Turn Signal Circuit Test....25768
    Table 54Right Front Turn Signal Circuit Test....25769
    Table 55Left Rear Turn Signal Circuit Test....25769
    Table 56Right Rear Turn Signal Circuit Test....25770
    Table 57Feature Codes....25771
    Table 58Diagnostic Trouble Codes....25771
    Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....25772
    Table 60Headlight Switch Test....25773
    Table 61Tail Light Circuit Test....25774
    Table 62Park, Marker, Clearance, and Identification Lights Circu....25774
    Table 63Feature Codes....25775
    Table 64Diagnostic Trouble Codes....25776
    Table 65Work Light System Preliminary Check....25777
    Table 66Work Light Switch Test....25777
    Table 67Work Light Circuit Test....25778
    Table 68Feature Codes....25779
    Table 69Lighted Air Shield DTC....25780
    Table 70Roof Auxiliary Load Preliminary Check....25780
    Table 71Lighted Air Shield Preliminary Check....25781
    Table 72Roof Auxiliary Load Switch Test....25782
    Table 73Roof Auxiliary Load Circuit Test....25783
    Table 74Lighted Air Shield Circuit Test....25783
    Table 75Feature Codes....25784
    Table 76Diagnostic Trouble Codes....25785
    Table 77Trailer Lights Preliminary Check....25786
    Table 78Trailer Socket Circuit Test....25786
    Table 79Trailer Left Turn Relay Circuit Test....25788
    Table 80Trailer Right Turn Relay Circuit Test....25789
    Table 81Trailer Marker Light Relay Circuit Test....25790
    Table 82Trailer Tail Light Relay Circuit Test....25791
    Table 83Trailer Stop Light Relay Circuit Test....25792
    Table 84Trailer ABS ECU Relay Circuit Test....25793
    Table 85Feature Code....25794
    Table 86Diagnostic Trouble Codes....25794
    Table 87Auxiliary Snowplow Lights Preliminary Checks....25795
    Table 88 Snowplow Switch Test....25796
    Table 89Snowplow Lights Circuit Test....25796
    Table 90Cigar Lighter and Power Feed Preliminary Check....25805
    Table 91Cigar Lighter Circuit Test....25805
    Table 92Two-Post Power Source Circuit Test....25805
    Table 93CB Radio Power Source Preliminary Check....25807
    Table 94CB Radio Circuit Test....25807
    Table 95Feature Codes....25808
    Table 96Diagnostic Trouble Codes....25808
    Table 97Compass and Temperature Display Preliminary Check....25810
    Table 98Compass Display Circuit Test....25811
    Table 99Ambient Temperature Sensor Circuit Test....25814
    Table 100Feature Codes....25815
    Table 101Diagnostic Trouble Codes....25816
    Table 102Power Locks Preliminary Check....25819
    Table 103Power Windows Preliminary Check....25819
    Table 104Locks and Windows Inoperative Circuit Test....25819
    Table 105Power Window Circuit Test....25820
    Table 106Power Door Lock Circuit Test....25821
    Table 107Feature Codes....25821
    Table 108Diagnostic Trouble Codes....25823
    Table 109Electric Horn Preliminary Check....25823
    Table 110Electric Horn Circuit Test....25824
    Table 111Feature Codes....25825
    Table 112Diagnostic Trouble Codes....25826
    Table 113Air Horn Preliminary Checks....25826
    Table 114Air Horn Circuit Test....25827
    Table 115Power Mirror Preliminary Check....25829
    Table 116Driver Power Mirror Circuit Test....25829
    Table 117Passenger Power Mirror Circuit Test....25830
    Table 118Feature Codes....25831
    Table 119Diagnostic Trouble codes....25832
    Table 120Heated Mirror Preliminary Check....25832
    Table 121Heated Mirror Switch Test....25833
    Table 122Driver Heated Mirror Circuit Test....25833
    Table 123Passenger Heated Mirror Circuit Test....25834
    Table 124Heated Windshield Circuit Test....25835
    Table 125Radio Preliminary Check....25837
    Table 126Radio Circuit Test (16 Way Connector)....25838
    Table 127Radio Circuit Test (12 Way Connector)....25838
    Table 128Speaker Circuit Test (16 Way Connector)....25839
    Table 129Speaker Circuit Test (12 Way Connector)....25840
    Table 130Two-Way Radio Circuit Test....25841
    Table 131Feature Codes....25842
    Table 132Diagnostic Trouble Codes....25844
    Table 133Wiper and Washer Preliminary Check....25845
    Table 134Washer Pump Circuit Test....25846
    Table 135Wiper Switch Circuit Test....25847
    Table 136Wiper Motor Circuit Test....25848
    Table 137Feature Codes....25849
    Table 138Diagnostic Trouble Codes....25850
    Table 139Brake Switch Preliminary Check....25851
    Table 140Brake Switch Circuit Test....25852
    Table 141Park Brake Switch Circuit Test....25853
    Table 142Feature Code....25856
    Table 143Diagnostic Trouble Codes....25856
    Table 144Clutch Switch Preliminary Checks....25857
    Table 145Engine Crank Clutch Switch Test....25858
    Table 146Cruise Control Clutch Switch Test....25860
    Table 147Feature Code....25861
    Table 148Diagnostic Trouble Codes....25862
    Table 149Latching Relay Circuit Test....25863
    Table 150Vehicle Data Recorder Preliminary Check....25864
    Table 151 Vehicle Data Recorder Circuit Test....25865
    Table 152VDR Brake Pressure Switch Circuit Test....25866
    Table 153VDR Headlight Input Relay Circuit Test....25867
    Table 154Feature Code....25868
    Table 155Diagnostic Trouble Codes....25869
    Table 156Theft Deterrent Preliminary Check....25870
    Table 157Theft Deterrent System Test....25870
    Table 158Feature Code....25872
    Table 159Seat Belt Preliminary Check....25873
    Table 160Seat Belt Indicator Circuit Test....25874
    Table 161Driver and Passenger Self-Contained Air Seats Prelimina....25875
    Table 162Driver and Passenger Self-Contained Air Seat Test....25876
    Table 163Driver and Passenger Heated Seats Preliminary Check....25877
    Table 164Driver and Passenger Heated Seat Test....25878
    Table 165Air Dryer and Heated Drain Valve Preliminary Check....25884
    Table 166Heated Drain Valve Circuit Test....25885
    Table 167Air Dryer Circuit Test....25886
    Table 168Feature Codes....25887
    Table 169Diagnostic Trouble Codes....25887
    Table 170Air Solenoid Preliminary Check....25893
    Table 171Air Solenoid Circuit Test....25894
    Table 172Feature Code....25895
    Table 173Diagnostic Trouble Codes....25896
    Table 174Suspension Dump Preliminary Check....25898
    Table 175Suspension Dump Test....25898
    Table 176Feature Codes....25900
    Table 177Diagnostic Trouble Codes....25901
    Table 178Differential Lock Preliminary Check....25903
    Table 179Differential Lock Test....25903
    Table 180Feature Code....25905
    Table 181Diagnostic Trouble Codes....25906
    Table 182Power Divider Lock Preliminary Check....25907
    Table 183Power Divider Lock Test....25907
    Table 184Feature Code....25908
    Table 185Diagnostic Trouble Codes....25909
    Table 186Power Take Off Preliminary Check....25911
    Table 187Power Take Off Circuit Test....25911
    Table 188Feature Code....25913
    Table 189Diagnostic Trouble Codes....25915
    Table 190Anti-Lock Braking System Preliminary Check....25915
    Table 191Bendix® ABS Module Circuit Test....25916
    Table 192Bendix® Steering Wheel Sensor Circuit Test....25918
    Table 193Bendix® Yaw Sensor Circuit Test....25918
    Table 194Wabco® ABS Module Circuit Test....25919
    Table 195Feature Code....25921
    Table 196Diagnostic Trouble Codes....25922
    Table 197Fifth Wheel Slide Preliminary Check....25923
    Table 198Fifth Wheel Slide Circuit Test....25923
    Table 199Fifth Wheel Jaw Lock Release Circuit Test....25924
    Table 200Fuel Heater Preliminary Check....25925
    Table 201Fuel Heater Circuit Test ....25926
    Table 202Diagnostic Trouble Codes....25928
    Table 203RPM Preliminary Check....25932
    Table 204RPM Circuit Test....25932
    Table 205Feature Code....25935
    Table 206Diagnostic Trouble Codes....25936
    Table 207Remote Start / Stop Preliminary Check....25937
    Table 208Remote Start / Stop Test....25937
    Table 209Feature Codes....25939
    Table 210Diagnostic Trouble Codes....25939
    Table 211Two-Speed Switch Preliminary Check....25940
    Table 212Two-Speed Switch Test....25940
    Table 213Feature Code....25941
    Table 214Diagnostic Trouble Codes....25942
    Table 215Lift Gate Preliminary Check....25943
    Table 216Lift Gate Test ....25944
    Table 217Feature Code....25945
    Table 218Diagnostic Trouble Codes....25945
    Table 219Auto Neutral Preliminary Check....25946
    Table 220Auto Neutral Switch Test ....25946
    Table 221Auto Neutral Circuit Test ....25946
    Table 222Feature Code....25948
    Table 223Diagnostic Trouble Codes....25950
    Table 224Axle Load Monitor Preliminary Check....25951
    Table 225Axle Pressure Transducer Circuit Test....25951
    Table 226Diagnostic Trouble Codes....25953
    Table 227Water-In-Fuel Monitor Preliminary Check....25953
    Table 228Water Probe Circuit Test....25954
    Table 229Feature Code....25959
    Table 230Diagnostic Trouble Codes....25960
    Table 231Transmission Preliminary Check....25961
    Table 232Eaton UltraShift® TCM Circuit Test....25963
    Table 233Eaton UltraShift® Selector Circuit Test....25965
    Table 234Eaton UltraShift® Selector Lighting Circuit Test ....25967
    Table 235Eaton T-Handle Shifter Circuit Test....25968
    Table 236Eaton T-Handle Shifter Lighting Circuit Test....25968
    Table 237Eaton Hybrid TCM Circuit Test....25969
    Table 238Allison TCU Circuit Test with IBB Engine....25971
    Table 239Allison Shift Selector Circuit Test....25972
    Table 240Allison Shift Selector Lighting Circuit Test....25974
    Table 241Allison TCU Circuit Test with I6/V8 Engine....25974
    Table 242Allison Column Mounted Shifter ....25975
    Table 243Allison T-Handle Shifter ....25976
    Table 244Shifter Ignition Relay Circuit Test....25977
    Table 245Park Position Unlock Solenoid Test....25978
    Table 246Body Controller Signals....25979
    Table 247J1939 Data Link Circuit Test....25985
    Table 248J1708 Data Link Circuit Test....25985
    Table 249Battery Power Distribution Preliminary Check....25989
    Table 250Accessory Power Distribution Check....25989
    Table 251Accessory Power Circuit Test....25990
    Table 252Body Controller Accessory Feed Input Circuit Test....25991
    Table 253Ignition Power Distribution Check....25992
    Table 254Ignition Power Circuit Test....25992
    Table 255Ground Circuit Test....25994
    Table 256Feature Code....25999
    Table 257Diagnostic Trouble Codes....25999
    Table 258Fan System Preliminary Check....26000
    Table 259Fan Override Switch Test....26000
    Table 260Feature Code....26001
    Table 261Diagnostic Trouble Codes....26002
    Table 262Compression / Exhaust Brake Preliminary Check....26003
    Table 263Compression Brake Switch Test....26003
    Table 264Soot Accumulation Level Indications....26005
    Table 265Feature Code....26006
    Table 266Diagnostic Trouble Codes....26006
    Table 267Aftertreatment Preliminary Check....26008
    Table 268Inhibit Regeneration Switch Test....26008
    Table 269Parked Regeneration Switch Test....26009
    Table 270Warning Lamp Test....26009
    Table 271Feature Code....26011
    Table 272Diagnostic Trouble Codes....26012
    Table 273Cruise Control Preliminary Check....26013
    Table 274Cruise Control Switch Test....26014
    Table 275Feature Code....26016
    Table 276Snow Valve Preliminary Check....26016
    Table 277Snow Valve Module Circuit Test....26017
    Table 278Diagnostic Trouble Codes....26021
    Table 279Diagnostic Trouble Codes....26023
    Table 280Feature Code....26031
    Table 281Vehicle Information Display Preliminary Check....26031
    Table 282Vehicle Information Display Circuit Test....26031
    Table 283Feature Code....26033
    Table 284Driver Information Display Preliminary Check....26034
    Table 285Driver Information Display Circuit Test....26034
S09002 - Hood, Grille, and Fenders - 2000, 4000, 8000 (Supersedes CTS-5269) (Feb 1999) Service Manual....26038
  toc....26040
    Table of Contents....26040
      1. DESCRIPTION....26044
        1.1. HOOD....26044
        1.2. SPLASH PANELS....26047
        1.3. MUD GUARDS....26049
        1.4. HOOD SEALS....26052
        1.5. GRILLE....26053
        1.6. AIR INTAKES....26056
        1.7. FENDERS....26057
        1.8. SPLASH SHIELDS....26058
      2. REMOVE AND INSTALL....26058
        2.1. 2000 SERIES HOOD....26058
          2500 and 2600 Model Original Hood — Remove....26058
          2500 and 2600 Model Original Hood — Install....26060
          2600 Model Aerodynamic Hood (After March, 1996) — Remove....26061
          2600 Model Aerodynamic Hood (After March, 1996) — Install....26063
        2.2. 4000 SERIES HOOD....26064
          4700 Thru 4900 Model Hood — Remove....26064
          4700 Thru 4900 Model Hood — Install....26066
        2.3. 8000 SERIES HOOD....26067
          8100 Model Hood (Before June 1994) — Remove....26067
          8100 Model Hood (Before June 1994) — Install....26069
          8100 Model Hood (After June 1994) — Remove....26070
          8100 Model Hood (After June 1994) — Install....26071
          8200 Model Hood — Remove....26072
          8200 Model Hood — Install....26074
        2.4. 2000 SERIES SPLASH PANELS....26075
          2500 and 2600 Model Splash Panels (Original Hood) — Remove....26075
          2500 and 2600 Model Splash Panels (Original Hood) — Install....26078
          2600 Model Splash Panels (Aerodynamic Hood After March 1996) — R....26079
          2600 Model Splash Panels (Aerodynamic Hood After March 1996) — I....26081
        2.5. 4000 SERIES SPLASH PANELS....26082
          4700 Thru 4900 Model Splash Panels — Remove....26082
          4700 Thru 4900 Model Splash Panels — Install....26082
        2.6. 8000 SERIES SPLASH PANELS....26083
          8100 Model Splash Panels — Remove....26083
          8100 Model Splash Panels — Install....26083
          8200 Model Splash Panels — Remove....26083
          8200 Model Splash Panels — Install....26086
        2.7. 2000 SERIES MUD GUARDS....26086
          2500 and 2600 Model Rear Mud Guard (Original Hood) — Remove....26086
          2500 and 2600 Model Rear Mud Guard (Original Hood) — Install....26087
          2600 Model Only-Outer Edge Fender and Fender Extension Mud Guard....26087
          2600 Model Only-Outer Edge Fender and Fender Extension Mud Guard....26089
          2600 Model Rear Mud Guard (Aerodynamic Hood After March 1996) — ....26089
          2600 Model Rear Mud Guard (Aerodynamic Hood After March 1996) — ....26090
        2.8. 4000 SERIES MUD GUARDS....26090
          4700 Thru 4900 Model Mud Guard — Remove....26090
          4700 Thru 4900 Model Mud Guard — Install....26091
        2.9. 8000 SERIES MUD GUARDS....26091
          8100 Model Mud Guard — Remove....26091
          8100 Model Mud Guard — Install....26092
          8200 Model Mud Guard — Remove....26092
          8200 Model Mud Guard — Install....26093
        2.10. 2000 SERIES HOOD SEALS....26093
          2500 and 2600 Model with Original Hood, Cab Cowl Hood Seal — Rem....26093
          2500 and 2600 Model with Original Hood, Cab Cowl Hood Seal — Ins....26093
          2600 Model with Aerodynamic Hood After March 1996, Cab Cowl Hood....26093
          2600 Model with Aerodynamic Hood After March 1996, Cab Cowl Hood....26094
          2600 Model with Original Hood, Fender Extension Hood Seal — Remo....26094
          2600 Model with Original Hood, Fender Extension Hood Seal — Inst....26095
          2600 Model with Aerodynamic Hood After March 1996, Fender Extens....26095
          2600 Model with Aerodynamic Hood After March 1996, Fender Extens....26095
        2.11. 4000 SERIES HOOD SEALS....26096
          4700 Thru 4900 Model Hood Seal — Remove....26096
          4700 Thru 4900 Model Hood Seal — Install....26097
        2.12. 8000 SERIES HOOD SEALS....26097
          8100 Model Hood Seal — Remove....26097
          8100 Model Hood Seal — Install....26098
          8200 Model Hood Seal — Remove....26098
          8200 Model Hood Seal — Install....26098
        2.13. 2000 SERIES GRILLE....26098
          2500 and 2600 Model Grille (Original Hood) — Remove....26098
          2500 and 2600 Model Grille (Original Hood) — Install....26099
          2500 and 2600 Model Stationary Grille (Original Hood), Grille Tr....26100
          2500 and 2600 Model Stationary Grille (Original Hood), Grille Tr....26101
          2500 and 2600 Model Stationary Grille (Original Hood), Vertical ....26101
          2500 and 2600 Model Stationary Grille (Original Hood), Vertical ....26101
          2600 Model Grille (Aerodynamic Hood After March 1996), Upper Gri....26102
          2600 Model Grille (Aerodynamic Hood After March 1996), Upper Gri....26103
          2600 Model Grille (Aerodynamic Hood After March 1996), Lower Gri....26103
          2600 Model Grille (Aerodynamic Hood After March 1996), Lower Gri....26104
        2.14. 4000 SERIES GRILLE....26104
          4700 thru 4900 Model Standard Grille....26104
          4700  thru 4900 Model Stationary Grille — Remove....26104
          4700  thru 4900 Model Stationary Grille — Install....26105
        2.15. 8000 SERIES GRILLE....26105
          8100 Model Grille....26105
          8200 Model Grille, Upper Grille — Remove....26106
          8200 Model Grille, Upper Grille — Install....26107
          8200 Model Grille, Lower Grille — Remove....26107
          8200 Model Grille, Lower Grille — Install....26107
      3. ADJUSTMENTS....26108
        3.1. RADIATOR....26108
          2000 Series....26108
          4000 Series — Forward Radiator Adjustment....26108
          4000 Series — Rearward Radiator Adjustment....26110
          8000 Series, 8100 Model (Before June 1994) — Forward Radiator Ad....26110
          8000 Series, 8100 Model (Before June 1994) — Rearward Radiator A....26112
          8000 Series, 8100 Model (After June 1994)....26112
          8000 Series, 8200 Model....26112
        3.2. HOOD....26112
          2000 Series — 2500 and 2600 Hood Adjustment Forward or Back at t....26113
          2000 Series — 2500 and 2600 Hood Adjustment Up or Down at the Lo....26115
          2000 Series — 2500 and 2600 Hood Adjustment Side-to-Side at the ....26116
          2000 Series — 2600 Hood Adjustment Forward or Back at the Lower ....26117
          2000 Series — 2600 Hood Adjustment Side-to-Side at the Lower Hin....26119
          4000 Series — 4700, 4800 and 4900 Hood Adjustment Forward or Bac....26120
          4000 Series — 4700, 4800 and 4900 Hood Adjustment Up or Down at ....26121
          4000 Series — 4700, 4800 and 4900 Hood Adjustment Side-to-Side a....26122
          8000 Series — 8100 Hood Adjustment Forward or Back at the Lower ....26124
          8000 Series — 8100 Hood Adjustment Up or Down at the Lower Hinge....26125
          8000 Series — 8100 Hood Adjustment Side-to-Side at the Upper Hin....26126
          8000 Series — 8100 Hood Adjustment Forward or Back and Up or Dow....26127
          8000 Series — 8100 Hood Adjustment Side-to-Side at the Upper Hin....26128
          8000 Series — 8200 Hood Adjustment Forward or Back at the Lower ....26129
          8000 Series — 8200 Hood Adjustment Side-to-Side at the Lower Hin....26130
          8000 Series — 8200 Hood Adjustment Up or Down at the Upper Hinge....26131
  tables....26132
    Table 1Torque Chart....26132
S09003 - 2001 Hood Grille Fender Bumper Service Manual....26135
S09003 - Hood, Grille, and Fenders (March 2001) Service Manual....26175
S09007 - Hood, Grille, Fenders and Bumper - 7000 (Oct 2002) Service Manual....26215
S09014 - Hood Grille Fenders Bumper Service Manual (Dec 2011)....26277
S09016 - 2010 Hood Grille Fenders Bumper WorkStar, TranStar Service Manual....26361
  toc....26363
    Table of Contents....26363
      1. Description....26365
        1.1. Bumper....26365
        1.2. Grille....26365
        1.3. Hood Assembly....26366
        1.4. Hood Tilt Assist....26366
        1.5. Hood Seal....26366
        1.6. Splash Shields....26366
        1.7. Air Intake Grilles....26366
        1.8. Fender....26366
        1.9. Fender Extensions....26367
        1.10. Headlight Assembly....26367
      2. Removal and Installation Procedures....26368
        2.1. Bumper....26369
          Bumper – Removal....26369
          Bumper – Installation....26369
        2.2. Grille and Bug Screen....26370
          WorkStar® Grille and Bud Screen – Removal....26370
          WorkStar® Grille and Bug Screen – Installation....26371
          WorkStar® Grille Shroud – Removal....26371
          WorkStar® Grille Shroud – Installation....26372
          TranStar® Grille and Bug Screen – Removal....26373
          TranStar® Grille and Bug Screen – Installation....26374
        2.3. Splash Panels....26375
          WorkStar® Splash  Panel – Removal....26375
          WorkStar® Splash Panel – Installation....26375
          WorkStar® Upper Splash Panel – Removal....26376
          WorkStar® Upper Splash Panel – Installation....26376
          TranStar® Splash Panels – Removal....26377
          TranStar® Splash Panel – Installation....26378
        2.4. Hood....26379
          WorkStar® – Removal....26379
          WorkStar® Hood – Installation....26385
          TranStar® Hood – Removal....26387
          TranStar® Hood – Installation....26392
          Hood – Adjustment....26393
          Hood Stop – Adjustment....26396
          Hood Hatch – Removal (if equipped)....26397
          Hood Hatch – Installation (if equipped)....26397
        2.5. Hood Tilt Assist....26398
          Hood Tilt Assist – Removal....26398
          Hood Tilt Assist – Installation....26399
        2.6. Torsion Bars....26400
          WorkStar® Torsion Bar – Removal....26400
          WorkStar® Torsion Bar – Installation....26402
          TranStar® Torsion Bar – Removal....26403
          TranStar® Torsion Bar – Installation....26405
        2.7. Hood Latch....26406
          WorkStar® Hood Latch – Removal....26406
          WorkStar® Hood Latch – Installation....26407
          TranStar® Hood Latch – Removal....26408
          TranStar® Hood Latch – Installation....26408
        2.8. Hood Seal....26409
          WorkStar® Hood Seal – Removal....26409
          WorkStar® Hood Seal – Installation....26409
          TranStar® Hood Seal – Removal....26410
          TranStar® Hood Seal – Installation....26410
        2.9. Air Intake Grille....26411
          Air Intake Grille – Removal....26411
          Air Intake Grille – Installation....26411
        2.10. Fender Extensions....26412
          WorkStar® Fender Extensions – Removal....26412
          WorkStar® Fender Extensions – Installation....26412
          TranStar® Fender Extensions – Removal....26413
          TranStar® Fender Extensions – Installation....26413
        2.11. Fenderettes....26414
          Fenderette – Removal (if equipped)....26414
          Fenderette – Installation (if equipped)....26414
        2.12. High Beam Headlight Assembly....26415
          WorkStar® High Beam Headlight Assembly – Removal....26415
          WorkStar® High Beam Headlight Assembly – Installation....26416
          WorkStar® High Beam Headlight Bulb – Removal....26417
          WorkStar® High Beam Headlight Bulb – Installation....26417
          WorkStar® High Beam Headlight Adjustment....26417
          WorkStar® Turn Signal Bulb – Removal....26419
          WorkStar® Turn Signal Bulb – Installation....26419
          TranStar® High Beam Headlight Assembly – Removal....26420
          TranStar® High Beam Headlight Assembly – Installation....26421
          TranStar® High Beam Bulb Replacement....26421
          TranStar® High Beam Headlight Adjustment ....26422
        2.13. Low Beam Headlight Assembly....26423
          WorkStar® Low Beam Headlight Assembly – Removal....26423
          WorkStar® Low Beam Headlight Assembly – Installation....26423
          TranStar® Low Beam Headlight Assembly – Removal....26424
          TranStar® Low Beam Headlight Assembly – Installation....26425
          Low Beam Bulb Replacement ....26425
  tables....26426
    Table 1Torque Chart....26426
S09018 - 2011 Hood Grille Fenders Bumper Service Manual....26427
S10020 - USPS International 4400 Master Index (June 2005) Service Manual....26461
S10024 - Eaton Hybrid System Service Manual (Oct 2009)....26469
S11002 - Spicer 13-Inch (310 mm) and 14-Inch (350 mm) Angle-Ring Single Plate Push-Type Clutch Supersedes CTS-5057 Service Manual....26540
S11003 - Spicer 14-Inch (355.6 mm) Stamped Angle-Spring Clutch Supersedes CTS-5140 (March 1996) Service Manual....26551
S11004 - Spicer 14 Inch (350 mm) Solo Clutch Supersedes CTS-5256 (March 1996) Service Manual....26597
S11006R - Clutch Control Linkage Supersedes CTS-5053R (Oct 2002) Service Manual....26631
S11014 - Hydraulic Clutch Service Manual (2010) Service Manual....26647
S12008 - Radiator, Removal and Replacement (2012) Service Manual....26676
  cover....26676
  S12008....26678
    RADIATOR, REMOVE AND REPLACE....26678
      DESCRIPTION....26678
      RADIATOR AND COMPONENT REMOVAL....26678
        CROSS-MEMBER....26678
        SURGE TANK....26681
        CHARGE AIR COOLER PIPES....26684
        COOLING SYSTEM RADIATOR HOSE....26686
        RADIATOR....26689
        RADIATOR SHROUD AND FRAME....26690
        CHARGE AIR COOLER....26693
        RADIATOR CORE....26693
      RADIATOR AND COMPONENT INSTALLATION....26693
        RADIATOR CORE....26693
        RADIATOR HOSE....26693
        CHARGE AIR COOLER PIPES....26696
        SURGE TANK....26696
        FRONT CROSS-MEMBER....26697
S12010 - Radiator, Removal and Replacement (April 2003) Service Manual....26698
S12022 - Radiator _ Cooling System (Aug 2010) Service Manual....26739
  toc....26741
    Table of Contents....26741
      1. DESCRIPTION....26743
        1.1. Overflow Tank....26744
        1.2. Deaeration Tank....26744
        1.3. Fan Shroud....26745
        1.4. A/C Condenser....26745
        1.5. Radiator....26745
        1.6. Charge Air Cooler....26745
        1.7. Low Temperature Radiator....26745
        1.8. Transmission Oil Cooler....26745
      2. COOLING PACKAGE COMPONENTS....26746
        2.1. Coolant Drain, Pressure Test, and Fill Procedures....26747
          Coolant Drain Procedure (Recommended)....26750
          Pressure Test Procedure (Recommended)....26752
          Coolant Fill Procedure (Recommended)....26753
          Coolant Drain Procedure (Optional)....26755
          Coolant Fill Procedure (MaxxForce® DT, 9, and 10 Engines) (Optional)....26756
          Coolant Fill Procedure (MaxxForce® 11 and 13 Engines) (Optional)....26757
        2.2. Grille....26759
          Grille – Removal....26759
          Grille – Installation....26759
        2.3. Splash Panels....26760
          Splash Panel – Removal....26760
          Splash Panel – Installation....26760
        2.4. Overflow Tank....26761
          Overflow Tank – Removal....26761
          Overflow Tank – Installation....26762
        2.5. Deaeration Tank....26763
          Deaeration Tank – Removal....26763
          Deaeration Tank – Installation....26764
        2.6. Expansion Tank....26765
          Expansion Tank - Removal....26765
          Expansion Tank - Installation....26765
        2.7. A/C Condenser....26766
          A/C Condenser with Charge Air Cooler – Removal....26766
          A/C Condenser with Charge Air Cooler – Installation....26768
          A/C Condenser with Dual Radiators – Removal....26769
          A/C Condenser with Dual Radiators – Installation....26771
        2.8. Fan Shroud....26772
          Fan Shroud with Charge Air Cooler – Removal....26772
          Fan Shroud with Charge Air Cooler – Installation....26776
          Fan Shroud with Dual Radiators – Removal....26778
          Fan Shroud with Dual Radiators – Installation....26780
        2.9. Radiator Fan....26781
          Radiator Fan with Charge Air Cooler – Removal....26781
          Radiator Fan with Charge Air Cooler – Installation....26781
          Radiator Fan with Dual Radiators – Removal....26782
          Radiator Fan with Dual Radiators – Installation....26782
        2.10. Radiator Hose....26783
          Heat Shrink Clamp – Removal....26783
          Heat Shrink Clamp – Installation....26784
          Radiator Hose with Charge Air Cooler – Removal....26788
          Radiator Hose with Charge Air Cooler – Installation....26790
          Radiator Hose with Dual Radiators – Removal....26791
          Radiator Hose with Dual Radiators – Installation....26793
        2.11. Charge Air Cooler....26794
          Charge Air Cooler – Removal....26794
          Charge Air Cooler – Installation....26796
        2.12. Low Temperature Radiator....26798
          Low Temperature Radiator – Removal....26798
          Low Temperature Radiator – Installation....26801
        2.13. Radiator Core....26803
          Radiator Core with Charge Air Cooler – Removal....26803
          Radiator Core with Charge Air Cooler – Installation....26809
          Radiator Core with Dual Radiators – Removal....26812
          Radiator Core with Dual Radiators – Installation....26819
        2.14. Transmission Oil Cooler....26822
          Transmission Oil Cooler (13WAN) – Removal....26822
          Transmission Oil Cooler (13WAN) – Installation....26823
          Transmission Oil Cooler (13WCT) – Removal....26824
          Transmission Oil Cooler (13WCT)  – Installation....26825
          Transmission Oil Cooler (13WAW) – Removal....26826
          Transmission Oil Cooler (13WAW)  – Installation....26827
  tables....26828
    Table 1Torque Chart....26828
S12036 - Radiator_Cooling System 2010 Service Manual....26830
S12038 - 2011 Cooling System Service Manual....26907
S13006H - 6 Speed Transmissions International Model ES52-7A and ESO65-7A 6-Plus Service Manual....26954
S13008 - 6 Speed Transmissions Eaton Series FS-5106 and FS-6206 Supersedes CTS-5179 (June 1996) Service Manual....27038
S13009 - 5 Speed Transmissions Spicer ES43-5 and ES53-5 Supersedes CTS-5181 (March 1996) Service Manual....27118
S13016 7 - Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual....27178
S13037 - OMSI PFT-PCV_3000 Split Shaft PTO Service Manual....27241
S14019 - LIFT AXLE SYSTEMS (7400, 7500 7600 Models) Service Manual....27262
  toc....27262
    Table of Contents....27264
      1. INTRODUCTION....27268
        1.1. PRECAUTIONS....27268
      2. SYSTEM DESCRIPTION....27269
        2.1. AXLE TYPES....27270
          FIXED AXLES....27270
          SELF STEERING AXLES....27270
        2.2. AXLE MOUNTING LOCATIONS....27271
          PUSHER AXLES....27271
          TAG AXLES....27272
          AXLE SPACING....27272
        2.3. LIFT AXLE STATIC LOADED RADIUS....27272
        2.4. SYSTEM CONTROLS....27273
          IN CAB CONTROLS ONLY....27274
          MIXED CONTROLS PRESSURE GAUGE AND SWITCHES IN CAB/PRESSURE GAUGE....27275
      3. SYSTEM OPERATION....27275
        3.1. Enabling the Lift Axle System....27276
        3.2. Operating the Lift Axles....27276
        3.3. Disabling the Lift Axle System....27277
        3.4. Auto Lift in Reverse Feature (Self-Steering Systems Only)....27277
      4. TESTING AND TROUBLESHOOTING....27277
        4.1. Operational Test....27278
        4.2. DIAGNOSIS AND TROUBLESHOOTING....27282
      5. FIXED (RIGID) AXLE ASSEMBLIES....27296
        5.1. DESCRIPTION....27296
        5.2. IDENTIFICATION....27296
        5.3. OPERATION....27297
          AIR SUPPLY....27301
          ENABLING THE LIFT AXLE SYSTEM....27301
          LOWERING THE LIFT AXLE....27302
          RAISING THE LIFT AXLE....27302
          DISABLING THE LIFT AXLE SYSTEM....27302
        5.4. ADJUSTMENTS....27303
          AXLE ALIGNMENT....27303
        5.5. MAINTENANCE....27305
          MAINTENANCE SCHEDULE....27305
          AIR TANK MAINTENANCE....27305
          TORQUE SETTINGS....27305
        5.6. TESTING/TROUBLESHOOTING....27305
        5.7. REMOVAL....27306
          AIR LINES GENERAL....27306
          LIFT AXLE ASSEMBLY....27306
          LOAD BAG ....27307
          LIFT BAG/LIFT BAG QRV....27308
          QUICK RELEASE VALVE FOR LOAD BAGS....27309
          FULL FUNCTION RELAY VALVE (BRAKES)....27311
          PRESSURE PROTECTION VALVE....27311
          FIVE PORT VALVE/SOLENOID....27311
          AXLE MOUNTED TANK....27312
          BRAKE MECHANISM....27312
          AXLE SEAT BUSHINGS....27312
          ARM PIVOT BUSHINGS....27313
        5.8. CLEAN AND INSPECT....27313
          AIR TANK INSPECTION....27313
        5.9. INSTALL....27313
          AIR LINES GENERAL....27313
          LIFT AXLE ASSEMBLY....27314
          LOAD BAG ....27314
          LIFT BAG/LIFT BAG QRV....27315
          QUICK RELEASE VALVE FOR LOAD BAGS....27316
          FULL FUNCTION RELAY VALVE (BRAKES)....27316
          PRESSURE PROTECTION VALVE....27317
          FIVE PORT VALVE/SOLENOID....27317
          AXLE MOUNTED TANK....27317
          BRAKE MECHANISM....27318
          AXLE SEAT BUSHINGS....27318
          ARM PIVOT BUSHINGS....27319
      6. SELF-STEERING AXLE ASSEMBLIES....27319
        6.1. DESCRIPTION....27319
        6.2. IDENTIFICATION....27320
        6.3. OPERATION....27321
          AIR SUPPLY....27325
          ENABLING THE LIFT AXLE SYSTEM....27325
          LOWERING THE LIFT AXLE....27326
          RAISING THE LIFT AXLE....27327
          DISABLING THE LIFT AXLE SYSTEM....27327
          AUTO LIFT IN REVERSE FEATURE (SELF-STEERING SYSTEMS ONLY)....27327
        6.4. ADJUSTMENTS....27328
          AXLE ALIGNMENT....27328
          WHEEL ALIGNMENT....27328
        6.5. MAINTENANCE....27329
          MAINTENANCE SCHEDULE....27329
          AIR TANK MAINTENANCE....27330
          TORQUE SETTINGS....27330
        6.6. TESTING/TROUBLESHOOTING....27330
        6.7. REMOVAL....27330
          AIR LINES GENERAL....27330
          LIFT AXLE ASSEMBLY....27330
          LOAD BAG ....27331
          LIFT BAG/LIFT BAG QRV....27332
          QUICK RELEASE VALVE FOR LOAD BAGS....27333
          FULL FUNCTION RELAY VALVE (BRAKES) ....27336
          PRESSURE PROTECTION VALVE....27336
          FIVE PORT VALVE/SOLENOID....27336
          AXLE MOUNTED TANK....27337
          BRAKE MECHANISM....27337
          UPPER ARM BUSHINGS....27337
          LOWER ARM BUSHINGS....27338
        6.8. CLEAN AND INSPECT....27339
          AIR TANK INSPECTION....27339
        6.9. INSTALL....27339
          AIR LINES GENERAL....27339
          LIFT AXLE ASSEMBLY....27339
          LOAD BAG ....27340
          LIFT BAG/LIFT BAG QRV....27341
          QUICK RELEASE VALVE FOR LOAD BAGS....27342
          FULL FUNCTION RELAY VALVE (BRAKES)....27342
          PRESSURE PROTECTION VALVE....27342
          FIVE PORT VALVE/SOLENOID....27343
          AXLE MOUNTED TANK....27343
          BRAKE MECHANISM....27344
          UPPER ARM BUSHINGS....27344
          LOWER ARM BUSHINGS....27345
      7. CONTROLS....27346
        7.1. DESCRIPTION....27346
        7.2. IN-CAB CONTROLS....27347
        7.3. MIXED CONTROLS....27347
        7.4. PNEUMATIC CONTROL SYSTEM....27348
        7.5. ELECTRICAL CONTROL SYSTEM....27367
        7.6. OPERATION....27379
          ENABLING THE LIFT AXLE SYSTEM....27380
          LOWERING THE LIFT AXLE....27380
          RAISING THE LIFT AXLE....27381
          DISABLING THE LIFT AXLE SYSTEM....27381
          AUTO LIFT IN REVERSE FEATURE (SELF-STEERING AXLE SYSTEMS ONLY)....27382
        7.7. REMOVAL....27383
          LIFT AXLE PRESSURE GAUGE....27383
          PRESSURE REGULATOR....27383
          CONTROL SWITCHES (PEDESTAL MOUNTED)....27383
          CONTROL RELAYS (PEDESTAL MOUNTED)....27383
        7.8. INSTALL....27383
          LIFT AXLE PRESSURE GAUGE....27383
          PRESSURE REGULATOR....27384
          CONTROL SWITCHES (PEDESTAL MOUNTED)....27384
          CONTROL RELAYS (PEDESTAL MOUNTED)....27384
        7.9. TESTING/TROUBLESHOOTING....27384
      8. SPECIFICATIONS....27384
        8.1. LIFT AXLE SYSTEM SPECIFICATIONS....27384
        8.2. TORQUE SETTINGS....27385
  tables....27262
    Operational Test....27278
    Lift Axle Symptom List....27282
    Troubleshooting Table....27283
    Troubleshooting Table....27283
    Troubleshooting Table....27285
    Troubleshooting Table....27285
    Troubleshooting Table....27288
    Troubleshooting Table....27290
    Troubleshooting Table....27291
    Troubleshooting Table....27292
    Troubleshooting Table....27294
    Troubleshooting Table....27295
    Troubleshooting Table....27295
    Troubleshooting Table Mechanical Problems....27295
    Load Pressure Chart for 20,000 Pound Fixed Lift Axle....27302
    Periodic Maintenance on Fixed Lift Axles....27305
    Load Pressure Chart for 13,200 Pound Self-Steering Lift Axle....27326
    Periodic Maintenance on Self-Steering Lift Axles ....27329
    Lift Axle System Specifications 20,000 Pound Capacity Rigid Axle....27384
    Lift Axle System Specifications 13,200 Pound Capacity Self-Steer....27385
    Torque Chart for Specific Fasteners....27385
    U-Bolt Torque Values (Clean, Non-Plated, Lubricated Threads)....27388
    General Capscrew/Bolt Torque Values (Clean, Non-Plated, Lubricat....27388
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual....27389
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual....27399
S16016 - Air Conditioning - Heater System_ 2000, 4000, and 8000 - 12_06_1994 and After Formerly (CTS-5227) Service Manual....27445
S16017X - Air Conditioning Compressor and Clutch, Two Cylinder Reciprocating Type - After 01_01_1993 (R-134A) (Formerly CTS-5241) Service Manual....27484
S16025 - HEAT VENTILATION AIR CONDITIONING (HVAC), Orifice Tube System, Pre-March 2007 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Service Manual....27511
S160263 - CAB 4100, 4200, 4300, 4400, DuraStar, TerraStar 4100, 4200, 4300, 4400, DuraStar, TerraStar Service Manual....27757
S16027 - SERVICE CAB 4100, 4200, 4300, 4400 SERVICE MANUAL ....28074
S16034 - HEAT VENTILATION AIR CONDITIONING (HVAC), TXV System, March 2007 - 2009  3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Models, CXT,   DuraStar, TranStar,  WorkStar and RXT....28104
S16038 - CAB_ 7300, 7400, 7500, 7600, 7700, 8500, 8600, TranStar, and WorkStar Models Service Manual....28251
S16046 - 3200 Bus, DuraStar, TerraStar, TranStar, WorkStar Models Heat Ventilation Air Conditioning (HVAC) for 2010 Service Manual....28452
S16053 - Heat Ventilation Air Conditioning (HVAC) for 2010 - South Africa _ 7000 RHD AND 8000 RHD Service Manual....28602
S16054 - SERVICE MANUAL CAB MANUALModel DuraStar Vehicle....28753
S16055 - HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 HVAC DuraStar Vehicle Service Manual....28930
s04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual....29086
s12005 - Radiator Shutters, Supersedes CTS-5084 (March 1996) Service Manual....29117

International/Navistar Trucks DuraStar and WorkStar Series Repair Service Manual

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