International/NaviStar HX-series Trucks Repair Service Manual 2017-2020
Complete service repair manual with Electrical Wiring Diagrams for 2017-2020 International/NaviStar HX-series Trucks, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
2017-2020 International/NaviStar HX-series Trucks 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.
0000862512 - 2017-2020 HX Technician Manual (Service and Diagnostics).pdf
PRODUCT DETAILS:
Total Pages: 1,607 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
toc....3
Table of Contents....3
Safety Terminology....6
Safety Instructions....6
Work Area....6
Safety Equipment....6
Protective Measures....6
Vehicle....6
Engine....7
Fire Prevention....7
Batteries....7
Compressed Air....7
Tools....7
Fluids Under Pressure....8
Fuel....8
Removal of Tools, Parts, and Equipment....8
Frame....9
1. Front Bumper....11
Overview....11
2. Frame....12
Deck Plate....13
Base Frame....14
Tool Box....15
Towing....16
Tow Hook....17
Tow Loop....18
Tow Pin....19
Front Axle....21
1. Front Axles....23
Overview....23
Front Suspension....25
1. Set Back Axle....27
Multi-leaf Springs....27
Overview....27
Parabolic Taper Leaf....29
Overview....29
Parabolic Taper Leaf Springs....29
Increased Capacity Parabolic Taper Leaf Springs....30
Front Suspension Rubber Auxiliary Springs....30
Multi-leaf Slipper Type with Torque Rod....31
Overview....31
2. Set Forward Axle....32
Multi-leaf Spring....32
Overview....32
Parabolic Taper Leaf....33
Overview....33
Increased Capacity Parabolic Taper Leaf Springs....34
Front Suspension Rubber Auxiliary Springs....34
3. Torque....35
Brakes....37
1. Air Brakes - Foundation....39
Service Brakes....39
Overview....39
2. Air Brakes - Bendix....40
ABS / ATC / ESC....40
Overview....40
ABS....43
ATC....44
ESC....45
ABS Module....45
Modulator Valve....47
Removal....47
Overview....47
Special Tools....47
Equipment Conditions....47
Removal Procedure....48
Follow-On Procedure....48
Installation....49
Overview....49
Special Tools....49
Torque Specifications....49
Equipment Conditions....49
Installation Procedure....50
Follow-On Procedure....50
Steering Angle Sensor....51
Removal....51
Overview....51
Special Tools....51
Equipment Conditions....51
Removal Procedure....52
Follow-On Procedure....53
Installation....54
Overview....54
Special Tools....54
Equipment Conditions....54
Installation Procedure....55
Follow-On Procedure....56
Traction Relay Valve....57
Front Removal....57
Overview....57
Special Tools....57
Equipment Conditions....57
Removal Procedure....58
Follow-On Procedure....58
Front Installation....59
Overview....59
Special Tools....59
Torque Specifications....59
Equipment Conditions....59
Installation Procedure....60
Follow-On Procedure....60
Rear Removal....61
Overview....61
Special Tools....61
Equipment Conditions....61
Removal Procedure....62
Follow-On Procedure....62
Rear Installation....63
Overview....63
Special Tools....63
Torque Specifications....63
Equipment Conditions....63
Installation Procedure....64
Follow-On Procedure....64
Wheel Speed Sensor....65
Removal....65
Overview....65
Special Tools....65
Equipment Conditions....65
Removal Procedure....66
Follow-On Procedure....66
Installation....67
Overview....67
Special Tools....67
Torque Specifications....67
Equipment Conditions....67
Installation Procedure....68
Follow-On Procedure....68
Yaw Rate Sensor....69
Removal....69
Overview....69
Special Tools....69
Equipment Conditions....69
Removal Procedure....70
Follow-On Procedure....70
Installation....71
Overview....71
Special Tools....71
Equipment Conditions....71
Installation Procedure....72
Follow-On Procedure....72
3. Air Systems....73
Air Compressors....73
Cummins® 18.7 CFM....73
Overview....73
Knorr-Bremse 31.8 CFM....74
Overview....74
Yoosung® 21.0 CFM....75
Overview....75
Bendix 15.9 CFM....76
Overview....76
Air Dryers....77
Bendix® AD-9™....77
Overview....77
Bendix® AD-IP™....78
Meritor WABCO System Saver 1200 Plus....79
Overview....79
Steering....81
1. Steering Column....83
Tilting and Telescoping Steering Column....83
Overview....83
Steering Wheel....84
Overview....84
Clock Spring....85
Overview....85
Steering Column....86
Overview....86
Description....86
Maintenance....87
End Yoke Pinch Bolts....87
Lubrication....87
Steering Wheel Alignment....87
Operation....88
Tilt....88
Telescope....88
2. Steering Gear....89
Sheppard M-Series Integral Power Steering Gear....89
Overview....89
Sheppard M-100/HD94 Dual Power....89
Overview....89
Sheppard M-100/M-80 Dual Power....89
Overview....89
Sheppard M-110/M-80 Dual Power....89
Overview....89
Sheppard M-100 Power....90
Overview....90
Service Information....90
Sheppard Service Manual....90
Torque Chart....90
Drivelines....91
1. Driveline....93
Overview....93
Driveshaft....93
Overview....93
Inner-Axle Shaft....94
Overview....94
Service Information....94
Driveline Vibration and Troubleshooting Procedures....95
Inspect and Measure Driveline....95
Overview....95
Required Tools....95
Equipment Conditions....95
Troubleshooting Driveline Vibration....95
Exhaust....97
1. Aftertreatment....99
Aftertreatment with Special Temperature Control For Stationary Applications....100
Overview....100
Aftertreatment Reuse Guidelines....101
Overview....101
DOC, DPF and SCR Housing Reuse Guidelines....101
DPF Media Types....101
DOC Inspection and Reuse Guidelines....102
Overview....102
Special Tools....102
Equipment Condition....102
Inspection Procedure....103
Reuse Guidelines....104
DOC Inlet New....104
DOC Inlet / Outlet - Melted....105
DOC Inlet - Face Plugged....106
DOC Inlet / Outlet Face Gouged....107
Expected Outcome....107
Follow-On Procedure....108
DPF Inspection and Reuse Guidelines....109
Overview....109
Special Tools....109
Equipment Condition....109
Inspection Procedure....110
Reuse Guidelines....111
DPF Inlet - New....111
DPF Inlet - Dirty and Useable....112
DPF Inlet - Dirty and Useable 2....114
DPF Inlet - Clean....115
DPF Inlet - Gouged....116
DPF Inlet - Ash....117
DPF Inlet - Dark Soot Rings....118
DPF Outlet - Soot Stains....119
DPF Outlet - Burn Marks from Welding....120
DPF Outlet - Excessive Soot Stains....121
DPF Outlet - Face Cracked....122
DPF Outlet - Coolant Staining....123
DPF Outlet - Melted....124
Expected Outcome....124
Follow-On Procedure....124
SCR Catalyst Inspection and Reuse Guidelines....125
Overview....125
Special Tools....125
Equipment Condition....125
Inspection Procedure....126
Reuse Guidelines....127
New Aftertreatment SCR....127
Iron Deposits on SCR Inlet....128
DEF Deposits on SCR Inlet....129
Media Erosion on SCR Inlet....130
Water Stains on SCR Inlet....131
Expected Outcome....131
Follow-On Procedure....131
Single Can Indexing....132
Overview....132
Special Tools....132
Equipment Condition....132
Procedure....132
Follow-On Procedure....133
2. Engine Compression Brake....133
Cummins® Interbrake....133
Overview....133
Jacobs for N13 Engines....134
Overview....134
3. Exhaust System....136
Aftertreatment Mounting w / A26....136
Horizontal w / Single Vertical....136
Overview....136
Horizontal w / Dual Vertical....137
Overview....137
Vertical w / Vertical....139
Overview....139
Day Cab....141
Horizontal / Single Vertical Tailpipe....141
Overview....141
Horizontal / Dual Vertical Tailpipe....142
Overview....142
Single Can....143
Removal....143
Overview....143
Required Tools....143
Equipment Conditions....143
Procedure....144
Follow-On Procedure....144
Installation....145
Overview....145
Required Tools....145
Equipment Conditions....145
Procedure....146
Follow-On Procedure....146
Vertical / Single Vertical Tailpipe....147
Overview....147
Single Can....148
Removal....148
Overview....148
Required Tools....148
Equipment Conditions....148
Procedure....149
Follow-On Procedure....150
Installation....151
Overview....151
Required Tools....151
Equipment Conditions....151
Procedure....152
Follow-On Procedure....153
Switchback Horizontal Aftertreatment and Dual Vertical Tail Pipes....154
Overview....154
Horizontal / Horizontal Exhaust System....155
Removal....155
Equipment Conditions....155
Procedure....156
Installation....158
Procedure....158
Diesel Exhaust Fluid (DEF) Dosing Valve....160
Removal....160
Equipment Conditions....160
Procedure....161
Installation....162
Procedure....162
Decomposition Reactor Tube....163
Removal....163
Equipment Conditions....163
Procedure....164
Installation....165
Procedure....165
Switchback Horizontal Aftertreatment and Single Vertical Tail Pipes....166
Overview....166
Switchback Vertical Aftertreatment Device with Dual Cans....167
Overview....167
Vertical / Vertical Exhaust System....168
Removal....168
Equipment Conditions....168
Procedure....168
Installation....170
Torque Specification....170
Procedure....170
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield....171
Removal....171
Equipment Conditions....171
Procedure....171
Installation....173
Torque Specifications....173
Procedure....173
Power Distribution Module (PDM)....174
Removal....174
Equipment Conditions....174
Procedure....174
Installation....176
Procedure....176
Aftertreatment Control Module (ACM)....177
Removal....177
Equipment Conditions....177
Procedure....177
Installation....179
Torque Specification....179
Procedure....179
Horizontal Aftertreatment Device with Dual Vertical Tailpipes....180
Overview....180
4. Torque....181
Electrical / Software....183
1. Diagnostic Trouble Code (DTC) List....187
2. Electronic Service Tools (EST)....190
Diamond Logic® Builder....190
Overview....190
Selecting an Interface Cable....192
Overview....192
Special Tools....192
Equipment Conditions....192
Selection Procedure....192
Follow-On Procedure....193
Connecting to a Vehicle....194
Overview....194
Special Tools....194
Equipment Conditions....194
Connection Procedure....194
Follow-On Procedure....195
Activating Diagnostic Mode....196
Overview....196
Special Tools....196
Equipment Conditions....196
Activation Procedure....196
Follow-On Procedure....197
Starting a Session....198
Overview....198
Special Tools....198
Equipment Conditions....198
Starting Procedure....198
Follow-On Procedure....199
Viewing Fault Codes....200
Overview....200
Special Tools....200
Equipment Conditions....200
Viewing Procedure....200
Follow-On Procedure....200
Clearing Fault Codes....201
Overview....201
Special Tools....201
Equipment Conditions....201
Clearing Procedure....201
Follow-On Procedure....201
Modifying Signals Tab....202
Overview....202
Special Tools....202
Equipment Conditions....202
Modify Watched Signal Columns....202
Modify Watched Signals....203
Follow-On Procedure....203
Programming Modules....204
Overview....204
Special Tools....204
Equipment Conditions....204
Programming Procedure....205
Follow-On Procedure....208
Input Not Recognized by Body Control Module....209
Overview....209
Special Tools....209
Equipment Conditions....209
Troubleshooting Procedure....209
Follow-On Procedure....210
Output Not Commanded by Body Control Module....211
Overview....211
Special Tools....211
Equipment Conditions....211
Troubleshooting Procedure....211
Follow-On Procedure....212
3. General Electrical Repair....213
Electrical Connector Cleaning....213
Overview....213
Special Tools....213
Specifications....213
Equipment Conditions....213
Cleaning Procedure....213
Follow-On Procedure....213
4. 12 Volt Electrical System....214
Battery Box....214
Overview....214
Battery Disconnect....215
Overview....215
Special Tools....215
Torque Specifications....215
Equipment Conditions....215
Disconnect Procedure....216
Follow-On Procedure....216
Battery Reconnect....217
Overview....217
Special Tools....217
Torque Specifications....217
Equipment Conditions....217
Reconnect Procedure....218
Follow-On Procedure....218
Battery Terminal Cleaning....219
Overview....219
Special Tools....219
Equipment Conditions....219
Cleaning Procedure....220
Follow-On Procedure....220
Battery Disconnect Switch....221
Starting and Charging System....222
Operational Checkout Procedure....223
Starting System....224
Overview....224
Battery Pack....224
Starter....224
Control....224
No Click No Crank....225
Overview....225
Special Tools....225
Possible Causes....225
Click No Crank....227
Overview....227
Possible Causes....227
Low Cranking Speed....229
Overview....229
Possible Causes....229
No Starter Input Signal (Automated Manual Transmission)....230
Automated Manual Transmission Starter Input Diagnostics....230
Automated Manual Transmission Starter Input Pinpoint Tests....234
Tools Required....234
No Starter Input Signal (Automatic Transmission)....245
Automatic Transmission Starter Input Pinpoint Tests....249
Tools Required....249
No Starter Input Signal (Manual Transmission)....260
Manual Transmission Starter Input Pinpoint Tests....264
Tools Required....264
Charging System....275
Overview....275
Overview....275
Battery Pack....275
Alternator....275
Battery Gauge Reading High....277
Overview....277
Possible Causes....277
Battery Gauge Reading Low / Fluctuating....278
Overview....278
Possible Causes....278
Low Battery Warning / Alarm....280
Overview....280
Possible Causes....280
Repeated Jump Starts....282
Overview....282
Possible Causes....282
Tests....284
Individual Battery Test....284
Overview....284
Special Tools....284
Equipment Condition....284
Test Setup....284
Test Procedure....285
Expected Outcome....287
Follow-On Procedure....287
Cable Drop Test....288
Overview....288
Special Tools....288
Equipment Condition....288
Test Setup....288
Test Procedure....288
Expected Outcome....291
Follow-On Procedure....291
Electrical System Test....292
Overview....292
Special Tools....292
Equipment Condition....293
Test Setup....293
Battery Pack Test Procedure....295
Starter System Test Procedure....298
Charging System Test Procedure....300
Expected Outcome....303
Follow-On Procedure....303
Manual Engine Bar Test....304
Overview....304
Tools Required....304
Equipment Condition....304
Test Setup....304
Test Procedure....304
Expected Outcome....304
Follow-On Procedure....304
Parasitic Draw Test....305
Overview....305
Special Tools....305
Equipment Condition....305
Test Setup....305
Test Procedure....305
Expected Outcome....308
Follow-On Procedure....308
Starter Control Circuit Test....309
Overview....309
Tools Required....309
Equipment Condition....309
Test Setup....309
Test Procedure....309
Expected Outcome....310
Follow-On Procedure....310
Inspections....311
Electrical System Inspection....311
Overview....311
Special Tools....311
Equipment Condition....311
Inspection Procedure....311
Expected Outcome....312
Follow-On Procedure....312
Ring Gear Inspection....313
Overview....313
Special Tools....313
Equipment Condition....313
Inspection Procedure....313
Expected Outcome....314
Follow-On Procedure....314
5. Accessories....315
Sleeper-Mounted Radio Control....315
Overview....315
6. Aftertreatment....317
Diesel Particulate Filter (DPF)....317
Regeneration Inhibit Switch....317
Overview....317
Parked Regeneration Switch....320
Overview....320
HEST Monitoring....323
Overview....323
7. Brakes....326
Bendix® Air Brake System....326
Anti-Lock Brake System (ABS)....326
Overview....326
Inputs....328
Outputs....328
Automatic Traction Control (ATC) System....330
Overview....330
Inputs....331
Outputs....332
Electronic Stability Control (ESC) System....334
Overview....334
Inputs....335
Outputs....336
8. Chassis Body Building Wiring....338
Overview....338
Operational Checkout Procedure....341
Overview....341
Tail and Marker Diagnostics....344
Overview....344
Left Turn Light Diagnostics....347
Overview....347
Right Turn Light Diagnostics....350
Overview....350
Back Up Light Diagnostics....353
Overview....353
Accessory Diagnostics....355
Overview....355
Stop Light Diagnostics....357
Overview....357
Trailer Lighting Diagnostics....360
Overview....360
Remote Cruise Control Connection....366
Overview....366
9. Collision Mitigation Systems....367
Bendix® Wingman® Advanced™....367
Overview....367
Adaptive Cruise Control (ACC)....369
Alerts....369
Collision Mitigation Braking....369
Tech Tips....371
Operational Checkout Procedure....372
Overview....372
Special Tools....372
Driver Interface Unit....374
Electrical Test....374
Overview....374
Special Tools....374
Equipment Conditions....374
Test Setup....374
Follow-On Procedure....376
Removal....377
Overview....377
Special Tools....377
Equipment Conditions....377
Removal Procedure....377
Follow-On Procedure....377
Installation....378
Overview....378
Special Tools....378
Torque Specifications....378
Equipment Conditions....378
Installation Procedure....378
Follow-On Procedure....378
Radar Sensor....379
Electrical Test....379
Overview....379
Special Tools....379
Equipment Conditions....379
Test Setup....379
Follow-On Procedure....381
Removal....382
Overview....382
Special Tools....382
Equipment Conditions....382
Removal Procedure....382
Follow-On Procedure....383
Installation....384
Overview....384
Special Tools....384
Torque Specifications....384
Equipment Conditions....384
Installation Procedure....384
Follow-On Procedure....385
Adjustment....386
Overview....386
Special Tools....386
Equipment Conditions....386
Lateral Adjustment Procedure....386
Vertical Adjustment Procedure....388
Follow-On Procedure....390
10. Data Links....391
CAN Systems....391
Overview....391
Faults....391
Short....391
Terminating Resistor Failure....391
Backbone Open....392
Node Open....392
Tests....394
Module Communication Test....394
Overview....394
Tools Required....394
Equipment Condition....394
Test Setup....394
Test Procedure....395
Follow-On Procedure....395
11. Drivetrain....396
Driver Controlled Locking Differential....396
Overview....396
12. Engine....400
Cummins® Diagnostics....400
Table Of Contents....400
Fault Code Diagnostics....401
Fault Code List....401
SPN 111 FMI 1 (Cummins FC 235) - Coolant Level - Data Valid But Below Normal Operating Range - Most Severe Level....403
Fault Overview....403
Associated Faults....403
Fault Facts....403
Conditions For Clearing The Fault Codes....403
Possible Causes....403
SPN 111 FMI 3 (Cummins FC 195) - Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source....415
Fault Overview....415
Associated Faults....415
Fault Facts....415
Conditions For Clearing The Fault Codes....415
Possible Causes....415
SPN 111 FMI 4 (Cummins FC 196) - Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source....427
Fault Overview....427
Associated Faults....427
Fault Facts....427
Conditions For Clearing The Fault Codes....427
Possible Causes....427
SPN 111 FMI 17 (Cummins FC 2448) - Coolant Level - Data Valid But Below Normal Operating Range - Least Severe Level....439
Fault Overview....439
Associated Faults....439
Fault Facts....439
Conditions For Clearing The Fault Codes....439
Possible Causes....439
SPN 111 FMI 18 (Cummins FC 197) - Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level....451
Fault Overview....451
Associated Faults....451
Fault Facts....451
Conditions For Clearing The Fault Codes....451
Possible Causes....451
SPN 1569 FMI 15 (Cummins FC 6255) - Engine Protection Torque Derate - Data Valid But Above Normal Operating Range - Least Severe Level....463
Fault Overview....463
Associated Faults....463
Fault Facts....463
Conditions For Clearing The Fault Codes....463
Possible Causes....463
SPN 1569 FMI 31 (Cummins FC 3714) - Engine Protection Torque Derate - Condition Exists....464
Fault Overview....464
Associated Faults....464
Fault Facts....464
Conditions For Clearing The Fault Codes....464
Possible Causes....464
SPN 1761 FMI 1 (Cummins FC 1673) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Most Severe Level....465
Fault Overview....465
Associated Faults....465
Fault Facts....465
Conditions For Clearing The Fault Codes....465
Possible Causes....465
SPN 1761 FMI 3 (Cummins FC 1669) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Above Normal or Shorted to High Source....466
Fault Overview....466
Associated Faults....466
Fault Facts....466
Conditions For Clearing The Fault Codes....466
Possible Causes....466
SPN 1761 FMI 4 (Cummins FC 1668) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Below Normal or Shorted to Low Source....467
Fault Overview....467
Associated Faults....467
Fault Facts....467
Conditions For Clearing The Fault Codes....467
Possible Causes....467
SPN 1761 FMI 9 (Cummins FC 4677) Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Abnormal Update Rate ....468
Fault Overview....468
Associated Faults....468
Fault Facts....468
Conditions For Clearing The Fault Codes....468
Possible Cause....468
SPN 1761 FMI 10 (Cummins FC 4769) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal Rate of Change....473
Fault Overview....473
Associated Faults....473
Fault Facts....473
Conditions For Clearing The Fault Codes....473
Possible Causes....473
SPN 1761 FMI 11 (Cummins FC 4739) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Root Cause Not Known....476
Fault Overview....476
Associated Faults....476
Fault Facts....476
Conditions For Clearing The Fault Codes....476
Possible Causes....476
SPN 1761 FMI 13 (Cummins FC 4732) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of Calibration....477
Fault Overview....477
Associated Faults....477
Fault Facts....477
Conditions For Clearing The Fault Codes....477
Possible Causes....477
SPN 1761 FMI 17 (Cummins FC 3497) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Least Severe Level....478
Fault Overview....478
Associated Faults....478
Fault Facts....478
Conditions For Clearing The Fault Codes....478
Possible Causes....478
SPN 1761 FMI 18 (Cummins FC 3498) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Moderately Severe Level ....479
Fault Overview....479
Associated Faults....479
Fault Facts....479
Conditions For Clearing The Fault Codes....479
Possible Causes....479
SPN 3031 FMI 2 (Cummins FC 1679) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic, Intermittent, or Incorrect....480
Fault Overview....480
Associated Faults....480
Fault Facts....480
Conditions For Clearing The Fault Codes....480
Possible Causes....480
SPN 3031 FMI 3 (Cummins FC 1678) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Above Normal or Shorted to High Source ....482
Fault Overview....482
Associated Faults....482
Fault Facts....482
Conditions For Clearing The Fault Codes....482
Possible Causes....482
SPN 3031 FMI 4 (Cummins FC 1677) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Below Normal or Shorted to Low Source....483
Fault Overview....483
Associated Faults....483
Fault Facts....483
Conditions For Clearing The Fault Codes....483
Possible Causes....483
SPN 3031 FMI 9 (Cummins FC 4572) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal Update Rate....484
Fault Overview....484
Associated Faults....484
Fault Facts....484
Conditions For Clearing The Fault Codes....484
Possible Cause....484
SPN 3031 FMI 11 (Cummins FC 4737) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause Not Known....489
Fault Overview....489
Associated Faults....489
Fault Facts....489
Conditions For Clearing The Fault Codes....489
Possible Causes....489
SPN 3031 FMI 13 (Cummins FC 4731) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out of Calibration....490
Fault Overview....490
Associated Faults....490
Fault Facts....490
Conditions For Clearing The Fault Codes....490
Possible Causes....490
SPN 3364 FMI 2 (Cummins FC 3878) - Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or Incorrect....491
Fault Overview....491
Associated Faults....491
Fault Facts....491
Conditions For Clearing The Fault Codes....491
Possible Causes....491
SPN 3364 FMI 3 (Cummins FC 1686) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Above Normal or Shorted to High Source....492
Fault Overview....492
Associated Faults....492
Fault Facts....492
Conditions For Clearing The Fault Codes....492
Possible Cause....492
SPN 3364 FMI 4 - (Cummins 1685) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Below Normal or Shorted to Low Source....494
Fault Overview....494
Associated Faults....494
Fault Facts....494
Conditions For Clearing The Fault Codes....494
Possible Cause....494
SPN 3364 FMI 9 (Cummins FC 3868) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate....496
Fault Overview....496
Associated Faults....496
Fault Facts....496
Conditions For Clearing The Fault Codes....496
Possible Cause....496
SPN 3364 FMI 10 (Cummins FC 4277) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate of Change ....501
Fault Overview....501
Associated Faults....501
Fault Facts....501
Conditions For Clearing The Fault Codes....501
Possible Causes....501
SPN 3364 FMI 11 (Cummins FC 1715) - Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known....504
Fault Overview....504
Associated Faults....504
Fault Facts....504
Conditions For Clearing The Fault Codes....504
Possible Causes....504
SPN 3364 FMI 13 (Cummins FC 1714) - Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration....505
Fault Overview....505
Associated Faults....505
Fault Facts....505
Conditions For Clearing The Fault Codes....505
Possible Causes....505
SPN 3364 FMI 15 (Cummins FC 4842) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal Operating Range - Least Severe Level....506
Fault Overview....506
Associated Faults....506
Fault Facts....506
Conditions For Clearing The Fault Codes....506
Possible Causes....506
SPN 3364 FMI 18 (Cummins FC 3867) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal Operating Range - Moderately Severe Level....508
Fault Overview....508
Associated Faults....508
Fault Facts....508
Conditions For Clearing The Fault Codes....508
Possible Causes....508
SPN 3521 FMI 11 (Cummins FC 4768) - Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known....510
Fault Overview....510
Associated Faults....510
Fault Facts....510
Conditions For Clearing The Fault Codes....510
Possible Causes....510
SPN 3521 FMI 16 (Cummins FC 6765) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above Normal Operating Range - Moderately Severe Level....511
Fault Overview....511
Associated Faults....511
Fault Facts....511
Conditions For Clearing The Fault Codes....511
Possible Causes....511
SPN 3521 FMI 18 (Cummins FC 6766) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below Normal Operating Range - Moderately Severe Level....513
Fault Overview....513
Associated Faults....513
Fault Facts....513
Conditions For Clearing The Fault Codes....513
Possible Causes....513
SPN 3521 FMI 31 (Cummins FC 4235) - Aftertreatment 1 Diesel Exhaust Fluid Property- Condition Exists....515
Fault Overview....515
Associated Faults....515
Fault Facts....515
Conditions For Clearing The Fault Codes....515
Possible Causes....515
SPN 4096 FMI 31 (Cummins FC 3547) - Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition Exists....517
Fault Overview....517
Associated Faults....517
Fault Facts....517
Conditions For Clearing The Fault Codes....517
Possible Causes....517
SPN 5246 FMI 0 (Cummins FC 3712) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Most Severe Level....518
Fault Overview....518
Associated Faults....518
Fault Facts....518
Conditions For Clearing The Fault Codes....518
Possible Causes....518
SPN 5246 FMI 15 (Cummins FC 4134) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Least Severe Level....519
Fault Overview....519
Associated Faults....519
Fault Facts....519
Conditions For Clearing The Fault Codes....519
Possible Causes....519
SPN 5246 FMI 16 (Cummins FC 6254) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Moderately Severe Level....520
Fault Overview....520
Associated Faults....520
Fault Facts....520
Conditions For Clearing The Fault Codes....520
Possible Causes....520
Tests and Inspections ....521
Overview ....521
DEF Head Unit Coolant Line Routing Inspection ....522
Overview ....522
Tools Required....522
Equipment Condition....522
Inspection Procedure....522
Expected Outcome....523
DEF Quality Test....524
Overview....524
Tools Required....524
Equipment Condition ....524
Test Procedure....524
Expected Outcome ....525
DEFTHV Coolant Flow Test....526
Overview....526
Tools Required....526
Equipment Condition....526
Test Setup....526
Test Procedure....526
Expected Outcome ....526
13. Exterior Lighting....528
Beacon Light....528
Overview....528
Work Light....529
Overview....529
14. HVAC....531
HVAC Control....531
Compressor....532
Condenser....532
Receiver/Drier....532
HVAC Assembly....533
Evaporator Core....533
Thermal Switch....533
Expansion Valve and Pressure Switches....534
Air Conditioning Protection and Diagnostic Systems (APADS)....536
HVAC Symptom Diagnostics....537
Operational Checkout Procedure....538
Overview....538
Blower Not Working Properly for One or More Speeds....541
Overview....541
Blower Control position 1 (lowest volume air flow)....541
Blower Control position 2....541
Blower Control position 3....541
Blower Control position 4 (highest volume air flow)....541
Possible Causes....541
Test Procedure....543
Pin-Point Tests - Blower Motor Control....546
HVAC System Air Not Cool After A/C Turned ON....548
Overview....548
Fault Facts....548
Possible Causes....548
HVAC System Air Not Warm After Heat Turned ON....552
Overview....552
Possible Causes....552
Air Not Flowing Out Correct HVAC Ducts....555
Overview....555
Possible Causes....555
Tests and Inspections....561
Blower Speeds Tests....561
Overview....561
Special Tools....561
Equipment Conditions....561
Test Setup....561
Procedure....562
Follow-On Procedure....569
Static Refrigerant Pressure Test....570
Overview....570
Special Tools....570
Equipment Conditions....570
Test Setup....570
Procedure....571
Follow-On Procedure....571
High and Low Side Refrigerant Pressure Test....572
Overview....572
Special Tools....572
Equipment Conditions....572
Test Setup....572
Procedure....573
Expected Outcome....573
Gauge Readings Indicating Possible Problems....573
HVAC Air Flow Control Test....575
Overview....575
Special Tools....575
Equipment Conditions....575
Test Setup....575
Procedure....575
Follow-On Procedure....578
Base A/C System Compressor Clutch Control Test....579
Overview....579
Special Tools....581
Equipment Conditions....581
Test Setup....581
Procedure....582
Follow-On Procedure....585
APADS A/C System Compressor Clutch Control Test....586
Overview....586
APADS Compressor Control Rules....587
Special Tools....587
Equipment Conditions....587
Test Setup....587
Test Procedure....587
Follow-On Procedure....587
A/C Compressor Compression Test....588
Overview....588
Special Tools....588
Equipment Conditions....588
Test Setup....588
Procedure....588
Follow-On Procedure....588
15. Instruments / Gauges....589
Auxiliary Gauge Pack....589
Overview....589
Air Application Gauge....591
Overview....591
Air Cleaner Restriction Gauge....592
Overview....592
Eaton Ultrashift Shifter Gauge....593
Overview....593
Manifold Pressure Gauge....594
Overview....594
Rear Axle Oil Temperature Gauge....595
Overview....595
Rear Suspension Air Pressure Gauge....596
Overview....596
Instrument Cluster....597
Overview....597
Instrument Cluster Display Readouts....597
Instrument Cluster Bulb Check....597
Instrument Cluster Self-diagnostic Mode....598
Air Tank Pressure Gauges....600
Overview....600
Coolant Temperature Gauge....601
Overview....601
Diesel Exhaust Fluid (DEF) Level Gauge....602
Overview....602
Engine Oil Pressure Gauge....603
Overview....603
Engine Oil Temperature Gauge....604
Overview....604
Fuel Level Gauge....605
Overview....605
Speedometer....606
Overview....606
Tachometer....607
Overview....607
Transmission Oil Temperature Gauge....608
Overview....608
Voltmeter....609
Overview....609
Park Brake Indicator....610
Overview....610
16. Lighting Systems....611
Turn, Hazard, and Brake Lights....611
Overview....611
Operational Checkout Procedure....613
Overview....613
Turn, Hazard or Brake Lights Not Illuminating....615
Overview....615
Fault Facts....615
Possible Causes....615
Turn and Hazard Lights Input Diagnostics....625
Overview....625
Fault Facts....625
Possible Causes....625
Fog Lights....632
Overview....632
Fog Lights Not Illuminating....634
Overview....634
Possible Causes....634
Pin-Point Test - Fog lights Not illuminating....642
Tools Required....642
Headlights....644
Overview....644
Operational Checkout Procedure....646
Overview....646
Low Beam Headlights Not Illuminating....648
Overview....648
Fault Facts....648
Possible Causes....648
Pin-Point Test - Low Beam Headlights Not illuminating....654
Tools Required....654
Low Beam Headlights Illuminate When Not Requested....662
Overview....662
Fault Facts....662
Possible Causes....662
Pin-Point Test - Low Beam Headlights Illuminate When Not Requested....666
Tools Required....666
SPN 2653 FMI 5 - Left Low Beam Under Current....669
Overview....669
Associated Faults....669
Fault Facts....669
Possible Causes....669
Pin-Point Test - SPN 2653 FMI 5....671
Tools Required....671
SPN 2653 FMI 6 - Left Low Beam Short to Ground....672
Overview....672
Associated Faults....672
Fault Facts....672
Possible Causes....672
Pin-Point Test - SPN 2653 FMI 6....673
Tools Required....673
SPN 2655 FMI 5 - Right Low Beam Open Circuit....674
Overview....674
Associated Faults....674
Fault Facts....674
Possible Causes....674
Pin-Point Test - SPN 2655 FMI 5....676
Tools Required....676
SPN 2655 FMI 6 - Right Low Beam Short to Ground....677
Overview....677
Associated Faults....677
Fault Facts....677
Possible Causes....677
Pin-Point Test - SPN 2655 FMI 6....678
Tools Required....678
Operational Checkout Procedure....679
Overview....679
High Beam Headlights Not Illuminating....681
Overview....681
Fault Facts....681
Possible Causes....681
Pin-Point Test - High Beam Headlights Not illuminating....687
Tools Required....687
High Beam Headlights Illuminate When Not Requested....695
Overview....695
Fault Facts....695
Possible Causes....695
Pin-Point Test - High Beam Headlights Illuminate When Not Requested....699
Tools Required....699
Flash-To-Pass Not Illuminating Headlights....702
Overview....702
Fault Facts....702
Possible Causes....702
Pin-Point Test - Flash-To-Pass Not illuminating Headlights....705
Tools Required....705
SPN 4011 FMI 5 - Left High Beam Open Circuit....707
Overview....707
Associated Faults....707
Fault Facts....707
Possible Causes....707
Pin-Point Test - SPN 4011 FMI 5....709
Tools Required....709
SPN 4011 FMI 6 - Left High Beam Short to Ground....710
Overview....710
Associated Faults....710
Fault Facts....710
Possible Causes....710
Pin-Point Test - SPN 4011 FMI 6....711
Tools Required....711
SPN 4012 FMI 5 - Right High Beam Open Circuit....712
Overview....712
Associated Faults....712
Fault Facts....712
Possible Causes....712
Pin-Point Test - SPN 4012 FMI 5....714
Tools Required....714
SPN 4012 FMI 6 - Right High Beam Short to Ground....715
Overview....715
Associated Faults....715
Fault Facts....715
Possible Causes....715
Pin-Point Test - SPN 4012 FMI 6....716
Tools Required....716
Brake Switch Input....717
Overview....717
Brake Switch Input Diagnostics....719
Fault Facts....719
Possible Causes....719
SPN 597 FMI 0 - Brake Switch Reading Above Normal....722
Overview....722
Associated Faults....722
Fault Facts....722
Possible Causes....722
SPN 597 FMI 1 - Brake Switch Reading Below Normal Range....724
Overview....724
Associated Faults....724
Fault Facts....724
Possible Causes....724
Park / Marker Lights....725
Overview....725
Operational Checkout Procedure....727
Overview....727
Park Lights Not Illuminating....729
Overview....729
Fault Facts....729
Possible Causes....729
Pin-Point Test - Park Lights Not Illuminating....736
Tools Required....736
Park Lights Illuminate When Not Requested....743
Overview....743
Fault Facts....743
Possible Causes....743
Pin-Point Test - Park Lights Illuminate When Not Requested....746
Tools Required....746
SPN 2378 FMI 5 - Park Lights Undercurrent....748
Overview....748
Associated Faults....748
Fault Facts....748
Possible Causes....748
Pin-Point Test - SPN 2378 FMI 5....751
Tools Required....751
SPN 2378 FMI 6 - Park Lights Overcurrent....753
Overview....753
Associated Faults....753
Fault Facts....753
Possible Causes....753
Pin-Point Test - SPN 2378 FMI 6....755
Tools Required....755
Work Light....756
17. Seats....757
RollTek Supplemental Restraint System (SRS)....757
Overview....757
Operational Check....760
Symptoms....761
Diagnostics....762
18. Transmission....763
Allison Automatic Transmission....763
Overview....763
Push Button Shift Control (Allison)....767
Overview....767
PTO Controls Dash Mounted....769
Overview....769
19. Windshield Wiper System....771
Windshield Wiper Diagnostics....771
Overview....771
Wiper Operation....771
Park Operation....772
Washer Operation....772
Operational Checkout Procedure....778
Overview....778
Windshield Wiper Input 0 Not Working....783
Overview....783
Fault Fact....783
Possible Causes....783
Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working....785
Tools Required....785
Windshield Wiper Input 1 Not Working....789
Overview....789
Fault Fact....789
Possible Causes....789
Pin-Point Test - Windshield Wiper Input 1 Not Working....791
Tools Required....791
Windshield Wiper Input 2 Not Working....795
Overview....795
Fault Fact....795
Possible Causes....795
Pin-Point Test - Windshield Wiper Input 2 Not Working....797
Tools Required....797
Windshield Wiper Low Speed Not Working....801
Overview....801
Fault Facts....801
Possible Causes....801
Pin-Point Test - Windshield Wiper Low Speed Not Functioning....805
Tools Required....805
Windshield Wiper High Speed Not Working....811
Overview....811
Fault Facts....811
Possible Causes....811
Pin-Point Test - Windshield Wiper High Speed Not Working....815
Tools Required....815
SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit....821
Overview....821
Associated Faults....821
Fault Facts....821
Possible Causes....821
Pin-Point Test - SPN 2636 FMI 5....822
Tools Required....822
SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current....823
Overview....823
Associated Faults....823
Fault Facts....823
Possible Causes....823
Pin-Point Test - SPN 2636 FMI 6....824
Tools Required....824
SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or Open Circuit....825
Overview....825
Associated Faults....825
Fault Facts....825
Possible Causes....825
Pin-Point Test - SPN 2637 FMI 5....826
Tools Required....826
SPN 2637 FMI 6 - Wiper High / Low Relay Over Current....827
Overview....827
Associated Faults....827
Fault Facts....827
Possible Causes....827
Pin-Point Test - SPN 2637 FMI 6....828
Tools Required....828
SPN 4057 FMI 5 - Wiper Motor Under Current....829
Overview....829
Associated Faults....829
Fault Facts....829
Possible Causes....829
Pin-Point Test - SPN 4057 FMI 5....832
Tools Required....832
SPN 4057 FMI 6 - Wiper Motor Over Current....835
Overview....835
Associated Faults....835
Fault Facts....835
Possible Causes....835
Pin-Point Test - SPN 4057 FMI 6....838
Tools Required....838
Windshield Washer Pump Not Working....842
Overview....842
Fault Fact....842
Possible Causes....842
Pin-Point Test - Windshield Washer Pump Not Working....844
Tools Required....844
Windshield Wipers Not Working when Washer Pump Activated....848
Overview....848
Fault Fact....848
Possible Causes....848
Pin-Point Test - Windshield Wipers Not Working when Washer Pump Activated....850
Tools Required....850
Windshield Washer Pump and Wipers Not Working....851
Overview....851
Fault Fact....851
Possible Causes....851
Pin-Point Test - Windshield Wiper and Washer Pump Not Working....853
Tools Required....853
Front End....855
1. Bug Deflector/Screen....857
Overview....857
2. Fender Extensions....858
Overview....858
Quarter Fenders - Rear Wheels....858
Overview....858
3. Hood/Grill....859
Overview....859
Head Lights....860
Adjustment....860
Equipment Conditions....860
Adjustment....860
Bulb Replacement....861
Equipment Conditions....861
Bulb Replacement....861
Head Light Assembly....862
Removal....862
Equipment Conditions....862
Procedure....862
Installation....863
Procedure....863
Tilting Front End....864
Overview....864
Removal....866
Overview....866
Special Tools....866
Equipment Condition....866
Procedure....866
Follow-On Procedure....867
Installation....868
Overview....868
Special Tools....868
Equipment Condition....868
Procedure....868
Follow-On Procedure....869
Hood Alignment....870
Overview....870
Special Tools....870
Equipment Conditions....871
Alignment Procedure....871
Follow-On Procedure....876
Headlight Alignment Procedure....877
Overview....877
Special Tools....877
Equipment Conditions....878
Procedure....878
Follow-On Maintenance....878
Fifth Wheel and Misc.....879
1. Fifth Wheel....881
Air Slide ON / OFF Toggle Switch....881
Overview....881
Air Slide Fifth Wheel....882
Overview....882
Stationary Fifth Wheel....884
Overview....884
2. Keys....885
Door Lock and Ignition Keys....885
Overview....885
Clutch....887
1. Clutch System....889
Clutch Brake....889
Overview....889
Hydraulic Clutch Actuation System with Air Assist....890
Overview....890
Clutch Pedal....890
Master Cylinder....891
Reservoir....891
Air Assist Servo and Slave Cylinder....891
Hydraulic Hose....891
Bleeder Valve....891
Service Information....891
Master Cylinder....892
Equipment Conditions....892
Push Rod Adjustment....893
Clutch....894
Overview....894
Eaton® Fuller Solo Clutch....896
Eaton® Fuller Soft-Rate 7 Spring Damper....897
Eaton® Fuller Vibration Control Technology (VCT) Plus Soft-Rate Damper....898
Eaton® Fuller VCT Plus Soft-Rate Damper with Pre-Damper....899
Torque Specifications....900
Engines....901
1. Air Cleaner....905
Overview....905
2. Block Heater....907
Overview....907
3. Cold Start Assist....908
Either Cold Start....908
Overview....908
HX515 and HX615....909
HX620....909
4. Cooling System....910
Radiator System....910
Overview....910
Coolant System Drain, Fill, and Pressure Test Procedures....911
Coolant System Drain....911
Required Tools....911
Equipment Conditions....912
Coolant Drain....913
Deaeration Cap Pressure Test....915
Required Tools....915
Equipment Conditions....916
Pressure Test....917
Coolant System Fill....919
N13 Fill....919
Fill Procedure....919
Cummins® ISX Fill....921
Fill Procedure....921
Deaeration Tank....923
Relocate....923
Equipment Conditions....923
Procedure....923
Removal....925
Equipment Conditions....925
Installation....927
Engine Coolant Level (ECL) Sensor....928
Removal....928
Overview....928
Special Tools....929
Equipment Conditions....929
Procedure....930
Follow-On Procedure....930
Installation....931
Overview....931
Special Tools....931
Torque Specification....932
Equipment Conditions....932
Procedure....933
Follow-On Procedure....933
Power Steering Reservoir....934
Relocate....934
Equipment Conditions....934
Procedure....935
Reinstallation....936
Torque Specification....936
HVAC Condenser....937
Relocate....937
Equipment Conditions....937
Procedure....938
Removal....939
Navistar® N13....939
Equipment Conditions....939
Procedure....940
Cummins® ISX....941
Equipment Conditions....941
Procedure....941
Installation....943
Navistar® N13....943
Equipment Conditions....943
Procedure....943
Cummins® ISX....944
Torque Specifications....944
Procedure....944
Fan Shroud....945
Removal....945
Navistar® Upper (N13)....945
Equipment Conditions....945
Procedure....945
Navistar® Lower (N13)....948
Procedure....948
(Cummins® ISX) Two and Three Piece....952
Equipment Conditions....952
Procedure....952
Installation....956
Navistar® Upper (N13)....956
Procedure....956
Navistar® Lower (N13)....957
Procedure....957
Two Piece (Cummins® ISX)....958
Procedure....958
Fan Belt....959
Removal....959
Navistar® N13....959
Equipment Conditions....959
Procedure....959
Cummins® ISX....961
Procedure....961
Install....962
Navistar® N13....962
Torque Specifications....962
Equipment Conditions....962
Procedure....962
Cummins® ISX....963
Torque Specifications....963
Equipment Conditions....963
Procedure....963
Radiator Hose....964
Removal....964
Heat Shrink Clamp....964
Overview....964
Required Tools....964
Equipment Condition....964
Procedure....965
Radiator Hose Assemblies....966
Equipment Condition....966
Procedure....966
Upper....966
Lower....966
Installation....967
Heat Shrink Clamp....967
Torque Specifications....967
Radiator Hose Assemblies....970
Equipment Condition....970
Procedure....970
Lower....970
Upper....970
Charge Air Cooler....971
Removal....971
Navistar® N13....971
Equipment Conditions....971
Procedure....972
Cummins® ISX....973
Equipment Conditions....973
Procedure....973
Installation....975
Navistar® N13....975
Equipment Conditions....975
Procedure....975
Cummins® ISX....976
Procedure....976
Radiator Assembly....977
Removal....977
Navistar® N13....977
Equipment Conditions....977
Required Tools....978
Procedure....978
Cummins® ISX....980
Equipment Conditions....980
Procedure....980
Installation....986
Navistar® N13....986
Equipment Conditions....986
Procedure....986
Cummins® ISX....987
Procedure....987
Recirculation Seals....990
Removal....990
Navistar® N13....990
Equipment Conditions....990
Procedure....991
Driver Side Recirculation Seal....991
Passenger Side Recirculation Seal....991
Lower Recirculation Seal....992
Installation....993
Navistar® N13....993
Procedure....993
Lower Recirculation Seal....993
Passenger Side Recirculation Seal....993
Driver Side Recirculation Seal....993
Radiator Core....994
Removal....994
Navistar® N13....994
Overview....994
Equipment Conditions....994
Procedure....995
Cummins® ISX....996
Procedure....996
Installation....1001
Navistar® N13....1001
Equipment Conditions....1001
Procedure....1001
Cummins® ISX....1002
Procedure....1002
Power Steering Oil Cooler....1003
Removal....1003
Cummins® ISX....1003
Equipment Conditions....1003
Procedure....1004
Installation....1005
Cummins® ISX....1005
Torque Specifications....1005
Equipment Conditions....1005
Procedure....1005
Cooling Ring....1006
Overview....1006
5. Cooling System with Navistar® A26 Engine....1007
Cooling Package....1007
Overview....1007
Cooling System External Cleaning....1009
Special Tools....1009
Equipment Conditions....1009
Air Deflector Removal....1010
HVAC Condenser Cleaning....1010
Charge Air Cooler (CAC) Cleaning....1010
Front of Radiator Cleaning....1010
Air Deflector Installation....1011
Follow-On Procedure....1011
Deaeration Tank Inspection....1012
Overview....1012
Special Tools....1012
Specifications....1012
Equipment Conditions....1012
Setup....1013
Inspection Procedure....1014
Follow-On Procedure....1017
Check Coolant Condition....1018
Overview....1018
Special Tools....1018
Specifications....1018
Equipment Conditions....1018
Setup....1018
Coolant Check Procedure....1019
Follow-On Procedure....1020
Coolant Pressure Check Procedure....1021
Overview....1021
Special Tools....1021
Equipment Conditions....1021
Setup....1021
Pressure Check Procedure....1022
Follow-On Procedure....1024
Cooling Package Flush Procedure....1025
Overview....1025
Special Tools....1025
Specifications....1025
Equipment Conditions....1026
Preparation....1027
Coolant Filter Flush, if Applicable....1027
Flush Thermostat Housing....1027
Front Heater Core Flush....1028
Rear Heater Core Flush, if Applicable....1028
DEF Heater Core Flush....1029
Front and Rear, if Applicable, Heater Core Rinse....1030
DEF Heater Rinse....1030
Radiator and Engine Rinse....1031
Final Rinse....1031
Follow-On Procedure....1032
Follow-On Procedure....1032
Coolant Drain Procedure....1033
Overview....1033
Special Tools....1033
Specifications....1033
Equipment Conditions....1033
Coolant Drain Procedure....1034
Follow-On Procedure....1036
Deaeration Tank....1037
Removal....1037
Overview....1037
Special Tools....1037
Equipment Conditions....1037
Procedure....1038
Follow-On Procedure....1039
Installation....1040
Overview....1040
Special Tools....1040
Equipment Conditions....1040
Procedure....1041
Follow-On Procedure....1042
Engine Coolant Level (ECL) Sensor....1043
Removal....1043
Overview....1043
Special Tools....1043
Equipment Conditions....1044
Procedure....1045
Follow-On Procedure....1045
Installation....1046
Overview....1046
Special Tools....1046
Torque Specification....1047
Equipment Conditions....1047
Procedure....1048
Follow-On Procedure....1048
Power Steering Reservoir....1049
Relocation....1049
Overview....1049
Special Tools....1049
Equipment Conditions....1049
Procedure....1050
Follow-On Procedure....1050
Reinstallation....1051
Overview....1051
Special Tools....1051
Equipment Conditions....1051
Procedure....1052
Follow-On Procedure....1052
Radiator Hose....1053
Removal....1053
Overview....1053
Special Tools....1053
Equipment Conditions....1053
Removal Procedure....1055
Follow-On Procedure....1055
Installation....1056
Overview....1056
Special Tools....1056
Torque Specifications....1056
Equipment Conditions....1056
Installation Procedure....1057
Follow-On Procedure....1061
Cooling Package....1062
Removal....1062
Overview....1062
Special Tools....1062
Equipment Conditions....1062
Removal Procedure....1064
Follow-On Procedure....1068
Installation....1069
Overview....1069
Special Tools....1069
Equipment Conditions....1070
Installation Procedure....1070
Follow-On Procedure....1074
Radiator....1076
Removal....1076
Overview....1076
Special Tools....1076
Equipment Conditions....1076
Removal Procedure....1077
Follow-On Procedure....1083
Installation....1084
Overview....1084
Special Tools....1084
Equipment Conditions....1085
Installation Procedure....1086
Follow-On Procedure....1092
Coolant Fill Procedure....1093
Overview....1093
Special Tools....1093
Specifications....1093
Equipment Conditions....1093
Fill Procedure....1093
Follow-On Procedure....1095
HVAC Condenser....1096
Removal....1096
Overview....1096
Special Tools....1096
Equipment Conditions....1096
Procedure....1098
Follow-On Procedure....1099
Installation....1100
Overview....1100
Special Tools....1100
Equipment Conditions....1100
Procedure....1102
Follow-On Procedure....1103
Relocation....1104
Overview....1104
Special Tools....1104
Equipment Conditions....1104
Procedure....1106
Follow-On Procedure....1108
Reinstallation....1109
Overview....1109
Special Tools....1109
Torque Specifications....1109
Equipment Conditions....1109
Procedure....1111
Follow-On Procedure....1113
Charge Air Cooler (CAC)....1114
Overview....1114
Removal....1115
Overview....1115
Special Tools....1115
Equipment Conditions....1115
Removal Procedure....1117
Follow-On Procedure....1119
Installation....1120
Overview....1120
Special Tools....1120
Equipment Conditions....1120
Installation Procedure....1122
Follow-On Procedure....1124
Clean....1125
Overview....1125
Special Tools....1125
Equipment Conditions....1125
Off-Chassis Pressure Test....1126
Charge Air Cooler (CAC) Cleaning Management System (CMS) Install....1127
Cleaning Procedure....1128
Charge Air Cooler (CAC) Cleaning Management System (CMS) Removal....1128
Follow-On Procedure....1129
Flush....1130
Overview....1130
Special Tools....1130
Equipment Conditions....1130
Off-Chassis Pressure Test....1131
Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation....1132
Flush Procedure....1133
Charge Air Cooler (CAC) Cleaning Management System (CMS) Removal....1134
Follow-On Procedure....1134
Pressure Test....1135
Overview....1135
Special Tools....1135
Equipment Condition....1135
Test Setup....1136
Test Procedure....1137
Expected Outcome....1138
Follow-On Procedure....1139
6. Fan Drive....1142
Horton Fan Drive....1142
Overview....1142
Fan Drive with Override Switch....1143
Overview....1143
7. Power Take Off (PTO)....1144
Front Engine PTO....1144
Overview....1144
Rear Engine PTO....1145
Overview....1145
Transmissions....1147
1. Shifter....1149
Auxiliary Push Button Shift Control (Allison)....1149
Overview....1149
Troubleshooting - Powers, Grounds, and Data Link....1149
Push Button Shift Control (Allison)....1150
Overview....1150
Troubleshooting - Powers, Grounds, and Data Link....1151
Shift Control Parameters....1152
Overview....1152
2. Automated Manual Transmissions....1153
Eaton® UltraShift® PLUS....1153
Overview....1153
Removal....1155
Overview....1155
Special Tools....1155
Equipment Conditions....1155
Procedure....1156
Follow-On Procedure....1159
Installation....1160
Overview....1160
Special Tools....1160
Equipment Conditions....1161
Procedure....1161
Follow-On Procedure....1166
3. Automatic Transmissions....1168
Allison Transmission....1168
Overview....1168
Allison EVS Transmission....1170
Allison RDS Transmissions....1171
Allison OFS Transmissions....1172
Allison Automatic Transmission Flywheel....1174
Production Installation Instructions for Flywheel Bolts....1174
Service Installation Instructions for Flywheel Bolts....1174
Troubleshooting - Powers, Grounds, and Data Link....1174
Hydraulic Retarder....1175
Automatic Neutral....1175
Allison Spare Input / Output....1176
Overview....1176
Allison Spare Inputs/Outputs - Powers, Grounds, and Data Link....1177
4. Manual Transmissions....1178
Fuller....1178
Overview....1178
Removal....1180
Overview....1180
Special Tools....1180
Equipment Conditions....1180
Procedure....1181
Installation....1182
Overview....1182
Special Tools....1182
Equipment Conditions....1182
Procedure....1183
Follow On Procedure....1183
5. Transmission Oil....1184
Transmission Oil....1184
Overview....1184
Transmission Oil Level....1184
Auxiliary Transmission Lube....1185
Overview....1185
6. Transmission Oil Cooler....1186
Automatic Transmission Oil Cooler....1186
Overview....1186
Manual Transmission Oil Cooler....1187
Overview....1187
Auxiliary Transmission Oil Cooler....1188
Overview....1188
7. Auxiliary Transmissions....1189
Fuller....1189
Overview....1189
Spicer®....1190
Overview....1190
8. Power Take Off (PTO)....1191
Transmission Mounted PTO....1191
Overview....1191
Thru-shaft PTO....1192
Overview....1192
PTO Controls - Dash Mounted....1193
Overview....1193
Dash Mounted Electrical Controls....1194
Rear Axle and Suspension....1195
1. Axle Controls....1197
Axle Lift Controls....1197
Overview....1197
Axle Types....1197
Fixed Axles....1197
Self-Steering Axles....1197
Axle Mounting Locations....1198
Pusher Axles....1198
Tag Axles....1198
Axle Spacing....1198
System Controls....1198
Controls....1198
In Cab Controls....1199
Mixed Controls - Pressure Gauge and Switches in Cab and Pressure Gauge and Regulator Outside Cab....1199
Self-steering Axle Assemblies....1199
Overview....1199
2. Rear Suspension....1200
Air Suspensions....1200
Overview....1200
Torque Rods....1202
Removal....1202
Equipment Conditions....1202
Procedure....1202
Reinstallation....1203
Torque Specifications....1203
Procedure....1203
Installation....1204
Procedure....1204
Transverse Torque Rod....1205
Removal....1205
Equipment Conditions....1205
Procedure....1205
Installation....1206
Procedure....1206
Cross Tube....1207
Removal....1207
Equipment Conditions....1207
Procedure....1207
Installation....1208
Procedure....1208
Leveling Valve....1209
Removal....1209
Equipment Conditions....1209
Procedure....1209
Installation....1210
Procedure....1210
Ride Height Adjustment Procedure....1211
Overview....1211
Special Tools....1211
Specifications....1211
Equipment Conditions....1211
Procedure....1211
Follow-On Procedure....1214
Travel exceeds specification:....1214
Travel is less than specification:....1215
Tandem Rear Suspension (Chalmers Walking Beam Type)....1216
Overview....1216
Chalmers 800 Series....1217
Hendrickson - Walking Beam Type Suspension....1218
Overview....1218
Hendrickson RT Series....1219
Hendrickson HMX Suspensions....1220
Maintenance....1221
Fasteners....1221
Procedure....1221
Center Bushing Replacement Rubber or Bronze (On Vehicle)....1222
Removal....1222
Equipment Conditions....1222
Procedure....1222
Installation....1224
Procedure....1224
Three-piece Beam End Adapter with Rubber Bushing....1225
Remove (On Vehicle)....1225
Equipment Conditions....1225
Procedure....1225
Install (On Vehicle)....1226
Torque Specifications....1226
Procedure....1226
Torque....1227
Driveline Service and Troubleshooting....1228
Overview....1228
Height Control Valve....1230
Overview....1230
Driveline Angle Procedure - How to Measure....1232
Ride Height Measurement....1233
Overview....1233
Special Tools....1233
Equipment Conditions....1233
Measurement Procedure....1233
Follow-On Procedure....1236
Ride Height Adjustment....1237
Overview....1237
Special Tools....1237
Equipment Conditions....1237
Adjustment Procedure....1237
Travel exceeds specification:....1237
Travel is less than specification:....1237
Follow-On Procedure....1237
Drive Line Vibration....1238
Fuel System....1239
1. DEF System....1241
DEF Tank....1241
Overview....1241
DEF....1241
DEF Tank....1241
DEF Supply Module....1242
DEF Tank Pickup Assembly....1242
DEF Lines....1242
DEF Coolant Lines....1242
DEF Tank Heater Valve....1242
DEF Line Heater....1242
Inspection....1243
Overview....1243
Required Tools....1243
Equipment Condition....1243
Procedure....1243
Expected Outcome....1243
Follow-on Procedure....1243
Filter....1244
Removal....1244
Overview....1244
Required Tools....1244
Equipment Conditions....1244
Procedure....1245
Expected Outcome....1245
Follow-on Procedure....1245
Installation....1246
Overview....1246
Required Tools....1246
Torque Specifications....1246
Equipment Condition....1246
Procedure....1247
Expected Outcome....1247
Follow-on Procedure....1247
Diesel Exhaust Fluid (DEF) Tank....1248
Removal....1248
Overview....1248
Required Tools....1248
Equipment Conditions....1248
Procedure....1249
Expected Outcome....1249
Follow-on Procedure....1249
Installation....1250
Overview....1250
Required Tools....1250
Equipment Condition....1250
Procedure....1251
Expected Outcome....1251
Follow-on Procedure....1252
Diesel Exhaust Fluid (DEF) Head Module....1253
Removal....1253
Overview....1253
Required Tools....1253
Equipment Conditions....1253
Procedure....1254
Expected Outcome....1254
Follow-on Procedure....1254
Cleaning ....1255
Overview....1255
Required Tools....1255
Equipment Condition....1255
Procedure....1255
Expected Outcome....1256
Follow-on Procedure....1256
Installation....1257
Overview....1257
Required Tools....1257
Equipment Condition....1257
Procedure....1258
Expected Outcome....1258
Follow-on Procedure....1258
DEF Supply Module....1259
Removal....1259
Overview....1259
Required Tools....1259
Equipment Conditions....1259
Procedure....1260
Expected Outcome....1260
Follow-On Procedure....1260
Installation....1261
Overview....1261
Required Tools....1261
Equipment Conditions....1261
Procedure....1262
Expected Outcome....1262
Follow-On Procedure....1262
Inlet Screen....1263
Removal....1263
Overview....1263
Required Tools....1263
Equipment Conditions....1263
Procedure....1264
Expected Outcome....1264
Follow-On Procedure....1264
Cleaning....1265
Overview....1265
Required Tools....1265
Equipment Conditions....1265
Procedure....1266
Expected Outcome....1266
Follow-On Procedure....1266
Installation....1267
Overview....1267
Required Tools....1267
Equipment Conditions....1267
Procedure....1268
Expected Outcome....1268
Follow-On Procedure....1268
DEF Doser Inlet Screen....1269
Removal....1269
Overview....1269
Required Tools....1269
Equipment Conditions....1269
Procedure....1270
Expected Outcome....1270
Follow-On Procedure....1270
Cleaning....1271
Overview....1271
Required Tools....1271
Equipment Conditions....1271
Procedure....1272
Expected Outcome....1272
Follow-On Procedure....1272
Installation....1273
Overview....1273
Required Tools....1273
Equipment Conditions....1273
Procedure....1274
Expected Outcome....1274
Follow-On Procedure....1274
2. DEF Tank....1276
DEF Tank (9.5 Gallon)....1276
Overview....1276
DEF Tank Components....1280
Quality Sensor (DEFQ)....1280
Diesel Exhaust Fluid (DEF) Pump....1280
Coolant Control Valve (Diesel Exhaust Fluid (DEF) Tank Heater Valve)....1280
Diesel Exhaust Fluid (DEF) Fluid Level....1280
Diesel Exhaust Fluid (DEF) Supply and Return Lines....1281
DEF Tank (15.9 Gallon)....1282
Overview....1282
DEF....1282
DEF Tank....1282
DEF Supply Module....1283
DEF Tank Pickup Assembly....1283
DEF Lines....1283
DEF Coolant Lines....1283
DEF Tank Heater Valve....1283
DEF Line Heater....1283
DEF Tank....1284
Inspection....1284
Overview....1284
Special Tools....1284
Equipment Condition....1284
Procedure....1284
Expected Outcome....1284
Follow-On Procedure....1284
Removal....1285
Overview....1285
Special Tools....1285
Equipment Conditions....1285
Procedure....1286
Follow-On Procedure....1286
Installation....1287
Overview....1287
Special Tools....1287
Equipment Conditions....1287
Procedure....1288
Follow-On Procedure....1288
DEF Supply Module Filter....1289
Removal....1289
Overview....1289
Special Tools....1289
Equipment Conditions....1289
Procedure....1290
Follow-On Procedure....1290
Installation....1291
Overview....1291
Special Tools....1291
Torque Specifications....1291
Equipment Conditions....1291
Procedure....1292
Follow-On Procedure....1292
DEF Head Module....1293
Removal....1293
Overview....1293
Special Tools....1293
Equipment Conditions....1293
Procedure....1294
Follow-On Procedure....1294
Installation....1295
Overview....1295
Special Tools....1295
Equipment Conditions....1295
Procedure....1296
Follow-On Procedure....1296
DEF Tank (16 Gallon)....1297
Overview....1297
DEF Tank Components....1297
Quality Sensor (DEFQ)....1297
DEF Pump....1297
Coolant Control Valve (DEF Heater)....1297
DEF Fluid Level....1297
DEF Supply and Return Lines....1297
3. Fuel Cooler....1298
Fuel Cooler Without Thermostat....1298
Overview....1298
4. Fuel Heater....1299
Cummins....1299
Fuel Heater....1299
Overview....1299
5. Fuel Tanks....1301
Fuel Tank Diagnostics....1301
Overview....1301
Fuel Tanks Not Equalizing....1302
Overview....1302
Fault Facts....1302
Special Tools....1302
Possible Causes....1302
Fuel Tank Vent Test....1305
Overview....1305
Special Tools....1305
Equipment Conditions....1305
Test Setup....1305
Test Procedure....1305
Expected Outcome....1305
6. Fuel Water Separator....1306
Davco....1306
Preventive Maintenance....1308
Precautions....1308
Weekly - Drain Water....1308
Filter Change Procedure....1309
Every Filter Change....1309
Every 12 Months....1309
Racor....1310
Overview....1310
Fuel Filter Maintenance....1310
Common Issues with Winter Fuel....1311
Fuel Wax....1311
Fuel Blending....1312
7. Hydraulic Reservoir....1313
Hydraulic Reservoir (60 Gallon)....1313
Overview....1313
Torque....1314
Cab....1315
1. Accessories....1319
Power Door Locks....1319
Overview....1319
Door Panel....1320
Removal....1320
Equipment Conditions....1320
Procedure....1320
Installation....1325
Procedure....1325
Electric Window and Door Lock Switch....1326
Removal....1326
Equipment Conditions....1326
Procedure....1326
Installation....1327
Procedure....1327
Door Handle Replacement....1328
Removal....1328
Equipment Conditions....1328
Procedure....1328
Installation....1333
Torque Specification....1333
Procedure....1333
Mirrors....1334
Mirror Assembly Removal....1334
Overview....1334
Special Tools....1334
Equipment Conditions....1334
Removal Procedure....1335
Follow-On Procedure....1337
Mirror Assembly Installation....1338
Overview....1338
Special Tools....1338
Equipment Conditions....1339
Installation Procedure....1339
Follow-On Procedure....1341
2. Cab....1342
Battery Box (Driver Side)....1342
Removal....1342
Overview....1342
Special Tools....1342
Equipment Conditions....1342
Procedure....1343
Follow-on Procedure....1344
Installation....1345
Special Tools....1345
Procedure....1346
Follow-on Procedure....1347
Steps and Cover Panels (Passenger Side)....1348
Removal....1348
Overview....1348
Special Tools....1348
Equipment Conditions....1348
Procedure....1349
Follow-on Procedure....1350
Installation....1351
Special Tools....1351
Procedure....1352
Follow-on Procedure....1353
Cab Interior Trim - Base Level....1354
Overview....1354
Engine Cover....1355
Removal....1355
Equipment Conditions....1355
Procedure....1355
Installation....1357
Torque Specifications....1357
Procedure....1357
Air Switches....1358
Removal....1358
Equipment Conditions....1358
Procedure....1358
Air Valve(s)....1359
Installation....1360
Torque Specification....1360
Procedure....1360
Air Valve(s)....1360
Center Console Switches....1361
Removal....1361
Equipment Conditions....1361
Procedure....1361
Air Vent Module (Located Above Center Console Switch Panel)....1362
Air Valve(s) from Switch Panel....1362
Center Modules from Switch Panel....1362
Installation....1363
Torque Specifications....1363
Procedure....1363
Air Vent Module (Located Above Center Console Switch Panel)....1363
Center Modules in Switch Panel....1363
Air Valve(s) in Switch Panel....1363
Instrument Cluster....1364
Removal....1364
Equipment Conditions....1364
Procedure....1364
Installation....1365
Torque Specifications....1365
Procedure....1365
Lower Instrument Cluster Panel....1366
Removal....1366
Equipment Conditions....1366
Procedure....1366
Installation....1367
Torque Specifications....1367
Procedure....1367
Cab Interior Trim - Upgraded Trim....1368
Overview....1368
Vehicle Exterior - Paint....1369
Paint Schematics....1369
Standard Chassis and Cab Paint....1369
Body and Chassis Paint Guidelines....1374
Paint Code....1374
Description....1374
Inspection Criteria....1375
General Appearance Inspection Characteristics....1375
Chassis Paint Requirements....1376
Cab Rear Suspension....1377
Overview....1377
Ride Height Adjustment....1378
Equipment Conditions....1378
Adjustment - Set....1379
Cab Rear Suspension - Shock....1381
Removal....1381
Equipment Conditions....1381
Procedure....1382
Installation....1383
Procedure....1383
Cab Rear Suspension - Air Bag....1384
Removal....1384
Equipment Conditions....1384
Procedure....1384
Installation....1388
Procedure....1388
Cab Rear Suspension - Ride Height Valve....1389
Removal....1389
Equipment Conditions....1389
Procedure....1389
Installation....1391
Procedure....1391
Cab Rear Air Suspension - Sleeper Cab....1392
Overview....1392
Cab Skirts....1393
Overview....1393
Cab Interior Storage....1394
Overview....1394
Cab Sunshade....1395
Overview....1395
Day Cab....1396
Overview....1396
Cab Skirts....1397
Overview....1397
Door Adjustment Procedure....1398
Overview....1398
Special Tools....1398
Equipment Conditions....1398
Adjustment Procedure....1399
Follow-On Procedure....1401
Sleeper Cab....1402
Overview....1402
Vent Window....1403
Removal....1403
Overview....1403
Special Tools....1403
Equipment Condition....1403
Removal Procedure....1404
Expected Outcome....1404
Follow-On Procedure....1404
Installation....1405
Overview....1405
Special Tools....1405
Equipment Condition....1405
Installation Procedure....1406
Expected Outcome....1406
Follow-On Procedure....1406
Luggage Compartment - Release Cable....1407
Removal....1407
Overview....1407
Special Tools....1407
Equipment Condition....1407
Removal Procedure....1408
Expected Outcome....1408
Follow-On Procedure....1408
Installation....1409
Overview....1409
Special Tools....1409
Equipment Condition....1409
Installation Procedure....1410
Expected Outcome....1410
Follow-On Procedure....1410
Cab Side Fairing....1411
Overview....1411
Removal....1412
Overview....1412
Special Tools....1412
Equipment Conditions....1412
Removal Procedure....1413
Expected Outcome....1414
Follow-On Procedure....1414
Installation....1415
Overview....1415
Special Tools....1415
Equipment Conditions....1415
Installation Procedure....1416
Expected Outcome....1418
Follow-On Procedure....1418
Cab Skirts....1419
Overview....1419
Removal....1420
Overview....1420
Special Tools....1420
Equipment Conditions....1420
Removal Procedure....1421
Expected Outcome....1421
Follow-On Procedure....1421
Installation....1422
Overview....1422
Special Tools....1422
Torque Specifications....1422
Equipment Conditions....1422
Installation Procedure....1423
Expected Outcome....1423
Follow-On Procedure....1423
Windshield....1424
Overview....1424
Removal....1425
Installation....1431
3. HVAC....1443
HVAC with Integral Heater and Defroster....1443
Pre-Removal Procedures....1445
HVAC Compressor - Navistar® N13 Engine....1447
Removal....1447
Equipment Conditions....1447
Procedure....1447
Installation....1449
Procedure....1449
HVAC Blend Door Stepper Motor....1450
Removal....1450
Equipment Conditions....1450
Procedure....1450
Installation....1451
Procedure....1451
HVAC Expansion Valve....1452
Removal....1452
Equipment Conditions....1452
Procedure....1452
Installation....1454
Procedure....1454
Follow-On Procedure....1454
HVAC Fresh Air Door and Recirculation Stepper Motor....1455
Removal....1455
Equipment Conditions....1455
Procedure....1455
Installation....1456
Procedure....1456
HVAC High Pressure Switch....1457
Removal....1457
Equipment Conditions....1457
Procedure....1457
Installation....1458
Torque Specifications....1458
Procedure....1458
HVAC Control Head....1459
Removal....1459
Equipment Conditions....1459
Procedure....1460
Installation....1461
Torque Specifications....1461
Procedure....1461
HVAC Low Pressure Switch....1462
Removal....1462
Equipment Conditions....1462
Procedure....1462
Installation....1463
Torque Specifications....1463
Procedure....1463
HVAC Mode Door and Air Distribution Stepper Motor....1464
Removal....1464
Equipment Conditions....1464
Procedure....1464
Installation....1466
Procedure....1466
Sleeper HVAC....1467
Overview....1467
Sleeper Blend Door Actuator....1468
Removal....1468
Overview....1468
Special Tools....1468
Equipment Conditions....1468
Removal Procedure....1468
Follow-On Procedure....1468
Installation....1469
Overview....1469
Special Tools....1469
Torque Specifications....1469
Equipment Conditions....1469
Installation Procedure....1469
Follow-On Procedure....1469
General HVAC System Maintenance....1470
General Precautions....1470
Refrigerant Precautions....1470
Service Procedures....1474
Refrigerant Identification....1476
Adding Refrigerant to HVAC System....1477
Recover A/C System (Refrigerant Recovery)....1478
Evacuate A/C System....1480
Charge A/C System (Full Charge)....1483
Oil Fill Guidelines....1485
Overview....1485
Special Tools....1485
Equipment Conditions....1485
Procedure....1487
Oil separation during refrigerant recovery....1487
Component replacement....1487
Oil loss due to refrigerant leak....1487
Compressor replacement due to internal compressor failure....1487
Compressor replacement due to clutch failure....1487
Follow-On Procedure....1487
Check Compressor Oil Level....1488
Overview....1488
Special Tools....1488
Equipment Conditions....1488
Procedure....1488
Follow-On Procedure....1490
Leak Detection....1491
Sealant Detection....1491
Leak Detection....1491
Electronic Refrigerant Leak Detectors....1492
Ultraviolet (UV) Lamp Leak Testing....1493
Ultrasonic Leak Detectors....1493
Soap Solution with Nitrogen....1494
Refrigerant Leak Testing with Nitrogen....1494
A/C System Internal Damage Inspection....1495
Overview....1495
Special Tools....1495
Equipment Conditions....1495
Inspection Procedure....1495
Follow-On Procedure....1495
Flush and Purge A/C System....1496
Evaporator....1496
Overview....1496
Special Tools....1496
Equipment Conditions....1496
Procedure....1499
Follow-On Procedure....1500
Supply and Return Lines....1501
Overview....1501
Special Tools....1501
Equipment Conditions....1501
Procedure....1502
Follow-On Procedure....1505
Condenser....1507
Overview....1507
Special Tools....1507
Equipment Conditions....1507
Procedure....1509
Follow-On Procedure....1512
4. Instrumentation....1513
Driver Instrumentation Display....1513
Overview....1513
Gauge Cluster....1513
Overview....1513
Gauges....1513
Overview....1513
Air Application....1514
Air Cleaner Restriction....1514
Air Pressure for Rear Suspension....1514
Primary and Secondary Air Pressure....1514
Allison Oil Temperature....1514
Engine Oil Temperature....1514
Manual Transmission Oil Temperature....1514
Rear Axle Oil Temperature....1514
5. Seats....1515
National with RollTek®....1515
Drivers....1515
Overview....1515
Passenger....1517
Overview....1517
RollTek® Seat with Supplemental Restraint System (SRS)....1519
Removal (Driver and Passenger)....1519
Overview....1519
Required Tools....1519
Equipment Conditions....1519
Procedure....1519
Expected Outcome....1523
Follow-On Maintenance....1523
Installation (Driver and Passenger)....1524
Overview....1524
Required Tools....1524
Equipment Conditions....1524
Procedure....1524
Expected Outcome....1528
Follow-On Maintenance....1528
RollTek® Side Roll Airbag (SRA)....1529
Removal....1529
Overview....1529
Required Tools....1530
Equipment Conditions....1530
Procedure....1530
Expected Outcome....1533
Follow-On Maintenance....1533
Installation....1534
Overview....1534
Required Tools....1535
Torque Specifications....1535
Equipment Conditions....1535
Procedure....1535
Unpacking Replacement SRA Unit....1535
Product Identification....1536
RollTek® Side Roll Air Bag (SRA) - Installation....1537
Expected Outcome....1539
Follow-On Maintenance....1539
RollTek® Supplemental Restraint System (SRS) Module....1540
Removal....1540
Overview....1540
Required Tools....1541
Equipment Conditions....1541
Procedure....1541
Expected Outcome....1546
Follow-On Maintenance....1546
Installation....1547
Overview....1547
Required Tools....1548
Equipment Conditions....1548
Procedure....1548
Expected Outcome....1555
Follow-On Maintenance....1555
6. Windshield Wipers....1556
Windshield Wiper System....1556
Overview....1556
Windshield Wiper Motor....1557
Removal....1557
Overview....1557
Special Tools....1557
Equipment Conditions....1557
Removal Procedure....1558
Follow-On Procedure....1559
Installation....1560
Overview....1560
Special Tools....1560
Equipment Conditions....1560
Installation Procedure....1561
Follow-On Procedure....1562
Windshield Wiper Arm and Blade Assembly....1563
Removal....1563
Overview....1563
Procedure....1563
Installation....1564
Torque Specifications....1564
Procedure....1564
Windshield Wiper Assembly....1565
Removal....1565
Procedure....1565
Installation....1566
Procedure....1566
7. Torque....1567
Specifications for Ride Height Components....1567
Torque Chart....1568
Front Wheel....1569
1. Wheels and Tires....1571
Front Wheels....1571
Front Disc Wheels....1571
Hub Piloted Wheels....1571
Front Wheel Guards....1571
Front Wheel Seals....1571
Front Wheel Brand....1571
Rear Wheel....1573
1. Wheels, Rims and Tires....1575
Wheel Components....1575
Warnings....1578
Service Procedure....1579
Tire Service....1579
Brake Service....1579
Wheel and Wheel Assemblies Removal and Installation....1580
Disc Wheels....1580
Removal....1580
Installation....1583
OSHA Standards....1584
Wall Charts....1585
Care and Maintenance....1586
Wheel Studs and Mounting Nuts....1586
Installation, Tightening, and Alignment (Lateral Run-Out)....1589
Disc Wheels....1589
Disc Wheels with (Ball Seat) Nuts....1590
Disc Wheels with Flange Nuts....1591
Wheel and Tire Balancing....1593
Static Balancing....1593
Dynamic Balancing....1593
Tire Care....1594
Inspection....1594
Inflation....1594
Loads....1594
Tire Matching....1594
Dual Tires....1594
Tandem Drive Axles....1594
Front Wheel Drive, 4x4, 6x6 and 8x6....1594
Radial and Bias Ply Tires....1595
Rotation....1595
Rotation Is Always Advisable:....1595
Rotation May Be Advisable:....1595
Alignment - Front Axle....1595
Alignment - Rear Axle....1595
Tire Wear....1596
Service Load and Inflation Charts....1597
Tire and Rim Combinations....1604
Ply Rating Verses Load Range....1605
Torque Chart....1606
tables....46
Service Procedures....46
Torque Specification....54
Torque Specifications....71
Torque Specification....145
Torque Specifications....151
Torque Specifications....158
Torque Specifications....165
Torque Specifications....176
Procedures....191
Torque Specifications....219
Diagnostic Section....224
Diagnostic Section....276
Battery Type....286
Description....286
Battery Chemistry....286
Description....286
Battery Type....295
Description....295
Battery Chemistry....296
Description....296
Individual Battery Test RESULTS....298
Recommended Action....298
Starting System RESULTS....299
Recommended Action....299
RESULTS....303
Recommended Action....303
Regen Inhibit Switch Fault Code Diagnostics....318
Parked Regen Switch Fault Code Diagnostics....321
Chassis Body Builder Symptom Diagnostics....340
Test Procedure....374
Test Procedure....379
Specifications....386
Approximate CAN DC Voltage Measurements (Key ON)....393
Approximate CAN Resistance Measurements (Batteries Disconnected)....393
APADS Fault (Blink) Code Diagnostics....536
R-134a Static Temperature / Pressure Table....571
Instrumentation Sections....589
AGP Diagnostics....590
Instrument Cluster Gauge Diagnostics....599
Turn, Hazard and Brake Lights Symptom Diagnostics....612
Turn, Hazard and Brake Lights Fault Code Diagnostics....612
Fog Lights Symptom Diagnostics....633
Fog Lights Fault Code Diagnostics....633
Low Beam Headlights Symptom Diagnostics....645
Low Beam Headlights Fault Code Diagnostics....645
High Beam Headlights Symptom Diagnostics....645
High Beam Headlights Fault Code Diagnostics....645
Air Brakes Input Symptom Diagnostics....718
Air Brake Fault Code Diagnostics....718
Park / Marker Lights Symptom Diagnostics....726
Park / Marker Lights Fault Code Diagnostics....726
Check Communication....760
Test 1 – Power Circuit Check....760
Test 2– Ground Circuit Check....760
Service Information....764
Service Information....767
Feature Codes....771
Windshield Wiper Symptom Diagnostics....776
Windshield Wiper Fault Code Diagnostics....777
Windshield Wiper Input Switch....777
Torque Specification....863
Torque Specifications....868
Specifications....870
Torque Specifications....870
Torque Specifications....893
Torque Specifications....927
Torque Specifications....943
Torque Specifications....956
Torque Specifications....957
Torque Specifications....958
Torque Specifications....970
Torque Specifications....975
Torque Specifications....976
Torque Specifications....986
Torque Specifications....987
Torque Specifications....993
Torque Specifications....1001
Torque Specifications....1002
Specifications....1021
Torque Specifications....1040
Torque Specifications....1051
Torque Specifications....1069
Torque Specifications....1085
Torque Specifications....1100
Torque Specifications....1120
Torque Specifications....1135
Torque Specifications....1161
Flywheel Bolt Load and Stretch Targets....1174
Torque Specifications....1204
Torque Specifications....1206
Torque Specifications....1208
Torque Specifications....1221
Torque Specifications....1224
Maintenance Torque Chart....1227
Specifications....1233
Specifications....1237
Torque Specifications....1250
Torque Specifications....1261
Torque Specifications....1267
Torque Specifications....1273
Torque Specifications....1287
Torque Specifications....1295
Torque Specifications....1338
Torque Specifications....1345
Torque Specifications....1351
HX™ Series Special Paint Ordering Codes Chart....1373
Torque Specifications....1378
Torque Specifications....1383
Torque Specifications....1388
Torque Specifications....1391
Torque Specifications....1396
Specifications....1398
Torque Specifications....1398
Torque Specifications....1405
Torque Specifications....1415
Torque Specifications....1424
Overview....1443
Torque Specifications....1451
Torque Specifications....1454
Torque Specifications....1456
Torque Specifications....1466
Oil Capacity by Component....1485
Torque Specifications....1488
Torque Specifications....1524
Torque Specifications....1548
Torque Specifications....1560
Torque Specifications....1566
Torque Specifications....1567
Torque Specifications for Thread Size....1568
Service Load and Inflation Chart (not Michelin) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 1)....1597
Service Load and Inflation Chart (not Michelin) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 2)....1598
Service Load and Inflation Chart (not Michelin) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 3)....1599
Service Load and Inflation Chart (not Michelin) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 4)....1599
Service Load and Inflation Chart (Michelin only) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 5)....1600
Service Load and Inflation Chart (Michelin only) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 6)....1601
Service Load and Inflation Chart (Michelin only) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 7)....1602
Service Load and Inflation Chart (Michelin only) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 8)....1602
Service Load and Inflation Chart (Michelin only) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 9)....1603
Service Load and Inflation Chart (Michelin only) (For Trucks, Buses and Trailers in Normal Highway Service) (Page 10)....1603
Tire and Rim Combinations - Tires Designed for Normal Highway Service....1604
International/NaviStar HX-series Trucks Repair Service Manual 2017-2020
