International/NaviStar HX-series Trucks Repair Service Manual 2017-2020

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Price: US$ 75.00

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

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