International/Navistar Truck Models 5000-Series, 9000-Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for International/Navistar Truck Models 5000-Series (PayStar), 9000-Series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
International/Navistar Truck Models 5000-Series (PayStar), 9000-Series 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: 13,721 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
000000241 - SERVICE MANUAL Electrical Circuit Diagrams PayStar - 5900 (MaxxForce 11,13, 15L, N13 or ISX15 Engines with SCR).pdf
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10 Service Manual.pdf
0000001843 - Radiator, Cooling System- PayStar and 9900 Service Manual.pdf
0000002321 - PayStar 5000i and 9000i Conventional Cab Service (Supersedes S16021) Service Manual.pdf
0000002441 - PayStar Series Electrical Circuit Diagrams with MaxxForce 11_13, 15L, N13 or ISX15 Engines (Supersedes S08352) Circuit Diagrams.pdf
0000002568 - 5000i, 9100 , 9200i, 9400i, 9900i Models Heater System _ Air Conditioning (Supersedes S16023) Service Manual.pdf
0000003261 - 9900 Series Electrical Circuit Diagram Manual.pdf
0000003261 - SERVICE MANUAL Electrical Circuit Diagrams 9900 Series.pdf
0000011981 - PayStar _ 9200i and 9900i Series Electrical Circuit Diagrams (Supersedes S08326).pdf
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Service Manual (Supersedes 0000001601, 0000001843 & 0000002222).pdf
1087459R2 - 9300 Series Electrical Circuit Diagrams 1988 (Supersedes CTS-4382E) Circuit Diagrams.pdf
4328434 - New Truck Processing Manual.pdf
CTS-5119TA - 5000, 9200, 9300 and 9400 Electrical Circuit Diagrams Built After July 12, 1996.pdf
s04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual.pdf
s12005 - Radiator Shutters, Supersedes CTS-5084 (March 1996) Service Manual.pdf
S02005R - Rockwell Front Non-Drive Steering Axle, Supersedes CTS-5046R (April 1996) Service Manual.pdf
S02006 - Front Steer Axle_ Eaton EFA-12, Supersedes CTS-5171 (April 1996) Service Manual.pdf
S02007 - Front Steer Axle_ Eaton E1200I I-Beam, Supersedes CTS-5212 (March 1996) Service Manual.pdf
S02008 - Rockwell Front Drive Axle Wheel Ends, Supersedes CTS-5081 (April 1996) Service Manual.pdf
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual.pdf
S03002R - Neway Air Suspension, Supersedes CTS-5028R (March 1996) Service Manual.pdf
S03007 - Hendrickson Air Suspension with Trailing Leaf Springs, Supersedes CTS-5125 (March 1996) Service Manual.pdf
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual.pdf
S03010 - Neway AD-123_246 Drive Axle Air Suspensions, Supersedes CTS-5191 (March 1996) Service Manual.pdf
S03011 - Hendrickson HN-460 Suspension, Supersedes CTS-5221 (March 1996) Service Manual.pdf
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual.pdf
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual.pdf
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual.pdf
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual.pdf
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual.pdf
S04011 - Air Compressor_ Midland Models EL-1300 and EL-1600, Supersedes CTS-5146 (March 1996) Service Manual.pdf
S04013 - Stopmaster Wedge Type Brake, Supersedes CTS-5172 (March 1996) Service Manual.pdf
S04014 - Air Compressor_ Holset SS 296 and QE 296_338, Supersedes CTS-5197 (March 1996) Service Manual.pdf
S04020X - DCM and DDM Drum Type Parking Brake, Supersedes CTS-5135TA (July 1997) Service Manual.pdf
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual.pdf
S04022 - Antilock Air Brake System_ Bendix, Supersedes CTS-5059 (April 1998) Service Manual.pdf
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual.pdf
S04038 - EC-17 Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Service Manual.pdf
S04042 - Antilock Brakes _ Traction Control Troubleshooting_ Bendix Built March 1, 1998 and After, Supersedes CTS-5291 (Aug 2000) Service Manual.pdf
S04053 - ECE-13 Brake System (2010) Service Manual.pdf
S04055 - MCAC 465 Air Compressor Model PayStar, ProStar, TranStar, and WorkStar Vehicles SERVICE MANUAL.pdf
S04057 - ECE-13 Brake System Service Manual (9800 LHD) (2010) Service Manual.pdf
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual.pdf
S05004 - Power Steering Gear_ Sheppard Model 292, 392, 492, Supersedes CTS-5218 (April 1996) Service Manual.pdf
S05009T - Steering Column Assembly, Tilt_Telescoping, Supersedes CTS-5072T (Feb 1997) Service Manual.pdf
S05010T - 9600, 9700, 9800 Models Steering Column Assembly, Tilt, Supersedes CTS-5073T (Feb 1997) Service Manual.pdf
S05011 - 5000, 9200, 9300, 9400 Steering Column Assembly, Standard, Supersedes CTS-5078 (May 1996) Service Manual.pdf
S05015Y - Power Steering Gear_ Sheppard M-Series, Supersedes CTS-5262 (Sept 2000) Service Manual.pdf
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual.pdf
S08007 - 9200, 9300, 9400 Model Pro Sleeper Electrical System, Supersedes CTS-5201 (July 1992) Service Manual.pdf
S08018 - 9100, 9200, 9300, 9400, 9600, 9700, and 9800 Model Alternator (Delco-Remy 26-SI Series), Supersedes CTS-5077 (March 1996) Service Manual.pdf
S08033 - General Instrument Electronic Programmable Speedometer _ Tachometer, Supersedes CTS-5048 (1991) Service Manual.pdf
S08035X - 9200, 9300 and 9400 Gauges and Warning Lights, Supersedes CTS-5180 (Oct 1999) Service Manual.pdf
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual.pdf
S08127 - 9300 and 9400 Electronic Engine Controls - General Information, Supersedes CTS-5051-I (1991) Service Manual.pdf
S08154X - Speedometer _ Tachometer Diagnostics and Service, Supersedes CTS-5257 (Oct 1999) Service Manual.pdf
S08156 - 9800 Series Heating, Ventilation, and Air Conditioning (HVAC) Troubleshooting Guide, Supersedes CTS-5275 (Feb 1998) Service Manual.pdf
S08157 - 9200, 9300 and 9400 Models with Pro Sleeper and Skyrise Sleeper Heating, Ventilation, and Air Conditioning (HVAC) Troubleshooting Guide, Supersedes CTS-5284 (Feb 1998) Service Manual.pdf
S08184 - 9200, 9400 and 9900 Chassis (Only with Pro Sleeper Cab) Built October 1, 1998 to July 18, 1999 Electrical Circuit Diagrams, Supersedes CTS-5273W (Oct 1998).pdf
S08185 - 5000, 9100, 9200, 9400 and 9900 Chassis (Only with Daycab and With or Without Box Sleeper) Built October 1, 1998 To July 18, 1999 Electrical Circuit Diagrams, Supersedes CTS-5119W (Oct 1998).pdf
S08191 - 5000, 9100, 9200, 9400,and 9900 Models Electrical System Troubleshooting Guide, Supersedes CTS-5301 (Feb 1999) Service Manual.pdf
S08207X - 5000i, 5000, 9000, 9000i Model Gauges and Warning Lights, Supersedes CTS-5293 (Oct 1999) Circuit Diagrams.pdf
S08210 - 5000i, 9000i, 9100i, 9200i, 9400i and 9900i Model Electrical System Troubleshooting Guide (June 2002) Service Manual.pdf
S08225 - 5000i, 9100 i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built June 3, 2002 and After.pdf
S08225Y - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built July 19, 1999 To August 31, 2000 Circuit Diagrams.pdf
S08225YA - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built September 1, 2000 To June 2, 2002 Circuit Diagrams.pdf
S08242W - 9800 Model Electrical Circuit Diagram Built November 1, 1998 to March 31, 2004 Circuit Diagrams.pdf
S08270 - Electrical System Troubleshooting Guide 9800 Models Built Date 11_01_1998 Supersedes CTS-5304 (Oct 2002) Service Manual.pdf
S08316 - 5500, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 to February 28, 2007 Electrical Circuit Diagrams Manual.pdf
S08318 - 9800 Model Built April 1, 2004 and After Electrical Circuit Diagrams Manual.pdf
S08319 - Inverter_Charger Power System (Sept 2003) Service Manual.pdf
S08326 - 5500i, 5600i, 5900i, 9200i, and 9900i Chassis Built March 1, 2007 and After — ELECTRICAL CIRCUIT DIAGRAMS.pdf
S08346 - SERVICE MANUAL 9800 LHD Model Built November 01, 2010 - ELECTRICAL CIRCUIT DIAGRAMS.pdf
S09001V - Hood, Grille, and Fenders - 5000, 9100, 9200, 9300, and 9400 (Supersedes CTS-5154V) (1999) Service Manual.pdf
S09004 - Hood, Grille, and Fenders - 5000i, 9000i (Oct 2000) Service Manual.pdf
S11001S - Spicer 14-Inch (356 mm) and 15 1_2-Inch (394 mm) Two-Plate, Pull-Type Clutch Supersedes CTS-5043S (March 1996) Service Manual.pdf
S11008 - Clutch Control Linkage Supersedes CTS-5063R (March 1996) Service Manual.pdf
S11009R - Clutch Control Linkage Supersedes CTS-5064R (March 1996) Service Manual.pdf
S11010K - Clutch Control Linkage Supersedes CTS-5117K (March 1996) Service Manual.pdf
S11011 - Clutch Control Linkage Supersedes CTS-5231 (March 1996) Service Manual.pdf
S11016- 9800 HYDRAULIC, MECHANICAL CLUTCH SERVICE MANUAL.pdf
S12001J - Fan Drive Clutch_ Kysor 1090 Supersedes CTS-5015J (March 1996) Service Manual.pdf
S12004R - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual.pdf
S12034 - Radiator _ Cooling System Service Manual (2010).pdf
S13001 - 9600 _ 9700 Shift Control Linkage Adjustment Procedure with Manual Transmission Supersedes CTS-5094 (March 1996) Service Manual.pdf
S13003 - Power Take Off_ Rockwell Rear Engine Mounted Supersedes CTS-5210 (June 1996) Service Manual.pdf
S13007 - 13 Speed And 18 Speed Transmissions Eaton RTLO-713 _ 18 Series Supersedes CTS-5176 (June 1996) Service Manual.pdf
S13015 - 10 Speed And 15 Speed Transmissions Eaton RT, RTO, and RTX Series Supersedes CTS-5187 (June 1996) Service Manual.pdf
S13016 - 7 Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual.pdf
S13017 - 10 Speed Transmissions Eaton RTLO Series Supersedes CTS-5196 (March 1996) Service Manual.pdf
S13018 - 8 Speed, 9 Speed, And 13 Speed Transmissions Eaton Series Supersedes CTS-5205 (June 1996) Service Manual.pdf
S13019 - 18 Speed Transmissions Eaton RTLO-14618 and RTLO-16618 Series Supersedes CTS-5206 (June 1996) Service Manual.pdf
S14002 - 2 SPEED AXLE SHIFT UNIT_ EATON (Supersedes CTS-5166) Service Manual.pdf
S14004 - SINGLE REDUCTION, TANDEM AXLES_ SPICER J400-S, W460-S (Supersedes CTS-5259) Service Manual.pdf
S14006T - SINGLE REDUCTION CARRIERS_ ROCKWELL (Supersedes CTS-5080T) Service Manual.pdf
S14009 - SINGLE REDUCTION, TANDEM AXLE_ INTERNATIONAL (Supersedes CTS-5124) Service Manual.pdf
S14013 - SINGLE REDUCTION, TANDEM DRIVE AXLES_ EATON (Supersedes CTS-5213) Service Manual.pdf
S14014 - SINGLE REDUCTION, SINGLE SPEED AXLES_ SPICER D135-S, F155-S, F170-S SERIES (Supersedes CTS-5233) Service Manual.pdf
S14016 - 2 SPEED AND DOUBLE REDUCTION SINGLE DRIVE AXLES_ EATON (Supersedes CTS-5195) Service Manual.pdf
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual.pdf
S16001 - MAJOR STRUCTURAL REPAIR_ 9600 (Formerly CTS-4338) Service Manual.pdf
S16003 - Repair Instructions for Fiberglass and Plastic (ABS) Material (Formerly CTS-5173) Service Manual.pdf
S16005V - CAB_ 5000, 9100, 9200, 9300, 9400 (Formerly CTS-5024V) Service Manual.pdf
S16006 - Cab - Tilt_ 9600 and 9700 Sleeper and Non-Sleeper Cabs (Formerly CTS-5129) Service Manual.pdf
S16008 - Add-On Sleeper Box (Formerly CTS-5152) Service Manual.pdf
S16009 - Aerodynamic Panels (Formerly CTS-5153) Service Manual.pdf
S16010 - Aerodynamic Panels 9200, 9300, 9400 (Formerly CTS-5155) Service Manual .pdf
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual.pdf
S16015 - AIR CONDITIONING - HEATER SYSTEM_ 5000, 9000 Series Without Lowered heater Box 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
S16018 - CAB - TILT_ 9800 Service Manual.pdf
S16019 - AIR CONDITIONING BASIC THEORY, SYSTEM DIAGNOSIS AND SERVICE (with R-134a Refrigerant System) Service Manual.pdf
S16020 - AIR CONDITIONING - HEATER SYSTEM_ 9000 Pro Sleeper After 05_01_1997, and 9800 Model After 07_01_1997 Service Manual.pdf
S16022Y - Air Conditioning Protection and Diagnostic System (APAds) Description, Operation, Troubleshooting, Remove, Install, and Electrical Circuit Diagrams Maintenance Manual.pdf
S16024 - SKIRT PANELS, AERO SIDE SKIRT PANELS, BODY AIR DEFLECTORS, BUMPERS AND ROOFS Service Manual.pdf
S16028 - West Coast Magnum Mirrors and Aero Mirrors Service Manual.pdf
S16037 - No Idle APU_HVAC System Model_ 9200i 9400i 9900i 9900ix Feature Code_ 12WTK 16UZV Service Manual.pdf
S16049 - AIR CONDITIONING - HEATER SYSTEM 9800 HVAC Service Manual.pdf
S16050 - CAB - TILT_ Model 9800 (RHD) Service Manual.pdf
S16051 - AIR CONDITIONING - HEATER SYSTEM_ 9800 (RHD) Service Manual.pdf
S082252 - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built from June 3, 2002 To November 3, 2002.pdf
S082252A - 5000i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built November 4, 2002 to November 30, 2005.pdf
TABLE OF CONTENTS
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
0000001843 - Radiator, Cooling System- PayStar and 9900 Service Manual....126
toc....128
Summary of Changes....128
1. Description....134
1.1. Deaeration Tank....135
1.2. Fan Shroud....135
1.3. A/C Condenser....135
1.4. Transmission Oil Cooler....135
1.5. Radiator....136
1.6. Charge Air Cooler....136
1.7. Low-Temperature Radiator....136
1.8. Fan Drive....137
2. Removal and Installation....138
2.1. Cooling Package Cleaning Procedures....139
2.2. Coolant Drain, Pressure Test, and Fill Procedures....142
Coolant Drain Procedure (MaxxForce's 11 Liter, 13 Liter, 15 Liter and Cummins®ISX 15) (Recommended)....144
Pressure Test Procedure (MaxxForces 11 Liter, 13 Liter, 15 Liter& Cummins®ISX 15) (Recommended)....146
Coolant Fill Procedure (MaxxForce's 11 Liter, 13 Liter, 15 Liter & Cummins®ISX 15) (Recommended)....147
Coolant Drain Procedure (MaxxForce 11 Liter, 13 Liter, 15 Liter& Cummins®ISX 15) (Optional)....149
Coolant Fill Procedure MaxxForce 11 Liter, 13 Liter, 15 Liter (Optional)....150
Coolant Fill Procedure – Cummins® ISX 15 Engines (Optional)....152
2.3. Grille....153
Grille – Removal (All Engines)....153
Grille – Installation (All Engines)....153
2.4. Deaeration Tank....154
Deaeration Tank – Removal....154
Deaeration Tank – Installation....155
2.5. A/C Condenser....156
MaxxForce 11 Liter, 13 Liter, and 15 Liter A/C Condenser – Removal....156
MaxxForce 11 Liter, 13 Liter, and 15 Liter A/C Condenser – Installation....157
PayStar / 9900 with Cummins® ISX 15 A/C Condenser – Removal....158
PayStar / 9900 with Cummins® ISX 15 A/C Condenser – Installation....159
2.6. Fan Shroud....160
Upper Fan Shroud (MaxxForce11 Liter &13 Liter) – Removal....160
Upper Fan Shroud (MaxxForce 11 Liter or 13 Liter – Installation....161
Lower Fan Shroud (MaxxForce 11 Liter or 13 Liter ) – Removal....162
Lower Fan Shroud (MaxxForce 11 Liter or 13 Liter ) – Installation....164
Upper Fan Shroud (MaxxForce 15 Liter) – Removal....164
Upper Fan Shroud (MaxxForce 15 Liter ) – Installation....166
Lower Fan Shroud (MaxxForce 15 Liter ) – Removal....167
Lower Fan Shroud (MaxxForce 15 Liter ) – Installation....168
Fan Shroud (Two and Three Piece) Cummins® ISX 15 Engines – Removal....168
Fan Shroud (Two Piece) Cummins® ISX 15 Engines – Installation ....170
2.7. Radiator Fan....172
Radiator Fan (MaxxForce 11 Liter or 13 Liter) – Removal....172
Radiator Fan (MaxxForce 11 Liter or 13 Liter) – Installation....172
Radiator Fan (MaxxForce 15 Liter) – Removal....172
Radiator Fan (MaxxForce 15 Liter) – Installation....173
Radiator Fan Removal- Cummins®ISX 15 Engines....173
Radiator Fan Installation- Cummins®ISX 15 Engines....174
2.8. Fan Belts....175
Fan Belt (MaxxForce 11 Liter or 13 Liter) – Removal....175
Fan Belt (MaxxForce 11 Liter or 13 Liter) – Installation....176
Fan Belt (MaxxForce 15 Liter) – Removal....177
Fan Belt (MaxxForce 15 Liter) – Installation....178
Alternator Fan Belt (MaxxForce 15 Liter) – Removal....178
Alternator Fan Belt (MaxxForce 15 Liter) – Installation....179
Fan Belt (Cummins®ISX 15) Removal-....180
Fan Belt (Cummins®ISX 15) – Installation....181
2.9. Fan Drive....182
Fan Drive (MaxxForce11 Liter or 13 Liter ) – Removal....182
Fan Drive (MaxxForce 11 Liter or 13 Liter ) – Installation....183
Fan Drive (MaxxForce 15 Liter) – Removal....184
Fan Drive (MaxxForce 15 Liter) – Installation....184
Fan Drive Assembly (Cummins® ISX15) – Removal ....185
Fan Drive Assembly (Cummins® ISX15) – Installation....186
2.10. Transmission Oil Cooler....187
Transmission Oil Cooler (Crossmember Mounted) MaxxForce 11 Liter, 13 Liter, 15 Liter , Cummins® ISX15- Removal....187
Transmission Oil Cooler (Crossmember Mounted) MaxxForce 11 Liter, 13 Liter, 15 Liter , Cummins® ISX15- Installation....189
Transmission Oil Cooler (Front Mounted) Cummins®ISX15 –Removal ....189
Transmission Oil Cooler (Front Mounted) Cummins®ISX15 –Installation....190
2.11. Radiator Hose....191
Heat Shrink Clamp – Removal....191
Heat Shrink Clamp – Installation....192
Radiator Hoses (11 Liter or 13 Liter Shown) – Removal....195
Radiator Hoses (MaxxForce 11 Liter or 13 Liter ) – Installation....197
Radiator Hoses (MaxxForce 15 Liter) – Removal....199
Radiator Hoses (MaxxForce15 Liter) – Installation....200
Exhaust Gas Recirculation (EGR) Valve/Cooler Hoses (MaxxForce's 15 Liter) – Removal....201
Exhaust Gas Recirculation (EGR) Valve/Cooler Hoses (MaxxForce 15 Liter) – Installation....202
Radiator Hose (Series 9900 with Cummins® ISX15) – Removal ....203
Radiator Hose (Series 9900 with Cummins® ISX15) – Installation....206
2.12. Charge Air Cooler....208
Front Charge Air Cooler MaxxForce's 11 Liter, 13 Liter Engines– Removal....208
Front Charge Air Cooler – Installation....209
Rear Charge Air Cooler (MaxxForce 11 Liter or 13 Liter) – Removal ....210
Rear Charge Air Cooler (MaxxForce 11 Liter or 13 Liter ) – Installation....211
Charge Air Cooler (Cummins® ISX15) – Removal-....211
Charge Air Cooler (Cummins®ISX15) – Installation....213
2.13. Low-Temperature Radiator....213
Low-Temperature Radiator – Removal....213
Low-Temperature Radiator – Installation....216
2.14. Radiator Assembly....217
Radiator Assembly –Removal MaxxForce Engines ....217
Radiator Assembly – Installation MaxxForce Engines....220
Radiator Assembly (Cummins®ISX15) – Removal....220
Radiator Assembly (Cummins®ISX15) – Installation....227
2.15. Recirculation Seals....230
Recirculation Seals (MaxxForce 11 or 13 Liter) – Removal....230
Recirculation Seals (MaxxForce 11 or 13 Liter) – Installation....231
Recirculation Seals (MaxxForce 15 Liter) – Removal ....232
Recirculation Seals(MaxxForce 15) – Installation ....233
2.16. Radiator Core....235
Radiator Core (MaxxForce 11 Liter or 13 Liter ) – Removal....235
Radiator Core (MaxxForce 11 Liter or 13 Liter ) – Installation....236
Radiator Core (MaxxForce 15 Liter) – Removal....237
Radiator Core (MaxxForce 15 Liter) – Installation....238
Radiator Core- Removal – (Cummins® ISX15) ....239
Radiator Core Installation – (Cummins® ISX15) ....243
2.17. Power Steering Oil Cooler....244
Power Steering Oil Cooler (Cummins® ISX 15) – Removal....244
Power Steering Oil Cooler (Cummins® ISX 15) – Installation....244
tables....246
Table 2Torque Chart....246
0000002321 - PayStar 5000i and 9000i Conventional Cab Service (Supersedes S16021) Service Manual....248
toc....250
Summary of Changes....250
1. DESCRIPTION....262
1.1. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION....264
1.2. CAB AIR SUSPENSION SYSTEM....264
1.3. ELECTRIC WINDSHIELD WIPERS AND WING PANEL MOUNTED SWITCHES....264
1.4. WINDSHIELD WASHERS....264
2. OPERATION....265
2.1. ELECTRIC WINDSHIELD WIPERS AND WING PANEL MOUNTED SWITCHES....265
2.2. WING PANEL MOUNTED WINDSHIELD WASHER CONTROLS....265
3. MAINTENANCE....266
3.1. WINDSHIELD WASHER....266
3.2. CAB MOUNTING HARDWARE....266
3.3. CAB AIR SUSPENSION FASTENERS AND AIR LINE FITTINGS....266
4. REMOVE....267
4.1. Remove ONE PIECE ENCAPSULATED WINDSHIELD....267
4.2. Remove TWO PIECE ENCAPSULATED WINDSHIELD....274
4.3. Remove REAR WINDOW GLASS AND WEATHER SEAL (EXCEPT SLEEPER MODELS)....278
4.4. HOOD SEALS....279
Remove Hood Seals for 5000i and 9000i Series....279
Remove Hood Seals for 5000i SBA Series with Optional Butterfly Hood....280
4.5. Remove SUNSHADE....282
4.6. Remove SUN VISOR....284
4.7. ignition KEY SWITCH CYLINDER....285
4.8. INSTRUMENT PANEL....289
Remove Electrically Operated Gauges, Mechanical Air Gauges and Speedometer/Tachometer....289
4.9. Remove FLOOR MAT....291
4.10. Remove HEADLINER (DAY CAB MODELS ONLY)....292
4.11. Remove DRIVER AND PASSENGER SEATS....293
4.12. BACK PANEL....295
4.13. Remove ENGINE COVER....297
4.14. CAB DOOR LOWER TRIM PANEL....298
Remove Driver Side Cab Door Lower Trim Panel....298
Remove Passenger Side Cab Door Lower Trim Panel....299
4.15. CAB DOOR COURTESY LIGHT ASSEMBLY....300
Remove Driver Side Cab Door Courtesy Light Assembly....300
Remove Passenger Side Cab Door Courtesy Light Assembly....300
4.16. UPPER DOOR TRIM/INNER DOOR PANEL AND WINDOW REGULATOR ASSEMBLY....300
Remove Driver Side Upper Door Trim/Inner Door Panel and Window Regulator Assembly....300
Remove Passenger Side Upper Door Trim/Inner Door Panel and Window Regulator Assembly....310
4.17. CAB DOOR AND HINGE....318
Remove Driver Side Cab Door....318
Remove Driver Side Cab Door Hinge....320
Remove Passenger Side Cab Door....321
Remove Passenger Side Cab Door Hinge....323
4.18. INNER DOOR HANDLE....323
Remove Driver Side Inner Door Handle....323
Remove Passenger Side Inner Door Handle....324
4.19. CAB DOOR GRAB HANDLE....325
Remove Driver Side Cab Door Grab Handle....325
Remove Passenger Side Cab Door Grab Handle....326
4.20. ELECTRIC WINDOW AND/OR ELECTRIC DOOR LOCK SWITCH ASSEMBLY....327
Remove Driver Side Electric Window and/or Electric Door Lock Switch Assembly....327
Remove Passenger Side Electric Window and/or Electric Door Lock Switch Assembly....329
4.21. UPPER DOOR TRIM PANEL....330
Remove Driver Side Upper Door Trim Panel....330
Remove Passenger Side Upper Door Trim Panel....331
4.22. WINDOW REGULATOR ASSEMBLY....332
Remove Driver Side Electric Window Regulator Assembly with Power Window Motor....332
Remove Passenger Side Electric Window Regulator Assembly with Power Window Motor....333
Remove Driver Side Manual Window Regulator Assembly....335
Remove Passenger Side Manual Window Regulator Assembly....339
4.23. CAB DOOR WINDOW GLASS AND FRONT RUN CHANNEL....344
Remove Driver Side Cab Door Window Glass and Front Run Channel....344
Remove Passenger Side Cab Door Window Glass and Front Run Channel....346
4.24. Remove CAB DOOR LATCH ASSEMBLY....349
4.25. Remove CAB DOOR STRIKER PIN....351
4.26. Remove DOOR LOCK ASSEMBLY....352
4.27. Remove OUTER DOOR HANDLE....354
4.28. Remove CAB DOOR OPENING SEALS....355
4.29. ELECTRIC WINDSHIELD WIPER SWITCHES....355
Remove Wiper/Washer Control Switches and Indicator Lights....356
4.30. Remove WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....356
4.31. Remove COWL TRAY....358
4.32. Remove AIR DUCT INLET....362
4.33. WINDSHIELD WIPER MOTOR, BRACKET AND LINKAGE ASSEMBLY....363
Remove Windshield Wiper Motor, Bracket and Linkage Assembly on Vehicles before 2002 Engines before May 2001....363
Remove Windshield Wiper Motor, Bracket and Linkage Assembly on Vehicles with 2002 Engines after May 2001....365
Remove Windshield Wiper Motor, Bracket and Linkage Assembly on Vehicles with 2002 Engines after January 2005....367
4.34. WIPER MOTOR....369
Remove Wiper Motor on Vehicles before 2002 Engines and after 2002 Engines before January 2005....369
Remove Wiper Motor with Electrical Connector part of Pig-Tail Wiring Harness on Vehicles with 2002 Engines after January 2005....371
Remove Wiper Motor with Electrical Connector as part of Wiper Motor on Vehicles with 2002 Engines after January 2005....373
4.35. Remove WASHER RESERVOIR/PUMP MOTOR ASSEMBLY....375
4.36. Remove WASHER RESERVOIR PUMP MOTOR — ELECTRIC....375
4.37. CAB....376
General Guidelines For Removal....376
Remove SBA and SFA Cab for 5000i Series with Rear Hard Mount before November 1999....377
Remove SBA and SFA Cab for 5000i Series with Rear Hard Mount after November 1999....379
Remove Front Cab Mounting Insulator for SBA and SFA 5000i Series with Rear Hard Mount after November 1999....381
Remove SBA Cab for 5000i Series with Rear Cab Air Suspension System after August 1994 and SFA Cab for 5000i Series with Rear Cab Air Suspension System after August 1996....381
Remove Front Cab Mounting Insulator for SBA Cab for 5000i Series with Rear Cab Air Suspension System after August 1994 and SFA Cab for 5000i Series with Rear Cab Air Suspension System after August 1996....383
Remove Day Cab for 9100i, 9200i, 9400i and 9900i Models with Rear Hard Mount....383
Remove Front Cab Mounting Insulator on Day Cab for 9100i, 9200i, 9400i and 9900i Models with Rear Hard Mount....385
Remove Day Cab for 9200i Models with Detroit Diesel Engines and with Rear Cab Air Suspension System before January 1997....385
Remove Front Cab Mounting Insulator on Day Cab for 9200i Models with Detroit Diesel Engines and with Rear Cab Air Suspension System before January 1997....387
Remove Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after January 1997....387
Remove Front Cab Mounting Insulator on Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after January 1997....387
Remove Day Cab for 9200iModels with Detroit Diesel Engines and with Rear Cab Air Suspension System before March 1997....388
Remove Front Cab Mounting Insulator on Day Cab for 9200i Models with Detroit Diesel Engines and with Rear Cab Air Suspension System before March 1997....390
Remove Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after March 1997....390
Remove Front Cab Mounting Insulator on Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after March 1997....390
Remove Day Cab with High Rise Crossmember for 9100i, 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....391
Remove Front Cab Mounting Insulator on Day Cab with High Rise Crossmember for 9100i, 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....393
Remove Day Cab with Standard 7 Piece Crossmember for 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....393
Remove Front Cab Mounting Insulator on Day Cab with Standard 7 Piece Crossmember for 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....395
Remove 51 Inch or 72 Inch Pro-Sleeper® Cab for 9200i and 9400i Models with Rear Cab Air Suspension System....395
Remove Front Cab Mounting Insulator on 51 Inch or 72 Inch Pro-Sleeper® Cab for 9200i and 9400i Models with Rear Cab Air Suspension System....397
Remove 51 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....397
Remove Front Cab Mounting Insulator on 51 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....399
Remove 72 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....399
Remove Front Cab Mounting Insulator on 72 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....401
4.38. CAB AIR RIDE System for 9200i/9400i/9900i DAY CAB MODELS WITHOUT DETROIT DIESEL ENGINES before DECEMBER 2001....401
Remove Cab Air Ride Shock Absorber....403
Remove Cab Air Ride Air Springs (Bags)....403
Remove Track Bar Rod....405
Remove Cab Air Ride Valve....405
4.39. CAB AIR SUSPENSION system for 9200i/9400i/9900i DAY CAB MODELS WITHOUT DETROIT DIESEL ENGINES after DECEMBER 2001....407
Remove Height Control Valve....409
Remove Cab Air Suspension Shock Absorber....410
Remove Cab Air Suspension Air Spring (Bag)....411
Remove Lateral Control Rod....411
4.40. CAB AIR SUSPENSION system for 9200i DAY CAB MODELS WITH DETROIT DIESEL ENGINES before JANUARY 1997....411
Remove Height Control Valve....413
Remove Cab Air Suspension Shock Absorber....414
Remove Cab Air Suspension Air Spring (Bag)....415
Remove Lateral Control Rod....415
4.41. CAB AIR SUSPENSION system for 9100i and 9200i DAY CAB MODELS after JANUARY 1997....415
Remove Height Control Valve....416
Remove Cab Air Suspension Shock Absorber....416
Remove Cab Air Suspension Air Spring (Bag)....417
Remove Lateral Control Rod....417
4.42. CAB AIR SUSPENSION system for 9200i DAY CAB MODELS WITH DETROIT DIESEL ENGINES before march 1997....418
Remove Height Control Valve....420
Remove Cab Air Suspension Shock Absorber....421
Remove Cab Air Suspension Air Spring (Bag)....422
Remove Lateral Control Rod....422
4.43. CAB AIR SUSPENSION system for 9100i and 9200iDAY CAB MODELS after march 1997....422
Remove Height Control Valve....423
Remove Cab Air Suspension Shock Absorber....423
Remove Cab Air Suspension Air Spring (Bag)....424
Remove Lateral Control Rod....424
4.44. CAB AIR SUSPENSION system for 9200i/9400i/9900i MODELS WITH PRO-SLEEPER® before APRIL 2000....425
Remove Height Control Valve....427
Remove Cab Air Suspension Shock Absorber....428
Remove Cab Air Suspension Air Spring (Bag)....428
Remove Lateral Control Rod....429
4.45. CAB AIR SUSPENSION system for 9200i/9400i/9900i MODELS WITH PRO-SLEEPER® after APRIL 2000....429
Remove Height Control Valve....431
Remove Cab Air Suspension Shock Absorber....432
Remove Cab Air Suspension Air Spring (Bag)....432
Remove Lateral Control Rod....433
4.46. CAB AIR SUSPENSION system for 5000i SERIES BEFORE SEPTEMBER 1997....434
Remove Height Control Valve....435
Remove Cab Air Suspension Shock Absorber....436
Remove Cab Air Suspension Air Spring (Bag)....437
Remove Lateral Control Rod....437
4.47. CAB AIR SUSPENSION system for 5000i SERIES After SEPTEMBER 1997....438
Remove Height Control Valve....440
Remove Cab Air Suspension Shock Absorber....442
Remove Cab Air Suspension Air Spring (Bag)....442
Remove Lateral Control Rod....443
4.48. CAB AIR SUSPENSION system for 5000i SERIES After FEBRUARY 2001....443
Remove Height Control Valve....445
Remove Cab Air Suspension Shock Absorber....445
Remove Cab Air Suspension Air Spring (Bag)....446
Remove Lateral Control Rod....447
5. INSTALL....448
5.1. ONE PIECE ENCAPSULATED WINDSHIELD....448
Install One Piece Encapsulated Windshield using Two Part U216 Urethane Adhesive (adhesive A and curative B)....448
Install One Piece Encapsulated Windshield using One Part U400HV Urethane Adhesive....467
5.2. TWO PIECE ENCAPSULATED WINDSHIELD....472
Install Two Piece Encapsulated Windshield using Two Part U216 Urethane Adhesive (adhesive A and curative B)....473
Install Two Piece Encapsulated Windshield using One Part U400HV Urethane Adhesive....486
5.3. Install REAR WINDOW GLASS AND WEATHER SEAL (EXCEPT SLEEPER MODELS)....491
5.4. HOOD SEALS....494
Install Hood Seals for 5000i and 9000i Series....494
Install Hood Seals for 5000i SBA Series with Optional Butterfly Hood....494
5.5. Install SUNSHADE....496
5.6. Install SUN VISOR....497
5.7. Install ignition KEY SWITCH CYLINDER....497
5.8. INSTRUMENT PANEL....498
Install Electrically Operated Gauges, Mechanical Air Gauges and Speedometer/Tachometer....498
5.9. Install FLOOR MAT....498
5.10. Install HEADLINER (DAY CAB MODELS ONLY)....499
5.11. Install DRIVER AND PASSENGER SEATS....499
5.12. Install BACK PANEL....499
5.13. Install ENGINE COVER....500
5.14. CAB DOOR LOWER TRIM PANEL....500
Install Driver Side Cab Door Lower Trim Panel....500
Install Passenger Side Cab Door Lower Trim Panel....500
5.15. CAB DOOR COURTESY LIGHT ASSEMBLY....500
Install Driver Side Cab Door Courtesy Light Assembly....500
Install Passenger Side Cab Door Courtesy Light Assembly....501
5.16. UPPER DOOR TRIM/INNER DOOR PANEL AND WINDOW REGULATOR ASSEMBLY....501
Install Driver Side Upper Door Trim/Inner Door Panel and Window Regulator Assembly....501
Install Passenger Side Upper Door Trim/Inner Door Panel and Window Regulator Assembly....503
5.17. CAB DOOR AND HINGE....504
Install Driver Side Cab Door Hinge....504
Install Driver Side Cab Door....505
Install Passenger Side Cab Door Hinge....506
Install Passenger Side Cab Door....506
5.18. INNER DOOR HANDLE....507
Install Driver Side Inner Door Handle....507
Install Passenger Side Inner Door Handle....507
5.19. CAB DOOR GRAB HANDLE....508
Install Driver Side Cab Door Grab Handle....508
Install Passenger Side Cab Door Grab Handle....508
5.20. ELECTRIC WINDOW AND/OR ELECTRIC DOOR LOCK SWITCH ASSEMBLY....508
Install Driver Side Electric Window and/or Electric Door Lock Switch Assembly....508
Install Passenger Side Electric Window and/or Electric Door Lock Switch Assembly....509
5.21. UPPER DOOR TRIM PANEL....509
Install Driver Side Upper Door Trim Panel....509
Install Passenger Side Upper Door Trim Panel....509
5.22. WINDOW REGULATOR ASSEMBLY....510
Install Driver Side Electric Window Regulator Assembly with Power Window Motor....510
Install Passenger Side Electric Window Regulator Assembly with Power Window Motor....511
Install Driver Side Manual Window Regulator Assembly....511
Install Passenger Side Manual Window Regulator Assembly....513
5.23. CAB DOOR WINDOW GLASS AND FRONT RUN CHANNEL....516
Install Driver Side Front Run Channel and Cab Door Window Glass....516
Install Passenger Side Front Run Channel and Cab Door Window Glass....517
5.24. Install CAB DOOR LATCH ASSEMBLY....518
5.25. Install CAB DOOR STRIKER PIN....518
5.26. Install DOOR LOCK ASSEMBLY....519
5.27. Install OUTER DOOR HANDLE....520
5.28. Install CAB DOOR OPENING SEALS....520
5.29. ELECTRIC WINDSHIELD WIPER SWITCHES....520
Install Wiper/Washer Control Switches and Indicator Lights....521
5.30. Install WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....521
5.31. COWL TRAY....521
5.32. AIR DUCT INLET....523
5.33. WINDSHIELD WIPER MOTOR, BRACKET AND LINKAGE ASSEMBLY....524
Install Windshield Wiper Motor, Bracket and Linkage Assembly on Vehicles before 2002 Engines before May 2001....524
Install Windshield Wiper Motor, Bracket and Linkage Assembly on Vehicles with 2002 Engines after May 2001....524
Install Windshield Wiper Motor, Bracket and Linkage Assembly on Vehicles with 2002 Engines after January 2005....525
5.34. WIPER MOTOR....526
Install Wiper Motor on Vehicles before 2002 Engines and after 2002 Engines before January 2005....526
Install Wiper Motor with Electrical Connector part of Pig-Tail Wiring Harness on Vehicles with 2002 Engines after January 2005....526
Install Wiper Motor with Electrical Connector as part of Wiper Motor on Vehicles with 2002 Engines after January 2005....527
5.35. Install WASHER RESERVOIR/PUMP MOTOR ASSEMBLY....528
5.36. Install WASHER RESERVOIR PUMP MOTOR — ELECTRIC....528
5.37. CAB....528
Install SBA and SFA Cab for 5000i Series with Rear Hard Mount before November 1999....528
Install Front Cab Mounting Insulator for SBA and SFA 5000i Series with Rear Hard Mount after November 1999....529
Install SBA and SFA Cab for 5000i Series with Rear Hard Mount after November 1999....529
Install Front Cab Mounting Insulator for SBA Cab for 5000i Series with Rear Cab Air Suspension System after August 1994 and SFA Cab for 5000i Series with Rear Cab Air Suspension System after August 1996....530
Install SBA Cab for 5000i Series with Rear Cab Air Suspension System after August 1994 and SFA Cab for 5000i Series with Rear Cab Air Suspension System after August 1996....530
Install Front Cab Mounting Insulator on Day Cab for 9100i, 9200i, 9400i and 9900i Models with Rear Hard Mount....531
Install Day Cab for 9100i, 9200i, 9400i and 9900i Models with Rear Hard Mount....531
Install Front Cab Mounting Insulator on Day Cab for 9200i Models with Detroit Diesel Engines and with Rear Cab Air Suspension System before January 1997....532
Install Day Cab for 9200i Models with Detroit Diesel Engines and with Rear Cab Air Suspension System before January 1997....532
Install Front Cab Mounting Insulator on Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after January 1997....533
Install Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after January 1997....533
Install Front Cab Mounting Insulator on Day Cab for 9200i Models with Detroit Diesel Engines and with Rear Cab Air Suspension System before March 1997....534
Install Day Cab for 9200iModels with Detroit Diesel Engines and with Rear Cab Air Suspension System before March 1997....534
Install Front Cab Mounting Insulator on Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after March 1997....535
Install Day Cab for 9100i and 9200i Models without Detroit Diesel Engines and with Rear Cab Air Suspension System after march 1997....535
Install Front Cab Mounting Insulator on Day Cab with High Rise Crossmember for 9100i, 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....536
Install Day Cab with High Rise Crossmember for 9100i, 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....536
Install Front Cab Mounting Insulator on Day Cab with Standard 7 Piece Crossmember for 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....537
Install Day Cab with Standard 7 Piece Crossmember for 9400i and 9900i Models with Rear Cab Air Suspension System after December 2001....537
Install Front Cab Mounting Insulator on 51 Inch or 72 Inch Pro-Sleeper® Cab for 9200i and 9400i Models with Rear Cab Air Suspension System....537
Install 51 Inch or 72 Inch Pro-Sleeper® Cab for 9200i and 9400i Models with Rear Cab Air Suspension System....538
Install Front Cab Mounting Insulator on 51 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....538
Install 51 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....539
Install Front Cab Mounting Insulator on 72 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....539
Install 72 Inch Pro-Sleeper® Cab for 9200i, 9400i and 9900i Models with Rear Cab Air Suspension System on Vehicles after April 2000....540
General Guidelines For Installation....540
Paint as Required....541
Reinstall Related Components....541
5.38. CAB AIR RIDE system for 9200i/9400i/9900i DAY CAB MODELS WITHOUT DETROIT DIESEL ENGINES before DECEMBER 2001....541
Install Cab Air Ride Shock Absorber....541
Install Cab Air Ride Air Springs (Bags)....542
Install Track Bar Rod....543
Install Cab Air Ride Valve....543
5.39. CAB AIR SUSPENSION system for 9200i/9400i/9900i DAY CAB MODELS WITHOUT DETROIT DIESEL ENGINES after DECEMBER 2001....544
Install Height Control Valve....545
Install Cab Air Suspension Shock Absorber....546
Install Cab Air Ride Air Spring (Bag)....546
Install Lateral Control Rod....547
5.40. CAB AIR SUSPENSION SYSTEM FOR 9200i DAY CAB MODELS WITH DETROIT DIESEL ENGINES before january 1997....547
Install Height Control Valve....547
Install Cab Air Suspension Shock Absorber....548
Install Cab Air Suspension Air Spring (Bag)....548
Install Lateral Control Rod....549
5.41. CAB AIR SUSPENSION SYSTEM FOR 9100i and 9200i DAY CAB MODELS after january 1997....549
Install Height Control Valve....550
Install Cab Air Suspension Shock Absorber....550
Install Cab Air Suspension Air Spring (Bag)....551
Install Lateral Control Rod....551
5.42. CAB AIR SUSPENSION SYSTEM FOR 9200i DAY CAB MODELS WITH DETROIT DIESEL ENGINES before march 1997....552
Install Height Control Valve....552
Install Cab Air Suspension Shock Absorber....553
Install Cab Air Suspension Air Spring (Bag)....553
Install Lateral Control Rod....554
5.43. CAB AIR SUSPENSION system for 9100i and 9200iDAY CAB MODELS after march 1997....554
Install Height Control Valve....554
Install Cab Air Suspension Shock Absorber....555
Install Cab Air Suspension Air Spring (Bag)....556
Install Lateral Control Rod....556
5.44. CAB AIR SUSPENSION SYSTEM FOR 9200i/9400i/9900i MODELS WITH PRO-SLEEPER® before APRIL 2000....556
Install Height Control Valve....557
Install Cab Air Suspension Shock Absorber....558
Install Cab Air Suspension Air Spring (Bag)....558
Install Lateral Control Rod....559
5.45. CAB AIR SUSPENSION SYSTEM FOR 9200i/9400i/9900i MODELS WITH PRO-SLEEPER® AFTER APRIL 2000....559
Install Height Control Valve....559
Install Cab Air Suspension Shock Absorber....560
Install Cab Air Suspension Air Spring (Bag)....560
Install Lateral Control Rod....561
5.46. CAB AIR SUSPENSION SYSTEM FOR 5000i SERIES BEFORE SEPTEMBER 1997....561
Install Height Control Valve....562
Install Cab Air Suspension Shock Absorber....562
Install Cab Air Suspension Air Spring (Bag)....563
Install Lateral Control Rod....563
5.47. CAB AIR SUSPENSION SYSTEM FOR 5000i SERIES AFTER SEPTEMBER 1997....564
Install Height Control Valve....564
Install Cab Air Suspension Shock Absorber....565
Install Cab Air Suspension Air Spring (Bag)....565
Install Lateral Control Rod....566
5.48. CAB AIR SUSPENSION SYSTEM FOR 5000i SERIES AFTER FEBRUARY 2001....566
Install Height Control Valve....567
Install Cab Air Suspension Shock Absorber....568
Install Cab Air Suspension Air Spring (Bag)....568
Install Lateral Control Rod....569
6. 5000i SERIES VEHICLES WITH F.W.P.T.O....570
6.1. ENGINE COVER ACCESS DOOR FOR VEHICLES WITH F.W.P.T.O....570
7. TROUBLESHOOTING....571
7.1. ELECTRIC WIPERS....571
7.2. WASHER PUMP....571
7.3. CAB AIR SUSPENSION SYSTEM FOR 5000i SERIES....572
8. ADJUSTMENTS....573
8.1. CAB SQUARING....573
8.2. CAB AIR RIDE SYSTEM FOR 9200i/9400i/9900i DAY CAB MODELS WITHOUT DETROIT DIESEL ENGINES BEFORE DECEMBER 2001....574
8.3. CAB AIR SUSPENSION SYSTEM FOR 9200i/9400i/9900i DAY CAB MODELS WITHOUT DETROIT DIESEL ENGINES AFTER DECEMBER 2001....577
8.4. CAB AIR SUSPENSION SYSTEM FOR 9200i DAY CAB MODELS WITH DETROIT DIESEL ENGINES BEFORE JANUARY 1997....579
8.5. CAB AIR SUSPENSION SYSTEM FOR 9100i AND 9200i DAY CAB MODELS AFTER JANUARY 1997....580
8.6. CAB AIR SUSPENSION SYSTEM FOR 9200i DAY CAB MODELS WITH DETROIT DIESEL ENGINES BEFORE MARCH 1997....581
8.7. CAB AIR SUSPENSION SYSTEM FOR 9100i and 9200i DAY CAB MODELS AFTER MARCH 1997....583
8.8. CAB AIR SUSPENSION SYSTEM FOR 9200i/9400i/9900i MODELS WITH PRO-SLEEPER® BEFORE APRIL 2000....583
8.9. CAB AIR SUSPENSION SYSTEM FOR 9200i/9400i/9900i MODELS WITH PRO-SLEEPER® AFTER APRIL 2000....585
8.10. CAB AIR SUSPENSION SYSTEM FOR 5000i SERIES BEFORE SEPTEMBER 1997....588
8.11. CAB AIR SUSPENSION SYSTEM FOR 5000i SERIES AFTER SEPTEMBER 1997....589
8.12. CAB AIR SUSPENSION SYSTEM FOR 5000i SERIES AFTER FEBRUARY 2001....590
8.13. HOOD....591
8.14. CAB DOOR HINGE....591
8.15. CAB DOOR STRIKER PIN AT LOCK PILLAR....591
8.16. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....591
9. FORMS....593
9.1. BONDED WINDSHIELD REPLACEMENT REPORT....593
10. TORQUE....594
10.1. TORQUE CHART....594
tables....571
Table 2Electric Wiper Troubleshooting Chart....571
Table 3Washer Pump Troubleshooting Chart....571
Table 4Cab Air Suspension System for 5000i Series....572
000000241 - SERVICE MANUAL Electrical Circuit Diagrams PayStar - 5900 (MaxxForce 11,13, 15L, N13 or ISX15 Engines with SCR)....613
0000002441 - PayStar Series Electrical Circuit Diagrams with MaxxForce 11_13, 15L, N13 or ISX15 Engines (Supersedes S08352) Circuit Diagrams....929
0000002568 - 5000i, 9100 , 9200i, 9400i, 9900i Models Heater System _ Air Conditioning (Supersedes S16023) Service Manual....1277
toc....1279
Summary of Changes....1279
1. AIR CONDITIONING SYSTEM SERVICE....1283
1.1. SERVICE WARNINGS....1283
2. DESCRIPTION....1285
3. OPERATION....1288
3.1. FRESH AIR VENTILATION....1288
3.2. HEATING....1288
Cab....1288
Sleeper Compartment....1288
3.3. COOLING....1289
Cab....1289
Sleeper Compartment....1289
3.4. DEFROSTING....1289
3.5. DEHUMIDIFYING....1290
4. SYSTEM DIAGNOSIS....1290
5. MAINTENANCE....1291
5.1. PRE-SEASON CHECKS AND OFF-SEASON CARE....1291
5.2. AIR FILTER....1291
Remove....1291
Install....1292
6. SERVICE HINTS....1292
7. REMOVE AND INSTALL....1294
7.1. EXPANSION VALVE....1294
Remove....1294
Install....1296
7.2. BLEND-AIR UNIT COVER....1297
Remove....1298
Install....1298
7.3. BLEND-AIR UNIT....1298
Remove....1298
Remove - Under the Cab....1299
Remove - Inside the Cab....1300
Install....1302
Install - Under the Cab....1302
Install - Inside the Cab....1303
7.4. THERMOSTATIC SWITCH....0
Install....1306
7.5. BUNK BLEND-DOOR ACTUATOR (sleeper models)....1306
Remove....1306
Install....1308
7.6. BUNK BLEND-DOOR ASSEMBLY (sleeper models)....1308
Remove....1308
Install....1310
7.7. CAB BLEND-DOOR ACTUATOR....1310
Remove....1310
Install....1311
7.8. CAB BLEND-DOOR ASSEMBLY....1311
Remove....1311
Install....1312
7.9. HEATER CORE....1313
Remove....1313
Install....1315
7.10. EVAPORATOR....1316
Remove....1316
Install....1317
7.11. BLOWER RESISTORS – CAB (MOUNTED IN BLEND-AIR UNIT)....1318
Remove....1318
Install....1319
7.12. BLOWER MOTOR ASSEMBLY – CAB (LOCATED IN BLEND-AIR UNIT)....1319
Remove....1319
Install....1322
7.13. BLOWER MOTOR ASSEMBLY – SLEEPER COMPARTMENT....1323
Remove....1323
Install....1323
7.14. BLOWER RESISTORS – sleeper compartment....1324
Remove....1324
Install....1324
7.15. DASH FAN MODE ACTUATORS....1324
Dash Fan Mode Actuator (Driver Side) — Remove....1324
Dash Fan Mode Actuator (Driver Side) — Install....1325
Dash Fan Mode Actuator (Passenger Side) — Remove....1326
Dash Fan Mode Actuator (Passenger Side) — Install....1326
7.16. AIR CONDITIONING AND HEATER CONTROL ASSEMBLY....1326
Cab - Remove....1326
Cab - Install....1328
7.17. SLEEPER COMPARTMENT CONTROL UNIT....1328
Remove....1328
Install....1329
8. SYSTEM OPERATING TEST....1331
8.1. SYSTEM PRESSURE TEST CHART....1332
9. SPECIFICATIONS....1332
10. COMPONENT LOCATIONS....1334
11. TORQUE CHART....1335
tables....1332
Table 2System Pressure Test Chart....1332
Table 3Specifications....1332
Table 4Component Locations....1334
Table 5Torque Chart....1335
0000003261 - 9900 Series Electrical Circuit Diagram Manual....1338
0000003261 - SERVICE MANUAL Electrical Circuit Diagrams 9900 Series....1751
0000011981 - PayStar _ 9200i and 9900i Series Electrical Circuit Diagrams (Supersedes S08326)....2143
toc....2145
Table of Contents....2145
INSTRUCTIONS AND CHARTS (Chapter 1)....2155
1.1. Circuit Identification Chart, p. 1....2155
1.2. Circuit Identification Chart, p. 2....2156
1.3. Circuit Identification Chart, p. 3....2157
1.4. Circuit Diagram Instructions, p. 4....2158
1.5. Circuit Diagram Instructions, p. 5....2159
1.6. Circuit Diagram Instructions, p. 6....2160
1.7. Schematic Symbol Chart, p. 7....2161
1.8. Schematic Symbol Chart, p. 8....2162
1.9. Schematic Symbol Chart, p. 9....2163
1.10. Relay Functions and Wiring Guide, p. 10....2164
1.11. Relay Pinout and Function Data Sealed Miniature Relay Data....2165
1.12. Lamp Bulb Chart, p. 12....2166
1.13. Cummins ISX07 / ISM07 Pinouts – 50 Pin Connector, p. 13....2167
1.14. Eaton GEN 3 TCM Pinouts – 38 Pin Connector, p. 14....2168
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....2169
2.1. 12 Volt Power Feed, p. 1....2169
2.2. 12V Power Distribution – Accessory, p. 2....2170
2.3. 12V Power Distribution Battery B1, p. 3....2171
2.4. 12V Power Distribution – B2 Battery Stud, p. 4....2172
2.5. 12V Power Distribution B2 Battery Stud (Cont.), p. 5....2173
2.6. 12V Power Distribution 3+1 Battery System, p. 6....2174
2.7. 12V Power Distribution – Ground Adapter Composite, p. 7....2175
2.8. Ground Stud Composite, p. 8....2176
2.9. Ground Stud Composite (Cont.), p. 9....2177
2.10. 12V Power Distribution Ignition, p. 10....2178
2.11. 12V Power Distribution – Panel Lights Adapter Composite, p....2179
2.12. Zero Volt Reference, p. 12....2180
12 VOLT CHARGING and CRANKING SYSTEM (Chapter 3)....2181
3.1. Charging and Cranking (12V) with 2002 CAT and Cummins Engin....2181
3.2. 12V Cranking System with Overcrank Protection with 2002 CAT....2182
3.3. Charging and Cranking (12V) with I6 HEUI Engine, p. 3....2183
3.4. 12V Cranking System with Overcrank Protection With I6 HEUI,....2184
3.5. 12V Charging System with Cummins ISX07 / ISM07 Engines, p. ....2185
3.6. With Cummins ISX07 / ISM07 Engines, p. 6....2186
3.7. Starter Interlock With CAT and Cummins Engines (Manual Tran....2187
3.8. 12V Cranking System with Overcrank Protection with 2007 CAT....2188
3.9. Thermal Overcrank with 15L IBB Engines, p. 9....2189
ENGINE SYSTEMS (Chapter 4)....2190
4.1. Caterpillar C10, C11, C12, C13, C15, and C16 Cruise Control....2190
4.2. Caterpillar C10, C11, C12, C13, C15, and C16 Cruise Control....2191
4.3. Caterpillar C10, C11, C12, C13, C15, and C16 Engine Control....2192
4.4. Cummins ISM, ISX Cruise Control, p. 4....2193
4.5. Cummins ISM, ISX Engine Brake, p. 5....2194
4.6. Cummins ISM , ISX – Engine Controls, p. 6....2195
4.7. Cummins AHD, ISM and ISL – Engine Controls, p. 7....2196
4.8. I6 HEUI – Cruise Control, p. 8....2197
4.9. I6 HEUI – Engine Brake, p. 9....2198
4.10. I6 HEUI – Engine Controls, p. 10....2199
4.11. I6 HEUI – Module Power and Ground System, p. 11....2200
4.12. I6 HEUI – Accelerator, BAP, Ambient Air Temp Sensor System....2201
4.13. I6 HEUI – Surge Tank and Exhaust Brake Solenoid, p. 13....2202
4.14. Cummins ISX07 / ISM07 ECM Pin Layout, p. 14....2203
4.15. Cummins ISX07 / ISM07 ECM Pin Layout, p. 15....2204
4.16. Cummins ISX07 / ISM07 ECM Pin Layout, p. 16....2205
4.17. Cummins ISX07 / ISM07 ECM Pin Layout, p. 17....2206
4.18. Cummins ISX07 / ISM07 Remote Cruise Control, p. 18....2207
4.19. Cummins ISX 07 / ISM 07 Engine Brake with Allison Transmis....2208
4.20. Cummins ISX07 / ISM07 Engine with Jake Brake Foot Switch, ....2209
4.21. Cummins ISX / ISM Aftertreatment Interface Emission, p. 21....2210
4.22. Cummins ISX07 / ISM07 Electronic Engine Control, p. 22....2211
4.23. Cummins ISX07 / ISM07 Electronic Engine Control, p. 23....2212
4.24. Cummins ISX07 / ISM07 Priming Pump, p. 24....2213
4.25. Cummins ISX07 / ISM07 Electronic Engine Control, p. 25....2214
4.26. Cummins ISX07 / ISM07 Electronic Engine Control, p. 26....2215
4.27. Cummins ISX07 / ISM07 Engine Block Ground Adapter, p. 27....2216
4.28. Cummins ISL – Intake Heater, p. 28....2217
4.29. Aftertreatment Control, p. 29....2218
4.30. Aftertreatment Control, p. 36....2219
4.31. 2007 CAT No Idle Engine Shutdown System, p. 37....2220
4.32. Aftertreatment Control Cat 2007, p. 38....2221
4.33. IBB 15L Electronic Engine Control, p. 39....2222
4.34. IBB 15L Electronic Engine Control (Cont.), p. 40....2223
4.35. IBB 15L Electronic Engine Control (Cont.), p. 41....2224
4.36. IBB 15L Electronic Engine Control (Cont.), p. 42....2225
4.37. Cruise Control, 15L IBB Engine, p. 43....2226
4.38. Cruise Control with Remote Engine Control PTO, 15L IBB Eng....2227
4.39. Aftertreatment Control, 15L IBB Engine, p. 45....2228
4.40. Aftertreatment Control, 15L IBB Engine (Cont.), p. 46....2229
4.41. Engine Brake, 15L IBB Engine, p. 47....2230
FANS (Chapter 5)....2231
5.1. Horton and Kysor Engine Fan With CAT C10, C11, C12, C13, C1....2231
5.2. Horton and Kysor Engine Fan With Cummins ISM, ISX with and ....2232
5.3. Horton and Kysor Engine Fan with I6 HEUI Engines with Shutt....2233
5.4. Freon Compressor, p. 4....2234
5.5. Cummins ISM On / Off Fan, p. 5....2235
5.6. Horton and Kysor Engine Fan with Cummins ISM, ISX with and ....2236
5.7. ECM Connector CAT 2007, p. 7....2237
5.8. ECM Connector CAT 2007, p. 8....2238
5.9. ECM Connector CAT 2007, p. 9....2239
5.10. ECM Connector CAT 2007, p. 10....2240
5.11. Fan Wiring – IBB Engine, p. 11....2241
GAUGES AND SYSTEMS (Chapter 6)....2242
6.1. 4x2 Rear Axle Oil Temperature Gauge, p. 1....2242
6.2. 6x4 Axle Forward-Rear and Rear-Rear Temperature Gauge, p. 2....2243
6.3. Engine Oil Pressure Gauge, p. 3....2244
6.4. Engine Oil Temperature Gauge, p. 4....2245
6.5. Engine Water Temperature Gauge, p. 5....2246
6.6. Fuel Level Gauge, p. 6....2247
6.7. Pyrometer Gauge, p. 7....2248
6.8. Speedometer Gauge – Tachometer Gauge, p. 8....2249
6.9. Speedometer Gauge – Tachometer Gauge, p. 8A....2250
6.10. Transmission Oil Temperature Gauge, p. 9....2251
6.11. Voltmeter Gauge, p. 10....2252
6.12. Ether Start, p. 11....2253
6.13. Manifold Pressure Gauge, p. 12....2254
6.14. Cummins ISX07 / ISM07 Auto Ether Start, p. 13....2255
6.15. 6x4 Axle Forward – Rear and Rear – Temperature Gauge, p. 1....2256
WARNING LIGHTS (Chapter 7)....2257
7.1. Air Suspension Release Warning Light, p. 1....2257
7.2. Engine Oil Pressure Warning Light, p. 2....2258
7.3. Engine Water Temperature Warning Light, p. 3....2259
7.4. Low Air Pressure Warning Light, p. 4....2260
7.5. Low Fuel Level Warning Light, p. 5....2261
7.6. Power Divider Lock (PDL) Warning Light and Buzzer, p. 6....2262
7.7. Differential Lock Warn Light – 4x2, p. 7....2263
7.8. Differential Lock Warn Light – 6x4, p. 8....2264
7.9. Cummins ISL – Wait to Start, p. 9....2265
CAB ACCESSORIES (Chapter 8)....2266
8.1. Cigar Lighter (Cab), p. 1....2266
8.2. Clock (Cab), p. 2....2267
8.3. Electric Window – Right, p. 3....2268
8.4. Electric Window – Right and Left, p. 4....2269
8.5. Defroster Fan(s), p. 5....2270
8.6. Electric Windshield Wipers with Intermittent Wipe and Wash,....2271
8.7. Horn, p. 7....2272
8.8. Mirror Lights and Heated Mirrors, p. 8....2273
8.9. Left and Right Motorized Mirror, p. 9....2274
8.10. Dual Axis Motorized Mirrors, p. 10....2275
8.11. Power Source (CB), p. 11....2276
8.12. Radio-CB Accommodation Package, p. 12....2277
8.13. Radio-Cab, Speakers, p. 13....2278
8.14. Owner / Operator Spare Switch, p. 14....2279
8.15. Electric Lock – Right and Left, p. 15....2280
8.16. Intervision Display, p. 16....2281
8.17. Eaton Vorad – Collision Avoidance, p. 17....2282
8.18. Eaton Vorad – Collision Avoidance, p. 18....2283
8.19. Temperature / Compass Display, p. 19....2284
8.20. Road Relay IV, p. 20....2285
8.21. Heated Seat – Driver, p. 21....2286
8.22. Heated Seat – Passenger, p. 22....2287
8.23. Electric Windshield Wiper with Intermittent Wipe and Wash ....2288
8.24. Battery Discharge Protection System, p. 24....2289
8.25. Battery Discharge Protection System with Temperature Compe....2290
8.26. Monsoon Premium Sound System, p. 26....2291
8.27. Monsoon Premium Sound System, p. 27....2292
8.28. Aux Power Source Wiring, p. 28....2293
CHASSIS ACCESSORIES (Chapter 9)....2294
9.1. Air Dryer, p. 1....2294
9.2. ABS / ATC (Bendix), p. 2....2295
9.3. ABS / ATC (Bendix) Left Control, p. 3....2296
9.4. ABS / ATC (Bendix) (Cont.), p. 4....2297
9.5. ABS / ATC (WABCO), p. 5....2298
9.6. ABS / ATC (WABCO) (Cont.), p. 6....2299
9.7. ABS / ATC (WABCO) (Cont.), p. 7....2300
9.8. ABS / ATC (WABCO) (Cont.), p. 8....2301
9.9. Trailer Connection with Four Wheel Trailer – Frame Mounted,....2302
9.10. Two Speed Axle Wiring, p. 10....2303
9.11. Truck Body Connection, p. 11....2304
9.12. Trailer Connection without Sleeper – Back of Cab Mounted w....2305
9.13. Trailer Connection with Four Wheel Trailer – Frame Mounted....2306
9.14. Meritor G Series Transmission, p. 14....2307
9.15. Eaton Autoshift Gen III Transmission, p. 15....2308
9.16. Eaton Ultrashift Gen III Transmission, p. 16....2309
9.17. Eaton Autoshift Gen III with Push Button Shifter, p. 17....2310
9.18. Eaton Autoshift Gen III with Cobra Shifter, p. 18....2311
9.19. Transmission Data Link with Engine Back Bone, p. 19....2312
9.20. Transmission Data Link – Freedom Line, p. 20....2313
9.21. ABS6 / ATC Bendix Air, p. 21....2314
9.22. ABS6 / ATC Bendix Air (Cont.), p. 22....2315
9.23. ABS6 / ATC Bendix Air (Cont.), p. 23....2316
9.24. ABS6 / ATC Bendix Air (Cont.), p. 24....2317
9.25. Allison Transmission Shift Tower Bulk Head, p. 25....2318
9.26. Allison Transmission Shift Tower Bulk Head, p. 26....2319
9.27. Allison Transmission Shift Tower Bulk Head, p. 27....2320
9.28. Allison Transmission Data Link, p. 28....2321
9.29. Freedom Line Transmission, p. 29....2322
9.30. Eaton Gen3 Transmission, p. 30....2323
9.31. Eaton Gen3 Transmission, p. 31....2324
9.32. Transmission Meritor – G Power Connector, p. 32....2325
9.33. ABS / ATC (Bendix) – Left Control, p. 33....2326
9.34. ABS-6 Advance ECU, with Bendix RSP, p. 34....2327
9.35. Trailer Connection – Back of Sleeper Mounted with Tractor ....2328
9.36. TCM Connector CAT 2007, p. 36....2329
9.37. Eaton Ultrashift VMS Transmission, p. 37....2330
9.38. ABS / HSA Bendix Air , p. 38....2331
9.39. Eaton Ultrashift – VMS, p. 39....2332
9.40. Air Dryer, p. 40....2333
9.41. Bendix Air ABS 4CH and 6CH, p. 41....2334
9.42. Bendix Air ABS 4CH and 6CH (Cont.), p. 42....2335
9.43. Bendix Air ABS 4CH and 6CH (Cont.), p. 43....2336
9.44. Bendix Air ABS 4CH and 6CH (Cont.), p. 44....2337
9.45. Bendix Advance Air ABS for 4CH and 6CH, p. 45....2338
9.46. Bendix Advance Air ABS, p. 46....2339
9.47. Bendix Advance Air ABS for 4CH and 6CH, with Trailer Tract....2340
9.48. Bendix Advance Air ABS 6CH, p. 48....2341
9.49. Wabco Air ABS for 4CH & 6CH, p. 49....2342
9.50. Wabco Air ABS for 4CH & 6CH, p. 50....2343
9.51. Wabco Air ABS for 4CH & 6CH, p. 51....2344
9.52. Wabco ABS with ATC, p. 52....2345
9.53. Wabco ABS, J1939, p. 53....2346
9.54. Wabco ABS with 6CH, p. 54....2347
9.55. Ultrashift Plus, p. 55....2348
9.56. Manual / Ultrashifter Plus / Reverse Switch Transmission, ....2349
9.57. Allison Transmission, p. 57....2350
9.58. Allison 4700 Transmission with EOF Shifter, p. 58....2351
9.59. Manual Transmission, J1939, p. 59....2352
9.60. Ultrashift Plus, J1939, p. 60....2353
9.61. Allison Transmission, J1939, p. 61....2354
9.62. Trailer Connection, p. 62....2355
SLEEPER LIGHTING AND ACCESSORIES (Chapter 10)....2356
10.1. Auxiliary Circulation Fan (Low Roof), p. 1....2356
10.2. Auxiliary Circulation Fan (High Roof), p. 2....2357
10.3. Auxiliary Circulation Fan (Skyrise), p. 3....2358
10.4. Bunk Fluorescent and Reading Lights, p. 4....2359
10.5. Bunk Speakers, p. 5....2360
10.6. Luggage Compartment Lights, p. 6....2361
10.7. Power Source, p. 7....2362
10.8. Refrigerator Wiring, p. 8....2363
10.9. TV / VCR Wiring, p. 9....2364
10.10. Overhead Cabinets, Accent Lights, p. 10....2365
10.11. Optional Sleeper Mounted Radio Controls, p. 11....2366
10.12. Shore Power Wiring (08WET) Not With Inverter, p. 12....2367
10.13. Shore Power Wiring (08WET) With Inverter (08WES), p. 13....2368
LIGHT SYSTEMS (Chapter 11)....2369
11.1. Back-Up Lights, p. 1....2369
11.2. Cab and Trailer Lights Switch and Relays Wiring, p. 2....2370
11.3. Cab Clearance and Identification Lights, p. 3....2371
11.4. Work Light withoutSleeper, p. 4....2372
11.5. Cab Dome, Reading and Courtesy Lights without Skyrise, p. ....2373
11.6. Cab Dome, Reading and Courtesy Lights with Skyrise, p. 6....2374
11.7. Daytime Running Lights (DRL) – USA, p. 7....2375
11.8. Fog Lights – Cab / Front End Effects, p. 8....2376
11.9. Headlight Switch and Dimmer Switch Wiring, p. 9....2377
11.10. Headlights, p. 10....2378
11.11. Panel Lights, p. 11....2379
11.12. Park / Turn / Side Marker Lights – With DRL, p. 12....2380
11.13. Spotlight, p. 13....2381
11.14. Stop, Tail, Turn and Hazard Signal Lights With Flasher, p....2382
11.15. Work Light with Sleeper, p. 15....2383
11.16. Cab and Trailer Light Switch and Relay Wiring with Bistab....2384
11.17. Cab Clearance and Identification Lights with Bistable Mar....2385
11.18. Park / Turn / Side Marker Lights with DRL, p. 18....2386
11.19. Headlight, p. 19....2387
11.20. Lights Stop, Tail, Turn and Back Up, p. 20....2388
HEATER AND AIR CONDITIONER (Chapter 12)....2389
12.1. Air Conditioner – Cab, p. 1....2389
12.2. Air Conditioner – Cab (Cont.), p. 1A....2390
12.3. Heater – Cab, p. 2....2391
12.4. Heater – Bunk Auxiliary Blower, p. 3....2392
12.5. Heater – Bunk with Standard Temperature Control, p. 4....2393
12.6. Heater – Bunk with Thermostat Temperature Control, p. 5....2394
12.7. Lowered Heater Box, p. 6....2395
12.8. Aux Heater, p. 7....2396
12.9. APU System: Distribution Box, p. 8....2397
12.10. APU System: Distribution Box, p. 9....2398
12.11. APU System, p. 10....2399
CONNECTOR COMPOSITES (Chapter 13)....2400
13.1. Left Gauge Cluster (Connector 423), p. 1....2400
13.2. Left Gauge Cluster (Connector 424), p. 2....2401
13.3. Left Gauge Cluster – Gauge Information, p. 3....2402
13.4. Left Gauge Cluster – Terminal Information, p. 4....2403
13.5. Left Gauge Cluster – Terminal Information, p. 5....2404
13.6. Right Gauge Cluster (Connector 424M), p. 6....2405
13.7. Right Gauge Cluster (Connector 420), p. 7....2406
13.8. Right Gauge Cluster – Gauge Information, p. 8....2407
13.9. Right Gauge Cluster – Terminal Information, p. 9....2408
13.10. Right Side Cluster (Connector 420M), p. 10....2409
13.11. Speedometer / Tachometer Module – Terminal Information, p....2410
13.12. Speedometer / Tachometer Module (422M), p. 12....2411
13.13. Connector Composite (1), p. 13....2412
13.14. Connector Composite (1F), p. 13A....2413
13.15. Connector Composite (2), p. 14....2414
13.16. Connector Composite (3), p. 15....2415
13.17. Connector Composite (3M) p. 15A....2416
13.18. Connector Composites (4M), (8), (9), (9M), (11), (15), p....2417
13.19. Connector Composites (20), (27), (29), (40M), (41), (42),....2418
13.20. Connector Composites (48), (65F), (66F), (67F), p. 18....2419
13.21. Connector Composites (71), (72), (76), (77), (94), p. 19....2420
13.22. Connector Composites (100), (100A), (105), (111), (112), ....2421
13.23. Connector Composites (100M3), (105M), p. 20A....2422
13.24. Connector Composites (115), (116), (117), p. 21....2423
13.25. Connector Composites (113F1), (113M1), (117), (118), p. 2....2424
13.26. Connector Composites (118), (127A), (128), p. 23....2425
13.27. Connector Composites (137), (142M), (143M), p. 24....2426
13.28. Connector Composites (144M), (145M), (146M), p. 25....2427
13.29. Connector Composites (147), (148), (149), (150), p. 26....2428
13.30. Connector Composites (156), (157), p. 27....2429
13.31. Connector Composites (161M), (162), p. 28....2430
13.32. Connector Composites (165), (166), (167), (168), p. 29....2431
13.33. Connector Composites (170), (170M), (171), (171M), (180),....2432
13.34. Connector Composite (190), p. 31....2433
13.35. Connector Composite (190), p. 32....2434
13.36. Connector Composite (190), p. 33....2435
13.37. Connector Composites (196), (199), (200), (200M), (201), ....2436
13.38. Connector Composites (201M), (209), (211M), (212M), (214)....2437
13.39. Connector Composites (218), (220), (221), (227), (228), p....2438
13.40. Connector Composites (229), (230), (231), (236), (236F), ....2439
13.41. Connector Composites (241M), (243), (244), (249), (250), ....2440
13.42. Connector Composites (252), (260) (267), p. 39....2441
13.43. Connector Composites (268), (273), (275), (278), (282), (....2442
13.44. Connector Composites (290), (291), (292), (293), (294), (....2443
13.45. Connector Composites (296M), (298), (303F2), (303M2), (31....2444
13.46. Connector Composites (312), (313), (315), (316), (315F), ....2445
13.47. Connector Composites (320), (321), (322), (323), p. 43....2446
13.48. Connector Composites (318F), (318F1), (318F2), (319F), (3....2447
13.49. Connector Composites (325), (345), (350), (351), (352), (....2448
13.50. Connector Composites (354), (355), (360), (363), p. 45....2449
13.51. Connector Composites (379), (393), (393F), (396), p. 46....2450
13.52. Connector Composites (400), (402), p. 47....2451
13.53. Connector Composites (400M), (402), p. 47A....2452
13.54. Connector Composites (404), (406), (409), (417), (425M), ....2453
13.55. Connector Composites (426M), (427), (428F), p. 49....2454
13.56. Connector Composites (429F), (430), (433M), p. 50....2455
13.57. Connector Composites (434M), p. 51....2456
13.58. Connector Composites (435M), p. 52....2457
13.59. Connector Composites (436M), (437), (440), p. 53....2458
13.60. Connector Composites (441), (442), (453M), (454M), p. 54....2459
13.61. Connector Composites (455M), (456M), (459), (460F), p. 55....2460
13.62. Connector Composites (462M), p. 56....2461
13.63. Connector Composites (462M), p. 57....2462
13.64. Connector Composites (462M), p. 58....2463
13.65. Connector Composites (462M), p. 59....2464
13.66. Connector Composites (462), (463M), p. 60....2465
13.67. Connector Composites (463M), p. 61....2466
13.68. Connector Composites (463M), p. 62....2467
13.69. Connector Composites (463M), (464), p. 63....2468
13.70. Connector Composites (464), p. 64....2469
13.71. Connector Composites (464), p. 65....2470
13.72. Connector Composites (464), (464M), p. 66....2471
13.73. Connector Composites (464M), p. 67....2472
13.74. Connector Composites (464M), p. 68....2473
13.75. Connector Composites (464M), p. 69....2474
13.76. Connector Composites (465M), (466M), (468F), p. 70....2475
13.77. Connector Composites (470), (471A), (471M), p. 71....2476
13.78. Connector Composites (471AM), p. 71A....2477
13.79. Connector Composites (471), p. 72....2478
13.80. Connector Composites (1000), p. 73....2479
13.81. Connector Composites (471M), (474), (483), p. 74....2480
13.82. Connector Composites (489), (491), (492), (494M), p. 75....2481
13.83. Connector Composites (495M), (497M), (498M), p. 76....2482
13.84. Connector Composites (499M), (501M), p. 77....2483
13.85. Connector Composites (502), (503M), p. 78....2484
13.86. Connector Composites (504M), (506M), p. 79....2485
13.87. Connector Composites (509M), (511M), p. 80....2486
13.88. Connector Composites (512F), (513M), p. 81....2487
13.89. Connector Composites (514M), (515M), p. 82....2488
13.90. Connector Composite (517), p. 83....2489
13.91. Connector Composites (520), (521), (522), (523), p. 84....2490
13.92. Connector Composites (524), (528), (529), (530), (531), p....2491
13.93. Connector Composites (550), (560), (562), (574), p. 86....2492
13.94. Connector Composites (575), (576), (577), (578), (579), p....2493
13.95. Connector Composites (582), (584), (585), (587), p. 88....2494
13.96. Connector Composites (592), (592F), (593), (594), (600), ....2495
13.97. Connector Composites (603), (605), (607), (610), p. 90....2496
13.98. Connector Composites (604), (606), (611), (612), (640), p....2497
13.99. Connector Composites (613), (642), (643), (659), p. 92....2498
13.100. Connector Composites (662), (675), (676), p. 93....2499
13.101. Connector Composites (690), p. 94....2500
13.102. Connector Composites (720), (753), (755), (766), (767), ....2501
13.103. Connector Composites (768), (769), (770), (771), (774), ....2502
13.104. Connector Composites (776), (777), (778), (789), (791), ....2503
13.105. Connector Composites (817M), (818M), (823), (851), (854)....2504
13.106. Connector Composites (851F), (851M), (887), p. 99....2505
13.107. Connector Composites (904), (905), (906), p. 100....2506
13.108. Connector Composites (906), (907), (909), (912), p. 101....2507
13.109. Connector Composites (913), (914), (915), (916), (918), ....2508
13.110. Connector Composites (922M), (923F), (925), p. 103....2509
13.111. Connector Composites (926), (934), (935F), p. 104....2510
13.112. Connector Composites (938), (939), (940), (941), (942), ....2511
13.113. Connector Composites (955), (956), (962), (963), (992), ....2512
13.114. Connector Composites (995-999), (1033), (1034), p. 107....2513
13.115. Connector Composites (1039), (1040), (1041), p. 108....2514
13.116. Connector Composites (1042), (1043), (1044), p. 109....2515
13.117. Connector Composites (1045), (1046), (1047), (1048), p. ....2516
13.118. Connector Composites (1049), (1050M), (1051 – 1052), p. ....2517
13.119. Connector Composites (1053), (1054M), (1056M), (1057M), ....2518
13.120. Connector Composites (1058M), (1059M), (1060M), (1084), ....2519
13.121. Connector Composites (1086), p. 114....2520
13.122. Connector Composites (1086), (1087), p. 115....2521
13.123. Connector Composites (1088), (1090M), (1090F), p. 116....2522
13.124. Connector Composites (1093), (1094), (1095F), p. 117....2523
13.125. Connector Composites (1097), (1097M), (1098), (1099), (1....2524
13.126. Connector Composites (1110), (1112), (1113), (1125), (11....2525
13.127. Connector Composites (1127), (1128), (1130), (1135), p. ....2526
13.128. Connector Composites (1137), (1138), (1139), (1140), p. ....2527
13.129. Connector Composites (1141), (1155), (1156), p. 122....2528
13.130. Connector Composites (1157), (1158), (1159), (1170), p. ....2529
13.131. Connector Composites (1171M), (1177), Junction Points J4....2530
13.132. Connector Composites (1190), p. 125....2531
13.133. Connector Composites (1193), p. 126....2532
13.134. Connector Composites (1223), (1224), (1225), p. 127....2533
13.135. Connector Composites (1227), (1229), p. 128....2534
13.136. Connector Composites (1239A, B, C), (1239), (1240), p. 1....2535
13.137. Connector Composites (1241), (1243), (1250), (1258F), (1....2536
13.138. Connector Composites (1261), (1262), p. 131....2537
13.139. Connector Composites (1263), (1265), (1279), p. 132....2538
13.140. Connector Composites (1284), (1285), p. 133....2539
13.141. Connector Composites (1286), (1287), (1288), (1289), p. ....2540
13.142. Connector Composites (1304), (1305), (1306), (1307), (13....2541
13.143. Connector Composites (1310), (1311), (1312), (1313), (13....2542
13.144. Connector Composites (1324), (1327), p. 137....2543
13.145. Connector Composites (1328), (1331), (1332), p. 138....2544
13.146. Connector Composites (1348), (1349), p. 139....2545
13.147. Connector Composites (1365), (1366), (1367), p. 140....2546
13.148. Connector Composites (1342), (1370), (1371), p. 141....2547
13.149. Connector Composites (1375), (1376), p. 142....2548
13.150. Connector Composites (1386), (1387), p. 143....2549
13.151. Connector Composites (1430), (1431), (4321), (4322), (5F....2550
13.152. Connector Composites (100F), p. 145....2551
13.153. Connector Composites (137M), (141M), (152M), p. 146....2552
13.154. Connector Composites (303F), (303M), (438M), p. 147....2553
13.155. Connector Composites (480F), (480M), (481M), (482M), p. ....2554
13.156. Connector Composites (1084M), (1085M), (1174M), (1209F),....2555
13.157. Connector Composites (1212M), (1213F), p. 150....2556
13.158. Connector Composites (1215F), (1216F), (1217M), p. 151....2557
13.159. Connector Composites (1218M), (1225), (1232M), (1233), (....2558
13.160. Connector Composites (1251M), (1252M), (1255), (1256M), ....2559
13.161. Connector Composites (1329M), (7104F), (7110A), (950F), ....2560
13.162. Connector Composites (1448M), p. 155....2561
13.163. Connector Composites (1874C), (4328), (4705), (4706), p....2562
13.164. Connector Composites (6018), p. 157....2563
13.165. Connector Composites (6019), p. 158....2564
13.166. Connector Composites (6033), (6200), (6260VH), p. 159....2565
13.167. Connector Composites (6260VL), (6260VM), (6260VN), (6300....2566
13.168. Connector Composites (6704D), (6720), (6720A), (6720B), ....2567
13.169. Connector Composites (6730), (7105), (7110), p. 162....2568
13.170. Connector Composites (7250), (7500W), (7501), (7600), (7....2569
13.171. Connector Composites (8104), (8107), (8303), (8410), (85....2570
13.172. Connector Composites (8501), (8502), (8503), (8504), (85....2571
13.173. Connector Composites (8803), (8953F), (8951), p. 166....2572
13.174. Connector Composites (8953F2), (8953M), p. 167....2573
13.175. Connector Composites (8953M1), (8953M2), (8957F1), (9100....2574
13.176. Connector Composites (9303A), (9303H), (9501D), p. 169....2575
13.177. Connector Composites (9501F), (9502A), (9502B), (9503D),....2576
13.178. Connector Composites (9504A), (9504B), (9505A), (9506D),....2577
13.179. Connector Composites (9507A), (9507B), (9508D), (9508E),....2578
13.180. Connector Composites (9510A), (9510M), (9511), (9511A), ....2579
13.181. Connector Composites (9512), (9513), (9514), p. 174....2580
13.182. Connector Composites (9515B), (9516), (9516M), p. 175....2581
13.183. Connector Composites (9516M), (9517), (9518), (9530), (9....2582
13.184. Connector Composites (9715F), (9715M), (9716F), (9716M),....2583
13.185. Connector Composites (9789FA), (9790MA), (9800F), p. 178....2584
13.186. Connector Composites (9800M), p. 179....2585
13.187. Connector Composites (9800M), p. 180....2586
13.188. Connector Composites (9800M), p. 181....2587
13.189. Connector Composites (9811), (9812), (9814), (9815), (98....2588
POWER DISTRIBUTION LAYOUT (Chapter 14)....2589
14.1. Power Distribution Center, Fuse and Circuit Breaker Locati....2589
14.2. Fuse and Circuit Breaker Location (Cont.), p. 2....2590
14.3. Relay Location, p. 3....2591
14.4. Pro Sleeper Fuse Index, p. 4....2592
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Service Manual (Supersedes 0000001601, 0000001843 & 0000002222)....2593
toc....2595
Table of Contents....2595
1. Description....2607
1.1. Cooling Package Visual Inspection....2612
2. Cooling Package Cleaning Procedures....2613
2.1. Cleaning Cooling Package (MaxxForce® 9, and 10 Engines) ....2614
2.2. Cleaning Cooling Package (Navistar® 11 and 13 Engines) ....2615
2.3. Charge Air Cooler Cleaning Procedure....2618
Overview....2618
Tools Required....2619
Service Parts....2619
2.3.1. Charge Air Cooler Cleaning Procedure Setup....2619
2.3.2. Off-chassis Pressure Test....2620
2.3.3. Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation....2622
2.3.4. Charge Air Cooler Cleaning Procedure....2624
2.3.5. Flushing Procedure....2625
2.3.6. Cleaning Management System (CMS) Removal Procedure....2626
3. PayStar® and 9900....2628
3.1. PayStar® and 9900 Description ....2634
3.1.1. Deaeration Tank ....2634
3.1.2. Fan Shroud ....2634
3.1.3. A/C Condenser ....2634
3.1.4. Transmission Oil Cooler ....2634
3.1.5. Radiator ....2634
3.1.6. Charge Air Cooler ....2634
3.1.7. Low-Temperature Radiator ....2634
3.1.8. Fan Drive....2635
3.2. Coolant Drain and Pressure Test Procedures....2637
3.2.1. Coolant Drain Procedure (Recommended)....2639
3.2.2. Pressure Test (Recommended)....2641
3.2.3. Coolant Fill Procedure (Recommended)....2643
3.2.4. Coolant Gravity Drain Procedure (Optional)....2646
3.2.5. Coolant Fill Procedure (Optional) Cummins® ISB6.7 Engine)....2647
3.2.6. Coolant Fill Procedure – MaxxForce 11 Liter, 13 Liter, 15 Liter (Optional)....2649
3.2.7. Coolant Fill Procedure – Cummins® ISX 15 Engines (Optional)....2652
3.3. PayStar® and 9900 Removal and Installation....2654
3.3.1. Splash Panel – Removal....2655
3.3.2. Splash Panel – Installation....2655
3.3.3. Grille – Removal....2656
3.3.4. Grille Installation....2656
3.3.5. Surge Tank (Cummins® ISB6.7 Engine) – Removal....2657
3.3.6. Surge Tank (Cummins® ISB6.7 Engine) – Installation....2657
3.3.7. Deaeration Tank – Removal....2659
3.3.8. Deaeration Tank – Installation....2660
3.3.9. A/C Condenser (N13 Engine) – Removal....2661
3.3.10. A/C Condenser (N13 Engine) – Installation....2662
3.3.11. A/C Condenser (Cummins® ISX) – Removal....2662
3.3.12. A/C Condenser (Cummins® ISX) – Installation....2663
3.3.13. Upper Fan Shroud (N13 Engine) – Removal....2664
3.3.14. Upper Fan Shroud (N13) – Installation....2666
3.3.15. Lower Fan Shroud (N13) – Removal ....2667
3.3.16. Lower Fan Shroud (N13) – Installation....2670
3.3.17. Fan Shroud (Two and Three Piece) Cummins® ISX15 Engines – Removal....2671
3.3.18. Fan Shroud (Two Piece) Cummins® ISX15 Engines – Installation ....2674
3.3.19. Fan Belt N13 – Removal....2675
3.3.20. Fan Belt (N13) – Installation....2676
3.3.21. Fan Belt (MaxxForce® 15 Engine) – Removal....2676
3.3.22. Fan Belt (MaxxForce® 15) – Installation....2678
3.3.23. Alternator Fan Belt (MaxxForce® 15) – Removal....2678
3.3.24. Alternator Fan Belt (MaxxForce® 15) – Installation....2679
3.3.25. Fan Belt (Cummins®ISX15) – Removal....2680
3.3.26. Fan Belt (Cummins® ISX15) – Installation....2681
3.3.27. Transmission Oil Cooler (Cross-member Mounted) – Removal....2682
3.3.28. Transmission Oil Cooler (Cross-member mounted) – Installation....2683
3.3.29. Transmission Oil Cooler (Front Mounted) – Removal....2684
3.3.30. Transmission Oil Cooler (Front Mounted) – Installation....2684
3.3.31. Radiator Hose Heat Shrink Clamp – Removal and Installation....2686
Heat Shrink Clamp – Removal....2686
Heat Shrink Clamp – Installation....2687
3.3.32. Radiator Hose (N13) – Removal....2689
3.3.33. Radiator Hose (N13) – Installation....2692
3.3.34. Radiator Hose (Series 9900 with Cummins® ISX15) – Removal ....2693
3.3.35. Radiator Hose (Series 9900 with Cummins® ISX15) – Installation....2696
3.3.36. Front Charge Air Cooler (N13) – Removal....2697
3.3.37. Front Charge Air Cooler (N13) – Installation....2698
3.3.38. Rear Charge Air Cooler (N13) – Removal....2699
3.3.39. Rear Charge Air Cooler (N13) – Installation....2699
3.3.40. Charge Air Cooler (Cummins® ISX15) – Removal....2700
3.3.41. Charge Air Cooler (Cummins®ISX15) – Installation....2701
3.3.42. Low-Temperature Radiator – Removal....2702
3.3.43. Low-Temperature Radiator – Installation....2704
3.3.44. Radiator Assembly (N13) – Removal....2705
3.3.45. Radiator Assembly (N13) – Installation ....2708
3.3.46. Radiator Assembly (Cummins®ISX15) – Removal....2709
3.3.47. Radiator Assembly (Cummins®ISX15) – Installation....2714
3.3.48. Recirculation Seals (MaxxForce® 11 or 13 L) – Removal....2717
3.3.49. Recirculation Seals (MaxxForce® 11 or 13 L) – Installation....2718
3.3.50. Recirculation Seals (MaxxForce® 15 L) – Removal ....2719
3.3.51. Recirculation Seals (MaxxForce® 15) – Installation ....2722
3.3.52. Radiator Core (MaxxForce® 11 L or 13 L) – Removal....2722
3.3.53. Radiator Core (MaxxForce® 11 L or 13 L) – Installation....2724
3.3.54. Radiator Core (MaxxForce® 15 L) – Removal....2724
3.3.55. Radiator Core (MaxxForce® 15 L) – Installation....2726
3.3.56. Radiator Core- Removal – (Cummins® ISX15) ....2727
3.3.57. Radiator Core Installation – (Cummins® ISX15) ....2730
3.3.58. Power Steering Oil Cooler (Cummins® ISX15) – Removal....2731
3.3.59. Power Steering Oil Cooler (Cummins® ISX15) – Installation....2731
3.4. PayStar® Inspection Procedures....2732
3.4.1. Deaeration Tank Inspection Procedure....2732
3.4.2. Deaeration Tank Cap Vacuum Relief Check....2733
3.4.3. Fan Drive Pulley Crack Inspection....2734
3.4.4. Fan Drive Pulley Nick Inspection....2734
3.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....2735
Fuel Cooler Valve (FCV) Filter Screen – Removal....2735
Fuel Cooler Valve (FCV) Filter Screen – Installation....2736
3.5. Torque Chart....2737
4. ProStar®....2739
4.1. ProStar®General Description....2745
4.1.1. Deaeration Tank....2745
4.1.2. Fan Shroud....2745
4.1.3. A/C Condenser....2745
4.1.4. Transmission Oil Cooler....2745
4.1.5. Radiator....2745
4.1.6. Charge Air Cooler....2745
4.1.7. Low-Temperature Radiator....2745
4.1.8. Fan Drive....2745
4.1.9. Power Steering Oil Cooler....2746
4.2. ProStar® Coolant Drain, Pressure Test, and Fill procedures ....2747
4.2.1. Coolant Drain Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....2751
4.2.2. Pressure Test Procedure – Navistar® 11, 13, 15, and Cummins® ISX15 (Recommended)....2753
4.2.3. Coolant Fill Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....2754
4.2.4. Coolant Drain Procedure – Navistar® 11, 13, 15, Cummins® ISX15 (Optional)....2757
4.2.5. Coolant Fill Procedure – Navistar® 11, 13, 15 (Optional)....2758
4.2.6. Coolant Fill Procedure – Cummins® ISX Engines (Optional)....2761
4.3. ProStar ® Removal and Installation....2763
4.3.1. Grille – Removal....2764
4.3.2. Grille – Installation....2764
4.3.3. Deaeration Tank Removal – Navistar® 11, 13, 15....2764
4.3.4. Deaeration Tank – Installation Navistar® 11, 13, N13, 15....2765
4.3.5. Deaeration Tank Removal – Cummins® ISX15....2766
4.3.6. Deaeration Tank Installation – Cummins® ISX15....2767
4.3.7. A/C Condenser Removal – MaxxForce® 11, 13 and N13....2768
4.3.8. A/C Condenser Installation – MaxxForce® 11, 13 or N13 ....2771
4.3.9. A/C Condenser Removal – Navistar® 15 L ....2772
4.3.10. A/C Condenser Installation – Navistar® 15 L ....2773
4.3.11. A/C Condenser Removal – Cummins® ISX15 ....2774
4.3.12. A/C Condenser Installation – Cummins® ISX15....2775
4.3.13. Fan Shroud Removal – MaxxForce® 11, 13, N13....2776
4.3.14. Fan Shroud Installation – MaxxForce® 11, 13 L and N13....2782
4.3.15. Fan Shroud Removal – (Three-Piece Upper) Navistar® 15 ....2782
4.3.16. Fan Shroud Installation – (Three-Piece Upper) Navistar® 15 ....2784
4.3.17. Fan Shroud Removal – (Three-Piece Lower) Navistar® 15 ....2785
4.3.18. Fan Shroud Installation – (Three-Piece Lower) Navistar® 15....2785
4.3.19. Fan Shroud (One-Piece) Removal – Navistar® 15....2786
4.3.20. Fan Shroud Installation – (One-Piece) Navistar® 15....2787
4.3.21. Fan Shroud Removal – (Two-Piece) Cummins® ISX15....2788
4.3.22. Fan Shroud Installation – (Two-Piece) Cummins® ISX15....2792
4.3.23. Radiator Fan Removal – Navistar® 11, 13....2792
4.3.24. Radiator Fan Installation – Navistar® 11, 13 ....2793
4.3.25. Radiator Fan Removal (With Three-Piece Fan Shroud) – Navistar® 15....2793
4.3.26. Radiator Fan Installation (With Three-Piece Fan Shroud) – Navistar® 15....2794
4.3.27. Radiator Fan Removal (With One-Piece Fan Shroud) – Navistar® 15....2794
4.3.28. Radiator Fan Installation (With One-Piece Fan Shroud) – Navistar® 15....2795
4.3.29. Radiator Fan Removal – Cummins® ISX15....2796
4.3.30. Radiator Fan Installation – Cummins® ISX15....2796
4.3.31. Fan Drive Removal – Navistar® 11, 13....2797
4.3.32. Fan Drive Installation – Navistar® 11, 13....2799
4.3.33. Fan Drive Removal – Navistar® 15....2799
4.3.34. Fan Drive Installation – Navistar® 15....2800
4.3.35. Fan Drive Assembly Removal – Cummins® ISX15 (Horton)....2800
4.3.36. Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ....2803
4.3.37. Fan Belt Removal – Navistar® 11, 13....2804
4.3.38. Fan Belt Installation – Navistar® 11, 13....2805
4.3.39. Fan Belt Removal – Navistar® 15 ....2805
4.3.40. Fan Belt Installation – Navistar® 15....2807
4.3.41. Alternator Fan Belt Removal – Navistar® 15 ....2807
4.3.42. Alternator Fan Belt Installation – Navistar® 15 ....2809
4.3.43. Fan Belt Removal – Cummins® ISX15 ....2809
4.3.44. Fan Belt Installation – Cummins® ISX15....2811
4.3.45. Radiator Hose Heat Shrink Clamp Removal and Installation....2811
Heat Shrink Clamp Removal....2811
Heat Shrink Clamp Installation....2812
4.3.46. Radiator Hose Removal – Navistar® 11, 13 ....2816
4.3.47. Radiator Hose Installation – Navistar® 11, 13....2817
4.3.48. Radiator Hose Removal – Navistar® 15 ....2818
4.3.49. Radiator Hose Installation – Navistar® 15....2819
4.3.50. Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Removal – Navistar® N13....2820
4.3.51. Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Installation – Navistar® N13....2822
4.3.52. Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Removal – Navistar® 15 ....2825
4.3.53. Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Installation – Navistar® 15....2827
4.3.54. Radiator Hose Removal – Cummins® ISX15....2830
4.3.55. Radiator Hose Installation – Cummins® ISX15 ....2832
4.3.56. Recirculation Seals Removal – Navistar® 11, 13....2833
4.3.57. Recirculation Seals Installation – Navistar® 11, 13 ....2834
4.3.58. Recirculation Seals Removal – Navistar® 15 ....2834
4.3.59. Recirculation Seals Installation – Navistar® 15....2835
4.3.60. Charge Air Cooler Removal – Navistar® 11, 13, 15....2836
4.3.61. Charge Air Cooler Installation – Navistar® 11, 13, 15....2837
4.3.62. Charge Air Cooler Removal – Cummins® ISX15....2837
4.3.63. Charge Air Cooler Installation – Cummins® ISX15....2841
4.3.64. Hood-Tilt Assist Cylinder – Removal....2842
4.3.65. Hood-Tilt Assist Cylinder – Installation....2844
4.3.66. Low-Temperature Radiator Removal – Navistar® 11, 13....2845
4.3.67. Low-Temperature Radiator Installation – Navistar® 11, 13....2847
4.3.68. Low-Temperature Radiator Removal – Navistar® 15....2848
4.3.69. Low-Temperature Radiator Installation – Navistar® 15....2852
4.3.70. Radiator Assembly Removal – Navistar® 11, 13....2853
4.3.71. Radiator Assembly Installation – Navistar® 11, 13....2854
4.3.72. Radiator Assembly Removal – Navistar® 15....2856
4.3.73. Radiator Assembly Installation – Navistar® 15....2858
4.3.74. Radiator Assembly Removal – Cummins® ISX15....2859
4.3.75. Radiator Assembly Installation – Cummins® ISX15....2865
4.3.76. Radiator Core Removal – Navistar® 11, 13....2867
4.3.77. Radiator Core Installation – Navistar® 11, 13....2870
4.3.78. Radiator Core Removal – Navistar® 15....2871
4.3.79. Radiator Core Installation – Navistar® 15....2873
4.3.80. Radiator Core- Removal – Cummins® ISX15 ....2874
4.3.81. Radiator Core Installation – Cummins® ISX15 ....2878
4.3.82. Power Steering Oil Cooler – Removal....2879
4.3.83. Power Steering Oil Cooler – Installation....2881
4.3.84. Transmission Oil Cooler Removal (Cummins® ISX15 ONLY)....2881
4.3.85. Transmission Oil Cooler – Installation....2882
4.4. ProStar® Inspection Procedures....2884
4.4.1. Deaeration Tank Inspection Procedure....2884
4.4.2. Deaeration Tank Cap Vacuum Relief Check....2885
4.4.3. Fan Drive Pulley Crack Inspection....2886
4.4.4. Fan Drive Pulley Nick Inspection....2886
4.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....2887
Fuel Cooler Valve (FCV) Filter Screen – Removal....2887
Fuel Cooler Valve (FCV) Filter Screen – Installation....2888
4.5. Torque Chart Navistar® Engines....2889
5. TranStar®....2892
5.1. TranStar® General Description....2897
5.1.1. Deaeration Tank....2897
5.1.2. Fan Shroud....2897
5.1.3. A/C Condenser....2897
5.1.4. Transmission Oil Cooler....2897
5.1.5. Radiator....2897
5.1.6. Charge Air Cooler....2897
5.1.7. Low-Temperature Radiator....2897
5.1.8. Fan Drive....2897
5.2. TranStar® Coolant Drain, Pressure Test, and Fill procedures....2898
5.2.1. Coolant Drain, Pressure Test, and Fill procedures (Recommended)....2901
5.2.2. Pressure Test Procedure (Recommended)....2903
5.2.3. Coolant Fill Procedure (Recommended)....2906
5.2.4. Coolant Drain Procedure (Optional)....2909
5.3. TranStar® Removal and Installation....2910
5.3.1. Grille – Removal....2911
5.3.2. Grille – Installation....2911
5.3.3. Deaeration Tank – Removal....2911
5.3.4. Deaeration Tank – Installation....2912
5.3.5. A/C Condenser – Removal....2914
5.3.6. A/C Condenser – Installation....2916
5.3.7. Fan Shroud – Removal....2917
5.3.8. Fan Shroud – Installation....2920
5.3.9. Radiator Fan – Removal....2920
5.3.10. Radiator Fan – Installation....2921
5.3.11. Fan Clutch – Removal....2922
5.3.12. Fan Clutch – Installation....2923
5.3.13. Fan Belt – Removal....2924
5.3.14. Fan Belt – Installation....2926
5.3.15. Heat Shrink Clamp Removal and Installation....2926
Heat Shrink Clamp Removal....2926
Heat Shrink Clamp Installation....2927
5.3.16. Radiator Hose – Removal....2930
5.3.17. Radiator Hose – Installation....2934
5.3.18. Charge Air Cooler – Removal....2935
5.3.19. Charge Air Cooler – Installation....2937
5.3.20. Low-Temperature Radiator – Removal....2938
5.3.21. Low-Temperature Radiator – Installation....2939
5.3.22. Radiator Assembly – Removal....2940
5.3.23. Radiator Assembly – Installation....2942
5.3.24. Radiator Core – Removal....2943
5.3.25. Radiator Core – Installation....2945
5.3.26. Transmission Oil Cooler (Crossmember mounted) – Removal....2946
5.3.27. Transmission Oil Cooler (Crossmember mounted) – Installation....2946
5.4. TranStar® Inspection Procedures....2948
5.4.1. Deaeration Tank Inspection Procedure....2948
5.4.2. Deaeration Tank Cap Vacuum Relief Check....2949
5.4.3. Fan Drive Pulley Crack Inspection....2950
5.4.4. Fan Drive Pulley Nick Inspection....2950
5.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....2951
Fuel Cooler Valve (FCV) Filter Screen – Removal....2951
Fuel Cooler Valve (FCV) Filter Screen – Installation....2952
5.5. Torque Chart....2953
6. WorkStar®....2954
6.1. WorkStar® and 9900 Description....2960
6.1.1. Surge Tank (If Equipped) ....2960
6.1.2. Deaeration Tank....2960
6.1.3. Fan Shroud....2960
6.1.4. Fan Drive....2960
6.1.5. A/C Condenser....2960
6.1.6. Radiator....2960
6.1.7. Charge Air Cooler....2960
6.1.8. Cross-Member....2960
6.1.9. Low-Temperature Radiator....2961
6.1.10. Low Temperature Radiator (LTR) Thermostat....2961
6.1.11. Fuel Cooler....2961
6.1.12. Transmission Oil Cooler....2961
6.2. WorkStar® Coolant Drain, Pressure Test, and Fill procedures....2962
6.2.1. Coolant Drain Procedure (Recommended)....2965
6.2.2. Pressure Test Procedure (Recommended)....2967
6.2.3. Coolant Fill Procedure (Recommended)....2970
6.2.4. Coolant Gravity Drain Procedure (Optional)....2973
6.2.5. Coolant Fill Procedure (MaxxForce® 9, and 10 Engines) (Optional)....2974
6.2.6. Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....2976
6.2.7. Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....2978
6.3. WorkStar® Removal and Installation....2981
6.3.1. Grille (Standard) – Removal....2982
6.3.2. Grille (Standard) – Installation....2982
6.3.3. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....2982
6.3.4. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....2983
6.3.5. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....2983
6.3.6. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....2984
6.3.7. Splash Panel (Standard) – Removal....2984
6.3.8. Splash Panel (Standard) – Installation....2985
6.3.9. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....2985
6.3.10. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....2986
6.3.11. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....2986
6.3.12. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....2987
6.3.13. Surge Tank (with Cummins® ISB6.7 Engine) – Removal....2987
6.3.14. Surge Tank (with Cummins® ISB6.7 Engine) – Installation....2988
6.3.15. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Removal....2988
6.3.16. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Installation....2989
6.3.17. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....2990
6.3.18. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....2991
6.3.19. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....2991
6.3.20. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....2992
6.3.21. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Removal ....2993
6.3.22. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Installation....2995
6.3.23. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Removal....2995
6.3.24. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Installation....2996
6.3.25. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....2997
6.3.26. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....2998
6.3.27. A/C Condenser (Navistar® 11 and 13 Engines) – Removal....2998
6.3.28. A/C Condenser (Navistar® 11 and 13 Engines) – Installation....2999
6.3.29. A/C Condenser (ISB6.7) Engine – Removal....3000
6.3.30. A/C Condenser (ISB6.7 Engine) – Installation....3000
6.3.31. Fan Belt with A/C (Cummins® ISB6.7 Engine) - Removal ....3001
6.3.32. Fan Belt with A/C (Cummins® ISB6.7 Engine) – Installation ....3001
6.3.33. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Removal....3003
6.3.34. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Installation....3005
6.3.35. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....3006
6.3.36. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....3007
6.3.37. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....3007
6.3.38. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....3009
6.3.39. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3010
6.3.40. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3012
6.3.41. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3012
6.3.42. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....3014
6.3.43. Fan Shroud (Cummins® ISB6.7 Engine) 7 similar - Removal....3014
6.3.44. Fan Shroud - Installation....3015
6.3.45. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Removal....3015
6.3.46. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Installation....3016
6.3.47. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Removal....3016
6.3.48. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Installation....3018
6.3.49. Radiator Fan (Standard) – Removal....3019
6.3.50. Radiator Fan (Standard) – Installation....3020
6.3.51. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....3020
6.3.52. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....3021
6.3.53. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3022
6.3.54. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3022
6.3.55. Heat Shrink Clamp Removal and Installation....3023
Heat Shrink Clamp Removal....3023
Heat Shrink Clamp Installation....3024
6.3.56. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Removal....3026
6.3.57. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Installation....3028
6.3.58. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....3028
6.3.59. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....3031
6.3.60. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....3032
6.3.61. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....3034
6.3.62. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3034
6.3.63. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3038
6.3.64. Coolant Package – Removal....3039
Overview....3039
6.3.65. Coolant Package – Installation....3043
6.3.66. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....3045
6.3.67. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....3046
6.3.68. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....3047
6.3.69. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....3047
6.3.70. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....3048
6.3.71. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....3051
6.3.72. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3052
6.3.73. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3053
6.3.74. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....3054
6.3.75. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....3056
6.3.76. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3056
6.3.77. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3057
6.3.78. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Removal....3058
6.3.79. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Installation....3060
6.3.80. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....3060
6.3.81. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....3061
6.3.82. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....3061
6.3.83. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....3064
6.3.84. Low Temperature Radiator (LTR) Thermostat – Removal....3065
6.3.85. Low Temperature Radiator (LTR) Thermostat – Installation....3066
6.3.86. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Removal....3068
6.3.87. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Installation....3072
6.3.88. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....3074
6.3.89. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation ....3080
6.3.90. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....3083
6.3.91. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....3085
6.3.92. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3086
6.3.93. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3088
6.3.94. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....3089
6.3.95. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....3090
6.3.96. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....3091
6.3.97. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....3092
6.3.98. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3092
6.3.99. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3093
6.3.100. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....3093
6.3.101. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....3094
6.3.102. Low Temperature Radiator Hoses – Removal....3094
6.3.103. Low Temperature Radiator (LTR) Thermostat Hose – Installation....3096
6.4. WorkStar® Inspection Procedures....3098
6.4.1. Deaeration Tank Inspection Procedure....3098
6.4.2. Deaeration Tank Cap Vacuum Relief Check....3099
6.4.3. Fan Drive Pulley Crack Inspection....3100
6.4.4. Fan Drive Pulley Nick Inspection....3100
6.4.5. 12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....3101
6.4.6. 12TTD Borg – Warner 842B Visctronics Inspection Procedure....3102
6.4.7. Fuel Cooler Valve (FCV) Inspection Procedure....3102
Fuel Cooler Valve (FCV) Filter Screen – Removal....3102
Fuel Cooler Valve (FCV) Filter Screen – Installation....3104
6.5. Torque Chart....3105
7. 12THT Horton DriveMaster Fan Drive System....3109
7.1. 12THT Horton Drivemaster Fan Drive System Removal and Installation....3109
7.1.1. 12THT Radiator Fan (N13) – Removal....3109
7.1.2. 12THT Radiator Fan (N13) – Installation....3109
7.1.3. 12THT Radiator Fan (Cummins® ISX15) – Removal....3110
7.1.4. 12THT Radiator Fan Cummins® ISX15 – Installation....3110
7.1.5. Fan Removal – (12THZ and 12THT Horton DA) (optional)....3111
7.1.6. Fan Installation – (12THZ and 12THT Horton DA) (optional)....3111
7.1.7. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....3112
7.1.8. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....3113
7.1.9. 12THT Horton (DMA) Serviceable Fan Drive – Removal....3113
7.1.10. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....3117
7.1.11. 12THT Pulley Bearing – Removal....3118
7.1.12. 12THT Pulley Bearing – Installation....3118
7.1.13. 12THT Fan Drive Friction Liner– Removal....3119
7.1.14. 12THT Fan Drive Friction Liner – Installation....3121
7.1.15. 12THT Clutch Pack Seal Face – Removal....3122
7.1.16. 12THT Clutch Pack Seal Face – Installation....3122
7.1.17. 12THT Air Cartridge – Removal....3122
7.1.18. 12THT Air Cartridge – Installation....3123
7.2. 12THT Horton Drivemaster Fan Drive System Inspection Procedures....3125
7.2.1. Fan Drive Movement / Clutch Pack Bearing Check....3125
7.2.2. Clutch Pack Face Seal....3126
7.2.3. Cartridge Assembly Seal and Spring....3127
7.2.4. Friction Liner Measurement....3128
7.2.5. Fan Drive Bearing Measurement and Inspection....3129
7.3. 12THT Horton Drivemaster Fan Drive System Diagnostics....3130
7.3.1. 12THT Horton DriveMaster Fan Drive Operational Checks....3130
Overview....3130
Tools Required....3130
Operational Checks – Start Fan Drive Diagnostics Here....3130
Visual Air Leak Check....3130
7.3.2. Symptom 1: Fan Always On....3133
7.3.3. Symptom 2: Fan Always Off....3149
7.3.4. Symptom 3: Cycles Too Frequently....3155
7.3.5. Symptom 4: Excessive Noise From Fan Drive....3157
8. 12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics ....3159
8.1. Start Diagnostics here: 12TTD Borg-Warner 842B Visctronic Fan Drive....3159
Overview....3159
Tools Required....3159
Operational Checks – Start Fan Drive Diagnostics Here....3159
8.2. Symptom 1: Fan Always ON....3161
8.3. Symptom 2: Fan Always OFF....3167
8.4. Symptom 3: Cycles Too Frequently....3184
8.5. Symptom 4: Excessive Noise From Fan Drive....3187
9. 12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....3189
9.1. Start Diagnostics Here: 12TSY Borg-Warner SA85 Fan Drive Assembly....3189
Overview....3189
Tools Required....3189
10. 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly....3191
10.1. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly Removal and Installation....3191
Tools Required....3191
10.1.1. 12TKY Borg-Warner Fan Drive Clutch Lining – Removal....3191
10.1.2. 12TKY Borg-Warner Fan Drive Clutch Lining – Installation....3191
10.1.3. 12TKY Borg-Warner Fan Drive and Hub Assembly – Removal....3192
10.1.4. 12TKY Borg-Warner Fan Drive and Hub Assembly – Installation....3192
10.2. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Inspection....3194
10.2.1. 12TKY Borg-Warner Fan Drive Clutch Friction Lining Inspection....3194
10.3. Start Diagnostics here: 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Diagnostics....3195
Overview....3195
Tools Required....3195
Operational Checks – Start Fan Drive Diagnostics here....3195
10.4. Symptom 1: Fan Always On....3197
10.5. Symptom 2: Fan Always Off....3198
10.6. Symptom 3: Fan Cycles Too Frequently....3199
10.7. Clutch Will Not Engage....3199
10.8. Clutch Will Not Disengage....3200
10.9. Air Leak In Drive....3201
10.10. Symptom 4: Excessive Noise From Fan Drive....3202
11. 12THX Horton Stratis V-Master-Ultra Viscous Fan Drive Assembly System....3205
11.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly Removal and Installation....3205
11.1.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Removal....3205
11.1.2. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Installation....3206
11.2. 12THX Horton Stratis Viscous Fan Drive Assembly System Diagnostics....3207
11.2.1. 12THX Horton Stratis Viscous Fan Drive Assembly Diagnostics – Operations Checks....3207
Overview....3207
Tools Required....3207
Operational Checks – Start Fan Drive Diagnostics here....3207
Visual Air Leak Check....3207
11.3. 12THX Horton Stratis Fan Drive Inspection, Pin Point Test, and ServiceMaxx™ Engine Fan Test....3210
11.3.1. Fan Drive Inspection....3210
11.3.2. Fan Drive Pin Point Test....3211
11.4. ServiceMaxx Engine Fan Test™....3211
11.5. Engine Fan Test Results....3214
11.5.1. Engine Fan Test Overview....3214
11.5.2. Properly Working Fan Hub Assembly....3214
11.6. Fan Engages Prematurely....3215
11.7. Symptom 1: Fan Always On....3215
11.8. Symptom 2: Fan Always Off....3216
11.9. Symptom 3: Fan Cycles Too Frequently....3217
11.10. Symptom 4: Excessive Noise From Fan Drive....3218
12. Abbreviations and Acronyms....3220
13. Terminology....3221
tables....2737
Table 7Torque Chart....2737
Table 13Torque Chart Navistar® Engines....2889
Table 14Torque Chart Cummins® ISX15 Engine....2891
Table 20Torque Chart....2953
Table 28Torque Chart....3105
1087459R2 - 9300 Series Electrical Circuit Diagrams 1988 (Supersedes CTS-4382E) Circuit Diagrams....3224
Blank Page....3225
4328434 - New Truck Processing Manual....3290
toc....3292
Table of Contents....3292
Introduction....3294
Safety....3294
UNDECKING AND STORAGE....3295
INTRODUCTION....3295
ASSISTANCE TO DEALER ....3295
DEALER RESPONSIBILITIES FOR UNDECKING EXPENSE....3295
CORRECT UNDECKING FACILITY CONFIGURATION....3295
LOAD LIMIT....3296
NEW VEHICLE RECEIVING PROCEDURES....3297
CARRIER DELIVERY and INSPECTION RESPONSIBILITIES ....3297
DEALER RECEIVING RESPONSIBILITIES ....3297
DEALER DELIVERY and INSPECTION RESPONSIBILITIES ....3297
VEHICLE STORAGE....3298
Storage Duration — Two Months Or Less....3298
Storage Duration — Over Two Months....3300
Storage Facilities....3300
NEW TRUCK RECEIVING AND DAMAGE CLAIM PROCESSING....3301
INTRODUCTION....3301
Exceptions....3301
Concealed Damage:....3301
CARRIER'S UNDECKING RESPONSIBILITIES....3301
VEHICLE RECEIVING / INSPECTION....3302
AFTER-HOURS DELIVERY....3302
DELIVERIES TO BODY COMPANIES OR FLEET LOCATIONS....3303
CONCEALED DAMAGE....3304
CARRIER DELIVERY RECEIPT....3304
Important:....3304
FILLING OUT THE DELIVERY RECEIPT....3304
FILING A DAMAGE AND LOSS CLAIM....3305
Supporting Documents....3306
VEHICLES NOT BUILT TO ORDER....3307
INTRODUCTION....3307
TRUCKS NOT BUILT TO ORDER — U.S. AND CANADA....3307
CHECKING ORDER CONFIRMATION — U.S. and CANADA....3307
CLAIM PROCEDURES (USE “TRUCK NOT BUILT TO ORDER” CLAIM FORM)....3308
U.S. AND CANADA:....3308
CLAIM FORM — TRUCK NOT BUILT TO ORDER....3310
ORDER CONTENT CONFIRMATION REPORT....3311
VEHICLE SAFETY CERTIFICATION....3315
INTRODUCTION....3315
INTERNATIONAL® MODEL LINEUP....3315
PENALTIES FOR VIOLATIONS....3316
CERTIFICATION....3316
PREPARATION AND DELIVERY....3317
INTRODUCTION....3317
NEW VEHICLE PRE-DELIVERY SERVICE ....3317
PREPARATION AND DELIVERY (P&D) REIMBURSEMENT (U.S. ONLY)....3317
NON-REIMBURSEMENT ADDENDUM ....3317
“Will Call”- Truck Specialty Center (TSC)....3318
Vehicle Identification Label....3318
CTS-1122, PRE-DELIVERY SERVICE IDENTIFICATION STICKER ....3318
New Vehicle Processing Documentation....3319
Quality Inspection Report....3319
FINAL DELIVERY GUIDELINES....3320
INTRODUCTION....3320
FINAL DELIVERY GUIDELINES....3320
Introduction....3320
Before Vehicle Pick-Up Or Delivery....3320
During Vehicle Pick-Up Or Delivery....3320
tables....3296
Table 1VEHICLE HOIST REQUIREMENT CHART....3296
CTS-5119TA - 5000, 9200, 9300 and 9400 Electrical Circuit Diagrams Built After July 12, 1996....3321
S02005R - Rockwell Front Non-Drive Steering Axle, Supersedes CTS-5046R (April 1996) Service Manual....3559
S02006 - Front Steer Axle_ Eaton EFA-12, Supersedes CTS-5171 (April 1996) Service Manual....3608
S02007 - Front Steer Axle_ Eaton E1200I I-Beam, Supersedes CTS-5212 (March 1996) Service Manual....3647
S02008 - Rockwell Front Drive Axle Wheel Ends, Supersedes CTS-5081 (April 1996) Service Manual....3671
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual....3720
S03002R - Neway Air Suspension, Supersedes CTS-5028R (March 1996) Service Manual....3741
S03007 - Hendrickson Air Suspension with Trailing Leaf Springs, Supersedes CTS-5125 (March 1996) Service Manual....3776
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual....3802
S03010 - Neway AD-123_246 Drive Axle Air Suspensions, Supersedes CTS-5191 (March 1996) Service Manual....3816
S03011 - Hendrickson HN-460 Suspension, Supersedes CTS-5221 (March 1996) Service Manual....3839
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual....3872
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual....3913
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual....3947
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual....3991
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual....3996
S04011 - Air Compressor_ Midland Models EL-1300 and EL-1600, Supersedes CTS-5146 (March 1996) Service Manual....4019
S04013 - Stopmaster Wedge Type Brake, Supersedes CTS-5172 (March 1996) Service Manual....4046
S04014 - Air Compressor_ Holset SS 296 and QE 296_338, Supersedes CTS-5197 (March 1996) Service Manual....4086
S04020X - DCM and DDM Drum Type Parking Brake, Supersedes CTS-5135TA (July 1997) Service Manual....4162
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual....4188
S04022 - Antilock Air Brake System_ Bendix, Supersedes CTS-5059 (April 1998) Service Manual....4214
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual....4323
S04038 - EC-17 Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Service Manual....4349
S04042 - Antilock Brakes _ Traction Control Troubleshooting_ Bendix Built March 1, 1998 and After, Supersedes CTS-5291 (Aug 2000) Service Manual....4418
S04053 - ECE-13 Brake System (2010) Service Manual....4461
S04055 - MCAC 465 Air Compressor Model PayStar, ProStar, TranStar, and WorkStar Vehicles SERVICE MANUAL....4497
toc....4499
Table of Contents....4499
1. DESCRIPTION....4501
1.1. Components....4502
Cylinder Head....4502
Crankcase....4503
1.2. Name Plate....4503
2. Compressor Maintenance....4504
3. Remove and Install Procedures....4505
3.1. MCAC 476 Air Compressor....4506
MCAC 476 Air Compressor – Removal....4506
MCAC 476 Air Compressor – Installation....4507
3.2. MCAC 476 Air Compressor Disassembly....4508
Cylinder Head Disassembly....4508
Crankcase Disassembly....4510
Drive Gear Removal....4511
Air Cylinder Cover Removal....4512
Crankcase Removal....4513
Air Cylinder Removal....4514
Air Cylinder Disassembly....4515
Clutch Housing Disassembly....4516
Piston Removal....4517
3.3. MCAC 476 Air Compressor – Assembly....4518
Crankcase Assembly....4518
Clutch Housing Assembly....4519
Air Cylinder Assembly....4520
Air Cylinder Installation....4521
Crankshaft Installation....4522
Air Cylinder Cover Installation....4523
Center Shaft Installation....4524
Center Shaft Nut Installation....4525
Cylinder Head Assembly (Lower)....4526
Cylinder Head Assembly (Upper)....4527
4. Troubleshooting....4528
4.1. Troubleshooting Table....4528
4.2. Tests....4532
Oil Leakage at the Head Gasket Test....4532
Air Brake System and Accessory Leakage Test....4532
Air Compressor Discharge Temperature and Air Dryer Inlet Tempera....4533
Governor Malfunction Test....4534
Governor Control Line Test....4534
Compressor Clutch Operation - No Air Charging Test....4534
Compressor Clutch Operation - Continuous Air Charging Test....4534
tables....4535
Table 3Torque Chart....4535
S04057 - ECE-13 Brake System Service Manual (9800 LHD) (2010) Service Manual....4536
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual....4564
S05004 - Power Steering Gear_ Sheppard Model 292, 392, 492, Supersedes CTS-5218 (April 1996) Service Manual....4641
S05009T - Steering Column Assembly, Tilt_Telescoping, Supersedes CTS-5072T (Feb 1997) Service Manual....4731
S05010T - 9600, 9700, 9800 Models Steering Column Assembly, Tilt, Supersedes CTS-5073T (Feb 1997) Service Manual....4746
S05011 - 5000, 9200, 9300, 9400 Steering Column Assembly, Standard, Supersedes CTS-5078 (May 1996) Service Manual....4770
S05015Y - Power Steering Gear_ Sheppard M-Series, Supersedes CTS-5262 (Sept 2000) Service Manual....4787
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual....4882
S08007 - 9200, 9300, 9400 Model Pro Sleeper Electrical System, Supersedes CTS-5201 (July 1992) Service Manual....4963
S08018 - 9100, 9200, 9300, 9400, 9600, 9700, and 9800 Model Alternator (Delco-Remy 26-SI Series), Supersedes CTS-5077 (March 1996) Service Manual....5035
S08033 - General Instrument Electronic Programmable Speedometer _ Tachometer, Supersedes CTS-5048 (1991) Service Manual....5056
S08035X - 9200, 9300 and 9400 Gauges and Warning Lights, Supersedes CTS-5180 (Oct 1999) Service Manual....5090
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual....5157
S08127 - 9300 and 9400 Electronic Engine Controls - General Information, Supersedes CTS-5051-I (1991) Service Manual....5186
S08154X - Speedometer _ Tachometer Diagnostics and Service, Supersedes CTS-5257 (Oct 1999) Service Manual....5196
S08156 - 9800 Series Heating, Ventilation, and Air Conditioning (HVAC) Troubleshooting Guide, Supersedes CTS-5275 (Feb 1998) Service Manual....5285
S08157 - 9200, 9300 and 9400 Models with Pro Sleeper and Skyrise Sleeper Heating, Ventilation, and Air Conditioning (HVAC) Troubleshooting Guide, Supersedes CTS-5284 (Feb 1998) Service Manual....5354
toc....5356
Table of Contents....5356
1. Heater and Air Conditioner (CAB)....5358
1.1. DESCRIPTION....5358
1.2. OPERATION....5358
1.3. TROUBLESHOOTING....5359
Cab Heater....5360
Cab Air Conditioner....5365
1.4. COMPONENT LOCATIONS....5370
2. HEATER AND AIR CONDITIONER BLOWER WITH STANDARD TEMPERATURE CONTROL (SLEEPER)....5384
2.1. DESCRIPTION....5384
2.2. OPERATION....5384
2.3. TROUBLESHOOTING....5385
Heater and Air Conditioner Blower (Sleeper)....5385
Air Conditioner (Cab/Sleeper)....5391
Standard Temperature Control (Sleeper)....5395
2.4. COMPONENT LOCATIONS....5397
3. HEATER AND AIR CONDITIONER BLOWER WITH THERMOSTAT TEMPERATURE CONTROL (SLEEPER)....5405
3.1. DESCRIPTION....5405
3.2. OPERATION....5405
3.3. TROUBLESHOOTING....5406
Heater and Air Conditioner Blower (Sleeper)....5406
Air Conditioner (Cab/Sleeper)....5412
Thermostat Temperature Control (Sleeper)....5417
3.4. COMPONENT LOCATIONS....5419
tables....5360
Table 1Cab Heater....5360
Table 2Cab Air Conditioner....5365
Table 3Component Locations....5383
Table 4Heater and Air Conditioner Blower (Sleeper)....5385
Table 5Air Conditioner (Cab/Sleeper)....5391
Table 6Standard Temperature Control (Sleeper)....5395
Table 7Component Locations....5404
Table 8Heater and Air Conditioner Blower (Sleeper)....5406
Table 9Air Conditioner (Cab/Sleeper)....5412
Table 10Thermostat Temperature Control (Sleeper)....5417
Table 11Component Locations....5425
S08184 - 9200, 9400 and 9900 Chassis (Only with Pro Sleeper Cab) Built October 1, 1998 to July 18, 1999 Electrical Circuit Diagrams, Supersedes CTS-5273W (Oct 1998)....5427
S08185 - 5000, 9100, 9200, 9400 and 9900 Chassis (Only with Daycab and With or Without Box Sleeper) Built October 1, 1998 To July 18, 1999 Electrical Circuit Diagrams, Supersedes CTS-5119W (Oct 1998)....5616
S08191 - 5000, 9100, 9200, 9400,and 9900 Models Electrical System Troubleshooting Guide, Supersedes CTS-5301 (Feb 1999) Service Manual....5802
S08207X - 5000i, 5000, 9000, 9000i Model Gauges and Warning Lights, Supersedes CTS-5293 (Oct 1999) Circuit Diagrams....6402
S08210 - 5000i, 9000i, 9100i, 9200i, 9400i and 9900i Model Electrical System Troubleshooting Guide (June 2002) Service Manual....6510
S08225 - 5000i, 9100 i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built June 3, 2002 and After....7120
S082252 - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built from June 3, 2002 To November 3, 2002....7358
S082252A - 5000i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built November 4, 2002 to November 30, 2005....7597
S082252AZ....7597
S082252AB....7685
S082252AC....7736
S08225Y - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built July 19, 1999 To August 31, 2000 Circuit Diagrams....7829
S08225YA - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built September 1, 2000 To June 2, 2002 Circuit Diagrams....8055
S08242W - 9800 Model Electrical Circuit Diagram Built November 1, 1998 to March 31, 2004 Circuit Diagrams....8281
toc....8283
Table of Contents....8283
INSTRUCTIONS AND CHARTS (Chapter 1)....8287
1.1. Circuit Number Identification and Color Chart, p. 1....8287
1.2. Circuit Number Identification and Color Chart, p. 2....8288
1.3. Circuit Diagram Instructions, p. 3....8289
1.4. Circuit Diagram Instructions, p. 4....8290
1.5. Schematic Symbols, p. 5....8291
1.6. Relay Pinout, Function Data & Sealed Miniature Relay Data, ....8292
1.7. Lamp Bulb Chart, p. 7....8293
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....8294
2.1. Start Feed, p. 1....8294
2.2. Accessory, p. 2....8295
2.3. Battery, p. 3....8296
2.4. B1 Battery Stud, p. 4....8297
2.5. B2 Battery Stud, p. 5....8298
2.6. 3+1 Battery System, p. 6....8299
2.7. Ground Adapter Composite, p. 7....8300
2.8. Ignition, p. 8....8301
2.9. Panel Lights Adapter Composite, p. 9....8302
2.10. Panel Lights Adapter Composite (Cont.), p. 10....8303
12 VOLT CHARGING & CRANKING SYSTEM (Chapter 3)....8304
3.1. With Cummins M11 and N14 Engines, p. 1....8304
3.2. With Cummins ISM Engines, p. 2....8305
3.3. With Detroit Diesel Series 60 Engines, p. 3....8306
3.4. With Thermal Overcrank Protection, p. 4....8307
ENGINES (Chapter 4)....8308
4.1. Cummins M11 and N14 — Electronic Engine Controls, p. 1....8308
4.2. Cummins M11 and N14 — Electronic Engine Controls, p. 2....8309
4.3. Cummins M11 and N14 — Cruise Control, p. 3....8310
4.4. Cummins M11, N14 — Engine Brake, p. 4....8311
4.5. Cummins ISM — Electronic Engine Controls, p. 5....8312
4.6. Cummins ISM — Electronic Engine Controls, p. 6....8313
4.7. Cummins ISM – Cruise Control, p. 7....8314
4.8. Cummins ISM – Engine Brake, p. 8....8315
4.9. Detroit Diesel Series 60 – Engine Controls, p. 9....8316
4.10. Detroit Diesel Series 60 – Engine Controls, p. 10....8317
4.11. Detroit Diesel Series 60 – Cruise Control, p. 11....8318
4.12. Detroit Diesel Series 60 – Engine Brake, p. 12....8319
4.13. Detroit Diesel Series 60 – Optimized Idle, p. 13....8320
FANS (Chapter 5)....8321
5.1. Horton and Kysor Engine Fan With Cummins M11 and N14 W/ and....8321
5.2. Horton and Kysor Engine Fan With Cummins ISM W/ and N/ Air ....8322
5.3. Horton and Kysor Engine Fan With Detroit Diesel Series 60 W....8323
TRANSMISSION, DISPLAYS, ETHER START (Chapter 6)....8324
6.1. With Dana Automate Top II Transmission, p. 1....8324
6.2. With Dana Automate Top II Transmission, p. 2....8325
6.3. Cummins Road Relay Display, p. 3....8326
6.4. Detroit Pro Driver Data Display, p. 4....8327
6.5. Engine Systems — Ether Start, p. 5....8328
6.6. Eaton Autoshift Transmission With Detroit Diesel 60 or Cumm....8329
6.7. Eaton Autoshift Transmission With Detroit Diesel 60 or Cumm....8330
GAUGES AND SYSTEMS (Chapter 7)....8331
7.1. Axle: Forward-Rear and Rear-Rear Temperature Gauge, p. 1....8331
7.2. Engine Oil Temperature Gauge With Detroit Series 60 Engine,....8332
7.3. Engine Oil Temperature Gauge With Cummins N14, M11 and ISM ....8333
7.4. Engine Water Temperature Gauge, p. 4....8334
7.5. Fuel Level Gauge, p. 5....8335
7.6. Pyrometer Gauge, p. 6....8336
7.7. Tachometer Gauge — Speedometer Gauge, p. 7....8337
7.8. Transmission Temperature Gauge, p. 8....8338
7.9. Voltmeter Gauge, p. 9....8339
WARNING LIGHTS (Chapter 8)....8340
8.1. Air Suspension Release Warning Light, p. 1....8340
8.2. Low Air Pressure Warning Light, p. 2....8341
8.3. PDL Warning Light and Alarm, p. 3....8342
CAB ACCESSORIES (Chapter 9)....8343
9.1. Cigar Lighter (Cab), p. 1....8343
9.2. Electric Window — Left, p. 2....8344
9.3. Electric Window — Right, p. 3....8345
9.4. Electric Windshield Wiper With Intermittent Wipe and Wash, ....8346
9.5. Horn, p. 5....8347
9.6. Mirror Lights and Heated Mirrors, p. 6....8348
9.7. Right Motorized Mirror, p. 7....8349
9.8. Dual Axis Motorized Mirrors, p. 8....8350
9.9. Power Source (CB), p. 9....8351
9.10. Radio — CB Accommodation Package, p. 10....8352
9.11. Radio — Cab Speakers, p. 11....8353
9.12. Fans — Windshield Defroster, p. 12....8354
9.13. Omnitracs Mobile Comm System, p. 13....8355
CHASSIS ACCESSORIES (Chapter 10)....8356
10.1. Air Dryer and Heated Fuel Filter, p. 1....8356
10.2. Bendix ABS/ATC, p. 2....8357
10.3. Bendix ABS/ATC (Cont.), p. 11....8358
10.4. ABS/ATC (Wabco), p. 4....8359
10.5. ABS/ATC (Wabco) (Cont.), p. 5....8360
10.6. Trailer Connection N/Sleeper — Back of Cab Mounted, p. 6....8361
10.7. Trailer Connection W/Sleeper — Mounted Back of Sleeper, p....8362
SLEEPER LIGHTING AND ACCESSORIES (Chapter 11)....8363
11.1. Spotlights, Bunk Fluorescent and Reading Lights, and Cigar....8363
11.2. Spotlights, Bunk Fluorescent and Reading Lights, and Cigar....8364
11.3. Bunk Fluorescent and Reading Lights, and Cigar Lighter (Ra....8365
11.4. Radio, Cab Speakers and Bunk Speakers (Flat Cab Roof), p. ....8366
11.5. Radio, Cab Speakers and Bunk Speakers (Raised Cab Roof), p....8367
11.6. Luggage Compartment Light — Right and Left, p. 6....8368
11.7. Refrigerator Wiring, p. 7....8369
11.8. TV/VCR Wiring, p. 8....8370
LIGHT SYSTEMS (Chapter 12)....8371
12.1. Back-Up Lights, p. 1....8371
12.2. Cab and Trailer Light Switch and Relay Wiring, p. 2....8372
12.3. Cab Clearance and Identification Lights — Flat Roof, p. 3....8373
12.4. Cab Clearance and Identification Lights — Raised Roof, p. ....8374
12.5. Cab Dome, Reading, Courtesy Lights and Switches, p. 5....8375
12.6. Daytime Running Lights (DRL) — Canada, p. 6....8376
12.7. Daytime Running Lights (DRL) — USA, p. 7....8377
12.8. Headlight, p. 8....8378
12.9. Headlights W/ and N/DRL — 9800SFA, p. 9....8379
12.10. Headlights W/ and N/DRL — 9800SBA, p. 10....8380
12.11. Panel Lights, p. 11....8381
12.12. Panel Lights (Cont.), p. 12....8382
12.13. Front Park, Turn and Marker Lights — 9800SFA, p. 13....8383
12.14. Front Turn-Park-Marker and Side Turn-Marker Lights W/SBA,....8384
12.15. Stop, Tail, Turn and Hazard Signal Lights, p. 15....8385
12.16. Trailer Work (Hook-up) Light Back of Cab Mounted, p. 16....8386
HEATER AND AIR CONDITIONER (Chapter 13)....8387
13.1. Air Conditioner — Cab, p. 1....8387
13.2. HVAC — Cab, p. 2....8388
13.3. HVAC — Bunk W/Pro Sleeper Blower, p. 3....8389
13.4. HVAC — Bunk W/Pro Sleeper W/Standard Temperature Control, ....8390
13.5. HVAC — Bunk W/Pro Sleeper W/Thermostat Temperature Control....8391
CONNECTOR COMPOSITES (Chapter 14)....8392
14.1. Instrument Cluster (Left Gauge Cluster), p. 1....8392
14.2. Instrument Cluster (Cluster Conn. 73), p. 2....8393
14.3. Instrument Cluster (Right Gauge Cluster), p. 3....8394
14.4. Instrument Cluster (Cluster Conn. 72), p. 4....8395
14.5. Connectors (2), (3), (4), (4A), (5), (7), (9), (10), p. 5....8396
14.6. Connectors (11), (12), (13), (16), (17), (18), (19), (20),....8397
14.7. Connectors (21), (22), (23), (24), (25), (27), (29), p. 7....8398
14.8. Connectors (30), (31), (34), (36), (37), (39), p. 8....8399
14.9. Connectors (40), (41), (42), (43), (44), (45), p. 9....8400
14.10. Connectors (48), (51), (52), (54), (55), (56), p. 10....8401
14.11. Connectors (57), (58), (59), (60), (62), (63), (64), (65)....8402
14.12. Connectors (67), (68), (69), (70), (71), (72), (73), p. 1....8403
14.13. Connectors (80), (81), (83), (84), (85), (86), p. 13....8404
14.14. Connectors (102), (114), (116), p. 14....8405
14.15. Connectors (87), (88), (94), (95), (97), p. 15....8406
14.16. Connectors (122), (123), (125), (127), (136), (155), p. 1....8407
14.17. Connectors (156), (157), (189), (207), (214), (220), (225....8408
14.18. Connectors (236), (239), (240), (241), (242), (243), (244....8409
14.19. Connectors (262), (263), p. 19....8410
14.20. Connectors (265), (278), (284), (293), (302), (306), (307....8411
14.21. Connectors (309), (310), (316), (328), (332), (338), (340....8412
14.22. Connectors (341), (342), (345), (347), p. 22....8413
14.23. Connectors (350), (351), (352), (353), (354), (357), (358....8414
14.24. Connectors (363), (400), (403), (407), (408), p. 24....8415
14.25. Connectors (409), (410), (411), (412), (413), (414), p. 2....8416
14.26. Connectors (415), (416), (418), (419), (420), (421), (423....8417
14.27. Connectors (437), (439), (440), (441), (444), (445), p. 2....8418
14.28. Connectors (446), (447), (448), (449), (451), (452), (454....8419
14.29. Connectors (456), (457), (462), (463), p. 29....8420
14.30. Connector (463), p. 30....8421
14.31. F10 Fuseblock (464), p. 31....8422
14.32. Connectors (462), (463), p. 32....8423
14.33. Connectors (464), (471), DRL Relays, (476), (477), p. 33....8424
14.34. Connectors (478), (480), (481), (482), (483), (494), (495....8425
14.35. Connectors (498), (501), (504), (505), (506), (507), (508....8426
14.36. Connectors (514), (515), (516), (517), (518), (529), (533....8427
14.37. Connectors (535), (540), (541), (544), (546), (550), (551....8428
14.38. Connectors (557), (558), (559), (560), (561), (562), (563....8429
14.39. Connectors (564), (568), (569), (570), (571), (572), (575....8430
14.40. Connectors (577), (581), (586), (587), (589), (591), (592....8431
14.41. Connectors (592F), (593), (595), (598), (599), (607), p. ....8432
14.42. Connectors (612), (613), (616), (623), p. 42....8433
14.43. Connectors (625), (626), (627), (633), (651), (652), p. 4....8434
14.44. Connectors (653), (657), (660), (662), (665), (675), (676....8435
14.45. Connectors (678), (679), (681), (682), (685), (686), p. 4....8436
14.46. Connector (690), p. 46....8437
14.47. Connectors (692), (693), (694), (695), (696), (697), (698....8438
14.48. Connectors (700), (702), (704), p. 48....8439
14.49. Connectors (732), (733), (734), (735), (736), (737), p. 4....8440
14.50. Connectors (738), (739), (740), (751), (766–770), (774), ....8441
14.51. Connectors (775), (776), (777), (782), (783), (905M), (90....8442
14.52. Connectors (911), (912), (913), (914), (915), (916), p. 5....8443
14.53. Connectors (918), (919), (920), (951), (955), p. 53....8444
14.54. Connectors (957), (958), (959), (960), (962), (963), (965....8445
14.55. Connectors (967), (1002), (1003), p. 55....8446
14.56. Gnd Stud (404), (429), (499), p. 56....8447
14.57. Connectors J3, J4, J5, J7, J8, J9, J11, J14, p. 57....8448
POWER DISTRIBUTION CENTER LAYOUT (Chapter 15)....8449
15.1. Fuse and Circuit Breaker Location, p. 1....8449
15.2. Fuse and Circuit Breaker Location (Cont.), p. 2....8450
15.3. Fuse and Circuit Breaker Location (Cont.), p. 3....8451
S08270 - Electrical System Troubleshooting Guide 9800 Models Built Date 11_01_1998 Supersedes CTS-5304 (Oct 2002) Service Manual....8452
S08316 - 5500, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 to February 28, 2007 Electrical Circuit Diagrams Manual....9010
S08318 - 9800 Model Built April 1, 2004 and After Electrical Circuit Diagrams Manual....9260
S08318a....9260
S08318b....9393
S08318c....9551
S08319 - Inverter_Charger Power System (Sept 2003) Service Manual....9783
S08326 - 5500i, 5600i, 5900i, 9200i, and 9900i Chassis Built March 1, 2007 and After — ELECTRICAL CIRCUIT DIAGRAMS....9811
5000 9000 (March 2007) Wiring Diagrams (S08326a).pdf (p.1-208)....9811
5000 9000 (March 2007) Wiring Diagrams (S08326b).pdf (p.209-368)....10019
S08346 - SERVICE MANUAL 9800 LHD Model Built November 01, 2010 - ELECTRICAL CIRCUIT DIAGRAMS....10179
S09001V - Hood, Grille, and Fenders - 5000, 9100, 9200, 9300, and 9400 (Supersedes CTS-5154V) (1999) Service Manual....10392
S09004 - Hood, Grille, and Fenders - 5000i, 9000i (Oct 2000) Service Manual....10545
S11001S - Spicer 14-Inch (356 mm) and 15 1_2-Inch (394 mm) Two-Plate, Pull-Type Clutch Supersedes CTS-5043S (March 1996) Service Manual....10670
S11008 - Clutch Control Linkage Supersedes CTS-5063R (March 1996) Service Manual....10705
S11009R - Clutch Control Linkage Supersedes CTS-5064R (March 1996) Service Manual....10718
S11010K - Clutch Control Linkage Supersedes CTS-5117K (March 1996) Service Manual....10737
S11011 - Clutch Control Linkage Supersedes CTS-5231 (March 1996) Service Manual....10750
S11016- 9800 HYDRAULIC, MECHANICAL CLUTCH SERVICE MANUAL....10771
S12001J - Fan Drive Clutch_ Kysor 1090 Supersedes CTS-5015J (March 1996) Service Manual....10824
S12004R - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual....10846
S12034 - Radiator _ Cooling System Service Manual (2010)....10874
S13001 - 9600 _ 9700 Shift Control Linkage Adjustment Procedure with Manual Transmission Supersedes CTS-5094 (March 1996) Service Manual....10920
S13003 - Power Take Off_ Rockwell Rear Engine Mounted Supersedes CTS-5210 (June 1996) Service Manual....10943
S13007 - 13 Speed And 18 Speed Transmissions Eaton RTLO-713 _ 18 Series Supersedes CTS-5176 (June 1996) Service Manual....10972
S13015 - 10 Speed And 15 Speed Transmissions Eaton RT, RTO, and RTX Series Supersedes CTS-5187 (June 1996) Service Manual....11138
S13016 - 7 Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual....11316
S13017 - 10 Speed Transmissions Eaton RTLO Series Supersedes CTS-5196 (March 1996) Service Manual....11379
S13018 - 8 Speed, 9 Speed, And 13 Speed Transmissions Eaton Series Supersedes CTS-5205 (June 1996) Service Manual....11530
S13019 - 18 Speed Transmissions Eaton RTLO-14618 and RTLO-16618 Series Supersedes CTS-5206 (June 1996) Service Manual....11756
S14002 - 2 SPEED AXLE SHIFT UNIT_ EATON (Supersedes CTS-5166) Service Manual....11920
S14004 - SINGLE REDUCTION, TANDEM AXLES_ SPICER J400-S, W460-S (Supersedes CTS-5259) Service Manual....11952
S14006T - SINGLE REDUCTION CARRIERS_ ROCKWELL (Supersedes CTS-5080T) Service Manual....12045
S14009 - SINGLE REDUCTION, TANDEM AXLE_ INTERNATIONAL (Supersedes CTS-5124) Service Manual....12164
S14013 - SINGLE REDUCTION, TANDEM DRIVE AXLES_ EATON (Supersedes CTS-5213) Service Manual....12228
S14014 - SINGLE REDUCTION, SINGLE SPEED AXLES_ SPICER D135-S, F155-S, F170-S SERIES (Supersedes CTS-5233) Service Manual....12257
S14016 - 2 SPEED AND DOUBLE REDUCTION SINGLE DRIVE AXLES_ EATON (Supersedes CTS-5195) Service Manual....12306
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual....12348
S16001 - MAJOR STRUCTURAL REPAIR_ 9600 (Formerly CTS-4338) Service Manual....12358
toc....12360
Table of Contents....12360
MAJOR STRUCTURAL REPAIRS....12362
1. GENERAL INSTRUCTIONS....12362
2. FASTENERS AND SEALERS....12368
2.1. FASTENERS....12370
2.2. SEALER....12372
3. REPAIRING CO-9670 CABS....12373
tables....12369
Table 1All CO-9670 Rivet and Lockbolt Fastener Usage Aid....12369
S16003 - Repair Instructions for Fiberglass and Plastic (ABS) Material (Formerly CTS-5173) Service Manual....12400
S16005V - CAB_ 5000, 9100, 9200, 9300, 9400 (Formerly CTS-5024V) Service Manual....12446
S16006 - Cab - Tilt_ 9600 and 9700 Sleeper and Non-Sleeper Cabs (Formerly CTS-5129) Service Manual....12615
S16008 - Add-On Sleeper Box (Formerly CTS-5152) Service Manual....12704
S16009 - Aerodynamic Panels (Formerly CTS-5153) Service Manual....12719
S16010 - Aerodynamic Panels 9200, 9300, 9400 (Formerly CTS-5155) Service Manual ....12734
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual....12774
S16015 - AIR CONDITIONING - HEATER SYSTEM_ 5000, 9000 Series Without Lowered heater Box Service Manual....12820
S16017X - Air Conditioning Compressor and Clutch, Two Cylinder Reciprocating Type - After 01_01_1993 (R-134A) (Formerly CTS-5241) Service Manual....12865
S16018 - CAB - TILT_ 9800 Service Manual....12892
S16019 - AIR CONDITIONING BASIC THEORY, SYSTEM DIAGNOSIS AND SERVICE (with R-134a Refrigerant System) Service Manual....13008
S16020 - AIR CONDITIONING - HEATER SYSTEM_ 9000 Pro Sleeper After 05_01_1997, and 9800 Model After 07_01_1997 Service Manual....13108
S16022Y - Air Conditioning Protection and Diagnostic System (APAds) Description, Operation, Troubleshooting, Remove, Install, and Electrical Circuit Diagrams Maintenance Manual....13179
S16024 - SKIRT PANELS, AERO SIDE SKIRT PANELS, BODY AIR DEFLECTORS, BUMPERS AND ROOFS Service Manual....13245
S16028 - West Coast Magnum Mirrors and Aero Mirrors Service Manual....13304
S16037 - No Idle APU_HVAC System Model_ 9200i 9400i 9900i 9900ix Feature Code_ 12WTK 16UZV Service Manual....13317
S16049 - AIR CONDITIONING - HEATER SYSTEM 9800 HVAC Service Manual....13369
S16050 - CAB - TILT_ Model 9800 (RHD) Service Manual....13468
S16051 - AIR CONDITIONING - HEATER SYSTEM_ 9800 (RHD) Service Manual....13574
s04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual....13672
s12005 - Radiator Shutters, Supersedes CTS-5084 (March 1996) Service Manual....13703
International/Navistar Truck Models 5000-Series, 9000-Series Repair Service Manual
