International HVHD-Series, HVMD-Series Repair Service Manual 2018-2020
Complete service repair manual with Electrical Wiring Diagrams for International/Navistar HVHD-Series, HVMD-Series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
2018-2020 International HV-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.
PRODUCT DETAILS:
Total Pages: 2,238 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0001027584 - 2018-2020 International HV Technician Manual (Service and Diagnostics), Revision 10.pdf
4328687 - Interactive Schematics User Guide.pdf
MAIN SECTIONS
0001027584 - 2018-2020 International HV Technician Manual (Service and Diagnostics), Revision 10...1
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. Frame and Bumper...11
Front Bumper...11
Overview...11
Removal...13
Overview...13
Special Tools...13
Equipment Conditions...13
Removal Procedure...14
Expected Outcome...14
Follow-On Procedure...14
Installation...15
Overview...15
Special Tools...15
Torque Specifications...15
Equipment Conditions...15
Installation Procedure...16
Follow-On Procedure...16
Pintle Hook...17
Overview...17
Tow Hook...18
Overview...18
Tow Pin...19
Overview...19
Front Axle...21
1. Front Axle...23
Non-Driving...23
Dana Spicer®...23
Overview...23
Service Information...24
Tech Tips...24
Meritor®...25
Overview...25
Service Information...26
Wheel Seals...27
Removal...27
Overview...27
Special Tools...27
Equipment Conditions...27
Procedure...27
Follow-On Procedure...30
Installation...31
Overview...31
Special Tools...31
Equipment Conditions...31
Procedure...31
Follow-On Procedure...33
Kingpins...35
Left Removal...35
Overview...35
Special Tools...35
Equipment Conditions...35
Procedure...35
Follow-On Procedure...38
Left Installation...39
Overview...39
Special Tools...39
Equipment Conditions...39
Procedure...39
Follow-On Procedure...42
Right Removal...43
Overview...43
Special Tools...43
Equipment Conditions...43
Procedure...43
Follow-On Procedure...46
Right Installation...47
Overview...47
Special Tools...47
Equipment Conditions...47
Procedure...47
Follow-On Procedure...50
Driving...51
Fabco®...51
Overview...51
Meritor®...52
Overview...52
Wheel Seals...54
Removal...54
Overview...54
Special Tools...54
Equipment Condition...54
Procedure...54
Follow-On Procedure...56
Installation...57
Overview...57
Special Tools...57
Equipment Condition...57
Procedure...57
Follow-On Procedure...59
Kingpins...60
Left Removal...60
Overview...60
Special Tools...60
Equipment Conditions...60
Procedure...60
Follow-On Procedure...66
Left Installation...67
Overview...67
Special Tools...67
Equipment Conditions...67
Procedure...67
Follow-On Procedure...74
Right Removal...75
Overview...75
Special Tools...75
Equipment Conditions...75
Procedure...75
Follow-On Procedure...81
Right Installation...82
Overview...82
Special Tools...82
Equipment Conditions...82
Procedure...82
Follow-On Procedure...89
Front Suspension...91
1. Suspension...93
Auxiliary Air Bags...93
Overview...93
Air Bag...94
Removal...94
Overview...94
Special Tools...94
Equipment Condition...94
Removal Procedure...95
Expected Outcome...95
Follow-On Procedure...95
Installation...96
Overview...96
Special Tools...96
Torque Specifications...96
Equipment Condition...96
Installation Procedure...97
Follow-On Procedure...97
Leaf Spring...98
Overview...98
Parabolic Taper Leaf Spring...100
Removal...100
Overview...100
Special Tools...100
Equipment Conditions...100
Procedure...101
Follow-On Procedure...101
Installation...102
Overview...102
Special Tools...102
Torque Specifications...102
Equipment Conditions...102
Procedure...103
Follow-On Procedure...104
Auxiliary Rubber Spring...105
Overview...105
Brakes...107
1. Air Brakes - Foundation...109
Disc Brakes...109
Front ...109
Overview...109
Caliper Removal...110
Overview...110
Special Tools...110
Equipment Condition...110
Removal Procedure...110
Follow-On Procedure...110
Caliper Installation...111
Overview...111
Special Tools...111
Equipment Condition...111
Installation Procedure...111
Follow-On Procedure...112
Rear...113
Overview...113
Caliper Removal...114
Overview...114
Special Tools...114
Equipment Condition...114
Removal Procedure...114
Follow-On Procedure...114
Caliper Installation...115
Overview...115
Special Tools...115
Equipment Condition...115
Installation Procedure...115
Follow-On Procedure...116
Drum Brakes...117
Front...117
Overview...117
Rear...118
Overview...118
Foot Brake Control Valve...119
Overview...119
Service Brake System...120
Overview...120
Foot Valve...121
Removal...121
Overview...121
Special Tools...121
Equipment Conditions...121
Removal Procedure...122
Follow-On Procedure...122
Installation...123
Overview...123
Special Tools...123
Torque Specifications...123
Equipment Conditions...123
Installation Procedure...124
Follow-On Procedure...124
Quick Release Valve...125
Removal...125
Overview...125
Special Tools...125
Equipment Conditions...125
Removal Procedure...126
Follow-On Procedure...126
Installation...127
Overview...127
Special Tools...127
Torque Specifications...127
Equipment Conditions...127
Installation Procedure...128
Follow-On Procedure...128
Spring (Park) Brake System...129
Spring Brake Modulator Valve...129
Overview...129
Slack Adjusters...130
Front Axle...130
Overview...130
Service Information...131
Pusher Axle...132
Overview...132
Rear Axle...133
Overview...133
Tag Axle...135
Overview...135
2. Air Brakes - Bendix...136
ABS / ATC / ESC...136
Overview...136
ABS...139
ATC...140
ESC...142
ABS Module...144
Removal...144
Overview...144
Special Tools...144
Equipment Conditions...144
Removal Procedure...145
Follow-On Procedure...146
Installation...147
Overview...147
Special Tools...147
Torque Specifications...147
Equipment Conditions...147
Installation Procedure...148
Follow-On Procedure...149
Modulator Valve...150
Removal...150
Overview...150
Special Tools...150
Equipment Conditions...150
Removal Procedure...151
Follow-On Procedure...151
Installation...152
Overview...152
Special Tools...152
Torque Specifications...152
Equipment Conditions...152
Installation Procedure...153
Follow-On Procedure...153
Steering Angle Sensor...154
Removal...154
Overview...154
Special Tools...154
Equipment Conditions...154
Removal Procedure...155
Follow-On Procedure...157
Installation...158
Overview...158
Special Tools...158
Equipment Conditions...158
Installation Procedure...159
Follow-On Procedure...161
Traction Relay Valve...162
Front Removal...162
Overview...162
Special Tools...162
Equipment Conditions...162
Removal Procedure...163
Follow-On Procedure...163
Front Installation...164
Overview...164
Special Tools...164
Torque Specifications...164
Equipment Conditions...164
Installation Procedure...165
Follow-On Procedure...165
Rear Removal...166
Overview...166
Special Tools...166
Equipment Conditions...166
Removal Procedure...167
Follow-On Procedure...167
Rear Installation...168
Overview...168
Special Tools...168
Torque Specifications...168
Equipment Conditions...168
Installation Procedure...169
Follow-On Procedure...169
Wheel Speed Sensor...170
Removal...170
Overview...170
Special Tools...170
Equipment Conditions...170
Removal Procedure...171
Follow-On Procedure...171
Installation...172
Overview...172
Special Tools...172
Torque Specifications...172
Equipment Conditions...172
Installation Procedure...173
Follow-On Procedure...173
Yaw Rate Sensor...174
Removal...174
Overview...174
Special Tools...174
Equipment Conditions...174
Removal Procedure...175
Follow-On Procedure...175
Installation...176
Overview...176
Special Tools...176
Equipment Conditions...176
Installation Procedure...177
Follow-On Procedure...177
3. Air Brakes - Wabco...178
ABS...178
Overview...178
ABS...180
Wheel Speed Sensor...181
Removal...181
Overview...181
Special Tools...181
Equipment Conditions...181
Procedure...182
Follow-On Procedure...182
Installation...183
Overview...183
Special Tools...183
Torque Specifications...183
Equipment Conditions...183
Procedure...184
Follow-On Procedure...184
4. Air Systems...185
Air Compressors...185
Cummins® 18.7 CFM...185
Overview...185
Cummins® 30.4 CFM...186
Overview...186
Knorr-Bremse® 31.8 CFM...187
Overview...187
Bendix® 15.9 CFM...188
Overview...188
Air Dryers...189
Bendix® AD-9™...189
Overview...189
Bendix® AD-IP™...190
Overview...190
Meritor® WABCO System Save 1200 Plus...191
Overview...191
Meritor® WABCO System Save 1800 Plus...192
Overview...192
Drain Valves...193
Heated Drain Valves...193
Overview...193
5. Trailer...195
Trailer Connections...195
Air Brakes - Trailer Connections...195
Overview...195
Trailer Foundation Brakes...197
Hand Control Valve...197
Overview...197
Steering...199
1. Steering Column...201
Stationary...201
Overview...201
Tilting...202
Overview...202
Tilting and Telescoping...203
Overview...203
2. Steering Wheel...204
Overview...204
Steering Wheel...205
Removal...205
Overview...205
Special Tools...205
Equipment Conditions...205
Removal Procedure...206
Follow-On Procedure...207
Installation...208
Overview...208
Special Tools...208
Equipment Conditions...208
Installation Procedure...209
Follow-On Procedure...210
Steering Wheel Switches...211
Removal...211
Overview...211
Special Tools...211
Equipment Condition...211
Removal Procedure...212
Follow-On Procedure...213
Installation...214
Overview...214
Special Tools...214
Equipment Condition...214
Installation Procedure...215
Follow-On Procedure...216
3. Power Steering...217
Power Steering Gear...217
Overview...217
Pump Flow Test...219
Overview...219
Special Tools...219
Equipment Condition...219
Setup...220
Procedure...220
Follow-On Procedure...221
Bleed Procedure...222
Overview...222
Special Tools...222
Equipment Conditions...222
System Bleed Procedure...223
Follow-On Procedure...223
Drivelines...225
1. Driveshaft...227
Dana Spicer®...227
Overview...227
U-joint...228
Removal...228
Overview...228
Special Tools...228
Equipment Condition...228
Removal Procedure...229
Follow-on Procedure...229
Installation...230
Overview...230
Special Tools...230
Equipment Condition...230
Installation Procedure...231
Follow-on Procedure...231
Center Bearing...232
Overview...232
Removal...232
Overview...232
Special Tools...232
Equipment Condition...232
Procedure...234
Follow-On Procedure...234
Inspection...235
Overview...235
Special Tools...235
Equipment Condition...235
Procedure...236
Follow-On Procedure...236
Installation...237
Overview...237
Special Tools...237
Torque Specifications...237
Equipment Condition...237
Procedure...238
Follow-On Procedure...238
Drive Line Service and Troubleshooting...239
Operational Check...239
Overview...239
Exhaust...243
1. Aftertreatment System...245
Aftertreatment Reuse Guidelines...245
Overview...245
DOC, DPF and SCR Housing Reuse Guidelines...245
DPF Media Types...245
DOC Inspection and Reuse Guidelines...246
Overview...246
Special Tools...246
Equipment Condition...246
Inspection Procedure...247
Reuse Guidelines...248
DOC Inlet New...248
DOC Inlet / Outlet - Melted...249
DOC Inlet - Face Plugged...250
DOC Inlet / Outlet Face Gouged...251
Expected Outcome...251
Follow-On Procedure...252
DPF Inspection and Reuse Guidelines...253
Overview...253
Special Tools...253
Equipment Condition...253
Inspection Procedure...254
Reuse Guidelines...255
DPF Inlet - New...255
DPF Inlet - Dirty and Useable...256
DPF Inlet - Dirty and Useable 2...258
DPF Inlet - Clean...259
DPF Inlet - Gouged...260
DPF Inlet - Ash...261
DPF Inlet - Dark Soot Rings...262
DPF Outlet - Soot Stains...263
DPF Outlet - Burn Marks from Welding...264
DPF Outlet - Excessive Soot Stains...265
DPF Outlet - Face Cracked...266
DPF Outlet - Coolant Staining...267
DPF Outlet - Melted...268
Expected Outcome...268
Follow-On Procedure...268
SCR Catalyst Inspection and Reuse Guidelines...269
Overview...269
Special Tools...269
Equipment Condition...269
Inspection Procedure...270
Reuse Guidelines...271
New Aftertreatment SCR...271
Iron Deposits on SCR Inlet...272
DEF Deposits on SCR Inlet...273
Media Erosion on SCR Inlet...274
Water Stains on SCR Inlet...275
Expected Outcome...275
Follow-On Procedure...275
Single Can Indexing...276
Overview...276
Special Tools...276
Equipment Condition...276
Procedure...276
Follow-On Procedure...277
Inhibit Regeneration Switch...278
Overview...278
2. Exhaust System...279
Exhaust System Procedures...279
Horizontal / Horizontal...280
Overview...280
Single Can...282
Removal...282
Overview...282
Special Tools...282
Equipment Condition...282
Removal Procedure...283
Expected Outcome...283
Follow-On Procedure...283
Installation...284
Overview...284
Special Tools...284
Equipment Condition...284
Installation Procedure...285
Expected Outcome...285
Follow-On Procedure...285
Horizontal / Vertical ...286
Overview...286
Vertical / Vertical...287
Overview...287
3. Engine Brake...288
Engine Compression Brake with Switch...288
Overview...288
Electrical / Software...289
1. Diagnostic Trouble Code (DTC) List...297
2. Electronic Service Tools (EST)...301
Diamond Logic® Builder...301
Overview...301
Selecting an Interface Cable...303
Overview...303
Special Tools...303
Equipment Conditions...303
Selection Procedure...303
Follow-On Procedure...304
Connecting to a Vehicle...305
Overview...305
Special Tools...305
Equipment Conditions...305
Connection Procedure...305
Follow-On Procedure...306
Activating Diagnostic Mode...307
Overview...307
Special Tools...307
Equipment Conditions...307
Activation Procedure...307
Follow-On Procedure...308
Starting a Session...309
Overview...309
Special Tools...309
Equipment Conditions...309
Starting Procedure...309
Follow-On Procedure...310
Viewing Fault Codes...311
Overview...311
Special Tools...311
Equipment Conditions...311
Viewing Procedure...311
Follow-On Procedure...311
Clearing Fault Codes...312
Overview...312
Special Tools...312
Equipment Conditions...312
Clearing Procedure...312
Follow-On Procedure...312
Modifying Signals Tab...313
Overview...313
Special Tools...313
Equipment Conditions...313
Modify Watched Signal Columns...313
Modify Watched Signals...314
Follow-On Procedure...314
Programming Modules...315
Overview...315
Special Tools...315
Equipment Conditions...315
Programming Procedure...315
Follow-On Procedure...318
Input Not Recognized by Body Control Module...319
Overview...319
Special Tools...319
Equipment Conditions...319
Troubleshooting Procedure...319
Follow-On Procedure...320
Output Not Commanded by Body Control Module...321
Overview...321
Special Tools...321
Equipment Conditions...321
Troubleshooting Procedure...321
Follow-On Procedure...322
3. General Electrical Repair...323
Electrical Connector Cleaning...323
Overview...323
Special Tools...323
Specifications...323
Equipment Conditions...323
Cleaning Procedure...323
Follow-On Procedure...323
4. 12 Volt System...324
Overview...324
Battery Box...330
Overview...330
Battery Disconnect...333
Special Tools...333
Equipment Conditions...333
Disconnect Procedure...333
Follow-On Procedure...334
Battery Reconnect...335
Special Tools...335
Equipment Conditions...335
Reconnect Procedure...336
Follow-On Procedure...336
Battery Terminal Cleaning...337
Overview...337
Special Tools...337
Equipment Conditions...337
Cleaning Procedure...338
Follow-On Procedure...338
Battery Disconnect Switch...339
Overview...339
Body Control Module...340
Diagnostics...340
Overview...340
Body Control Module Electrical Test...342
Overview...342
Special Tools...342
Equipment Conditions...342
Test Setup...342
SPN 1079 FMI 1 - 5V Sensor Supply Below Normal Range...348
Overview...348
Associated Faults...348
Fault Facts...348
Special Tools...348
Possible Causes...348
Charging and Starting System...354
Operational Checkout Procedure...355
Overview...355
Special Tools...355
Charging System...356
Overview...356
Red Battery Warning Light ON...359
Overview...359
Associated Faults...359
Fault Facts...359
Special Tools...359
Possible Causes...359
Repeated Jump Starts / Parasitic Draw...361
Overview...361
Associated Faults...361
Fault Facts...361
Special Tools...361
Possible Causes...361
Voltmeter Gauge Reading High...363
Overview...363
Associated Faults...363
Fault Facts...363
Special Tools...363
Possible Causes...363
Voltmeter Gauge Reading Low / Fluctuating...365
Overview...365
Associated Faults...365
Fault Facts...365
Special Tools...365
Possible Causes...365
Starting System...367
Overview...367
No Click No Crank...370
Overview...370
Associated Faults...370
Fault Facts...370
Special Tools...370
Possible Causes...370
Click No Crank...372
Overview...372
Associated Faults...372
Fault Facts...372
Special Tools...372
Possible Causes...372
Low Cranking Speed...374
Overview...374
Associated Faults...374
Fault Facts...374
Special Tools...374
Possible Causes...374
Charging and Starting Tests...375
Overview...375
Individual Battery Test...376
Overview...376
Special Tools...376
Equipment Condition...376
Test Setup...376
Test Procedure...377
Expected Outcome...379
Follow-On Procedure...379
Electrical System Test...380
Overview...380
Special Tools...380
Equipment Condition...381
Test Setup...381
Battery Pack Test Procedure...383
Starter System Test Procedure...386
Charging System Test Procedure...388
Expected Outcome...391
Follow-On Procedure...391
Cable Drop Test...392
Overview...392
Special Tools...392
Equipment Condition...392
Test Setup...392
Test Procedure...392
Expected Outcome...395
Follow-On Procedure...395
Parasitic Draw Test...396
Overview...396
Special Tools...396
Equipment Condition...396
Test Setup...396
Test Procedure...396
Expected Outcome...399
Follow-On Procedure...399
Manual Engine Bar Test...400
Overview...400
Special Tools...400
Equipment Conditions...400
Test Setup...400
Test Procedure...400
Expected Outcome...400
Follow-On Procedure...400
Starter Control Circuit Test...401
Overview...401
Special Tools...401
Equipment Conditions...401
Test Setup...401
Test Procedure...401
Follow-On Procedure...402
Starter Input Signal Test...403
Overview...403
Special Tools...403
Equipment Conditions...403
Test Setup...403
Test Procedure...403
Follow-On Procedure...406
Charging and Starting Inspections...407
Overview...407
Ring Gear Inspection...408
Overview...408
Special Tools...408
Equipment Conditions...408
Inspection Procedure...408
Expected Outcome...409
Follow-On Procedure...409
Electrical System Inspection...410
Overview...410
Special Tools...410
Equipment Conditions...410
Inspection Procedure...410
Expected Outcome...413
Follow-On Procedure...413
Starting System Inputs...414
Overview...414
Key Switch and Grid Control...414
Crank Inhibit...414
GridCtrl_CrankInhibit...414
Crank_Inhibit_Reason...414
Lower_Clutch_Signal...415
Neutral_Status_TCM...415
Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal)...415
Hood_Switch...415
Clutch Switch...417
Overview...417
Crank Inhibit...423
Overview...423
Hood Switch...424
Overview...424
Key Switch...427
Overview...427
Neutral Confirmation...432
Overview...432
Automatic Transmissions...432
Manual Transmissions...432
Automatic Transmissions...434
Overview...434
Manual Transmissions...435
Overview...435
Jump Start Stud...437
Overview...437
5. Accessories...438
Audio System...438
Radio...438
Overview...438
Radio...439
Speakers...440
Auxiliary Power Outlets...441
Overview...441
CB Radio...442
Accommodation Package...442
Overview...442
Cruise Control...443
Overview...443
Data Recorder...447
With Display...447
Overview...447
Horns...448
Air...448
Overview...448
Electric Horn...450
Overview...450
Electric Horn Inoperative...454
Overview...454
Fault Facts...454
Special Tools...454
Possible Causes...454
SPN 2641 FMI 5 - Electric Horn Undercurrent...458
Overview...458
Associated Faults...458
Fault Facts...458
Special Tools...458
Possible Causes...458
SPN 2641 FMI 6 - Electric Horn Overcurrent...460
Overview...460
Associated Faults...460
Fault Facts...460
Special Tools...460
Possible Causes...460
SPN 2641 FMI 14 - Horn Preserve for 10 Min...462
Fault Overview...462
Associated Faults...462
Fault Facts...462
Special Tools...462
Possible Causes...462
Power Door Locks / Windows / Mirrors...464
Auto Door Lock...464
Overview...464
Two Door...467
Overview...467
Four Door...473
Overview...473
Screenshot Codes...478
Keyless Entry Remote...479
Overview...479
Screenshot Codes...482
Remote Keyless Entry Fob Programming...483
Overview...483
Special Tools...483
Specifications...483
Equipment Conditions...483
Programming Procedure...483
Follow-On Procedure...483
Power Mirrors...484
Overview...484
Heated Mirrors...487
Overview...487
Screenshot Codes...491
Satellite Communication System...492
PeopleNet...492
Overview...492
Steering Wheel Switches...493
Left POD...493
Overview...493
Screenshot Codes...494
Right POD...495
Overview...495
Screenshot Codes...496
Steering Wheel Auxiliary Controls (Radio)...497
Overview...497
Screenshot Codes...498
Theft Deterrent System...500
W / Combination Code...500
Overview...500
Screenshot Codes...503
Operational Checkout Procedure...505
Overview...505
Theft Deterrent System Not Responding...506
Overview...506
Associated Faults...506
Fault Facts...506
Special Tools...506
Possible Causes...506
Two-Way Radio...508
Overview...508
Windshield...510
Heated...510
Overview...510
6. Aftertreatment System...513
Inhibit Regeneration Switch...513
Overview...513
Park Regeneration Switch...515
Overview...515
7. Alarms...517
Back Up Alarm...517
Overview...517
Park Brake Alarm...518
Overview...518
8. Brakes...519
Bendix® Air Brake System...519
Antilock Brake System (ABS)...519
Overview...519
Inputs...521
Outputs...521
Automatic Traction Control (ATC) System...523
Overview...523
Inputs...524
Outputs...525
Electronic Stability Control (ESC) System...527
Overview...527
Inputs...529
Outputs...530
Operational Checkout Procedure...532
Overview...532
Special Tools...532
ABS Module Electrical Test...533
Overview...533
Special Tools...533
Equipment Conditions...533
Test Setup...533
Meritor® WABCO Air Brake System...536
Antilock Brake System (ABS)...536
Inputs...538
Outputs...538
Park Brake...540
Overview...540
Park Brake Indicator...541
Parking Brake Alarm for Park Brake Not Applied...541
Parking Brake Alarm with Motion Warning System...541
9. Body Builder...542
Aerial Boom Warning...542
Light and Buzzer...542
Air Solenoids...543
Multiplexed...543
Overview...543
Non-Multiplexed...547
Overview...547
Auxiliary Load Switches...549
Multiplexed...549
Overview...549
Non-Multiplexed...556
Overview...556
Engine Speed...557
Emergency Power Output and Utility Application...557
Overview...557
Demand Engine Speed with Utility Application...559
Overview...559
On Demand Engine Speed with Utility Application, for Cummins® Engines...561
Overview...561
On Demand Engine Speed for Refuse...562
Overview...562
With Utility Application...564
Overview...564
Outrigger Warning...566
With Light and Buzzer...566
Overview...566
Power Source...567
Overview...567
Auxiliary Power Source...568
Overview...568
Lift Gate...569
Overview...569
Overview...569
Remote Power Module (RPM) with Switches...573
Overview...573
Remote Start / Stop...578
Overview...578
Transfer Case PTO...580
Overview...580
Transmission PTO...581
Single...581
Overview...581
Dual...583
Overview...583
PTO Control...586
Overview...586
PTO Shift...588
Air Clutch...588
Overview...588
Air Engagement Accommodation...589
Overview...589
Customer Provided PTO...590
Overview...590
Customer Provided PTO With Relay...592
Overview...592
Hydraulic Clutch or Air Engagement Accommodation...594
Overview...594
Lectra Shift Control...595
Overview...595
10. Collision Mitigation Systems...598
Bendix® Wingman® Advanced™...598
Overview...598
Adaptive Cruise Control (ACC)...600
Alerts...600
Collision Mitigation Braking...600
Tech Tips...601
Operational Checkout Procedure...602
Overview...602
Special Tools...602
Radar Sensor...604
Electrical Test...604
Overview...604
Special Tools...604
Equipment Conditions...604
Test Setup...604
Follow-On Procedure...606
Removal...607
Overview...607
Special Tools...607
Equipment Conditions...607
Removal Procedure...607
Follow-On Procedure...608
Installation...609
Overview...609
Special Tools...609
Torque Specifications...609
Equipment Conditions...609
Installation Procedure...609
Follow-On Procedure...610
Adjustment...611
Overview...611
Special Tools...611
Equipment Conditions...611
Lateral Adjustment Procedure (Radar or Mounting Plate Not Replaced)...611
Lateral Adjustment Procedure (Radar or Mounting Plate Replaced)...613
Vertical Adjustment Procedure...615
Follow-On Procedure...617
11. Datalinks...618
CAN Systems...618
Overview...618
CAN Faults...618
Backbone Open...618
Node Circuit Open...619
Short...619
Terminating Resistor Failure...619
Tech Tips...619
Operational Checkout Procedure...621
Overview...621
Special Tools...621
125K Low Speed...622
Overview...622
125K Low Speed J1939 Diagnostics...624
Overview...624
Associated Faults...624
Fault Facts...624
Special Tools...624
Possible Causes...624
250K Body...627
Overview...627
250K Body J1939 Diagnostics...628
Overview...628
Associated Faults...628
Fault Facts...628
Special Tools...628
Possible Causes...628
250K Cab...631
Overview...631
250K Cab J1939 Diagnostics...633
Overview...633
Associated Faults...633
Fault Facts...633
Special Tools...633
Possible Causes...633
500K Powertrain...636
Overview...636
500K Powertrain J1939 Diagnostics...638
Overview...638
Associated Faults...638
Fault Facts...638
Special Tools...638
Possible Causes...638
Tests...641
Overview...641
CAN Resistance Test...642
Overview...642
Special Tools...642
Equipment Conditions...642
Test Setup...642
Test Procedure...642
Follow-On Procedure...643
CAN Voltage Test...644
Overview...644
Special Tools...644
Equipment Conditions...644
Test Setup...644
Test Procedure...644
Follow-On Procedure...645
Module Communication Test...646
Overview...646
Special Tools...646
Equipment Condition...646
Test Setup...646
Test Procedure...646
Follow-On Procedure...647
Power and Ground Test...648
Overview...648
Special Tools...648
Equipment Conditions...648
Test Setup...648
Test Procedure...648
Follow-On Procedure...649
12. Engine...650
Compression Brake...650
Overview...650
Cummins® Diagnostics...653
Table of Contents...653
Fault Code Diagnostics...654
Fault Code List...654
SPN 111 FMI 1 (Cummins FC 235) - Coolant Level - Data Valid But Below Normal Operating Range - Most Severe Level...656
Fault Overview...656
Associated Faults...656
Fault Facts...656
Conditions For Clearing The Fault Codes...656
Possible Causes...656
SPN 111 FMI 3 (Cummins FC 195) - Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source...668
Fault Overview...668
Associated Faults...668
Fault Facts...668
Conditions For Clearing The Fault Codes...668
Possible Causes...668
SPN 111 FMI 4 (Cummins FC 196) - Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source...680
Fault Overview...680
Associated Faults...680
Fault Facts...680
Conditions For Clearing The Fault Codes...680
Possible Causes...680
SPN 111 FMI 17 (Cummins FC 2448) - Coolant Level - Data Valid But Below Normal Operating Range - Least Severe Level...692
Fault Overview...692
Associated Faults...692
Fault Facts...692
Conditions For Clearing The Fault Codes...692
Possible Causes...692
SPN 111 FMI 18 (Cummins FC 197) - Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level...704
Fault Overview...704
Associated Faults...704
Fault Facts...704
Conditions For Clearing The Fault Codes...704
Possible Causes...704
SPN 1569 FMI 15 (Cummins FC 6255) - Engine Protection Torque Derate - Data Valid But Above Normal Operating Range - Least Severe Level...716
Fault Overview...716
Associated Faults...716
Fault Facts...716
Conditions For Clearing The Fault Codes...716
Possible Causes...716
SPN 1569 FMI 31 (Cummins FC 3714) - Engine Protection Torque Derate - Condition Exists...717
Fault Overview...717
Associated Faults...717
Fault Facts...717
Conditions For Clearing The Fault Codes...717
Possible Causes...717
SPN 1761 FMI 1 (Cummins FC 1673) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Most Severe Level...718
Fault Overview...718
Associated Faults...718
Fault Facts...718
Conditions For Clearing The Fault Codes...718
Possible Causes...718
SPN 1761 FMI 3 (Cummins FC 1669) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Above Normal or Shorted to High Source...720
Fault Overview...720
Associated Faults...720
Fault Facts...720
Conditions For Clearing The Fault Codes...720
Possible Causes...720
SPN 1761 FMI 4 (Cummins FC 1668) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Below Normal or Shorted to Low Source...721
Fault Overview...721
Associated Faults...721
Fault Facts...721
Conditions For Clearing The Fault Codes...721
Possible Causes...721
SPN 1761 FMI 9 (Cummins FC 4677) Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Abnormal Update Rate ...722
Fault Overview...722
Associated Faults...722
Fault Facts...722
Conditions For Clearing The Fault Codes...722
Special Tools...722
Possible Cause...722
SPN 1761 FMI 10 (Cummins FC 4769) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal Rate of Change...727
Fault Overview...727
Associated Faults...727
Fault Facts...727
Conditions For Clearing The Fault Codes...727
Possible Causes...727
SPN 1761 FMI 11 (Cummins FC 4739) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Root Cause Not Known...730
Fault Overview...730
Associated Faults...730
Fault Facts...730
Conditions For Clearing The Fault Codes...730
Possible Causes...730
SPN 1761 FMI 13 (Cummins FC 4732) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of Calibration...731
Fault Overview...731
Associated Faults...731
Fault Facts...731
Conditions For Clearing The Fault Codes...731
Possible Causes...731
SPN 1761 FMI 17 (Cummins FC 3497) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Least Severe Level...733
Fault Overview...733
Associated Faults...733
Fault Facts...733
Conditions For Clearing The Fault Codes...733
Possible Causes...733
SPN 1761 FMI 18 (Cummins FC 3498) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range -Moderately Severe Level ...735
Fault Overview...735
Associated Faults...735
Fault Facts...735
Conditions For Clearing The Fault Codes...735
Possible Causes...735
SPN 3031 FMI 2 (Cummins FC 1679) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic, Intermittent, or Incorrect...737
Fault Overview...737
Associated Faults...737
Fault Facts...737
Conditions For Clearing The Fault Codes...737
Possible Causes...737
SPN 3031 FMI 3 (Cummins FC 1678) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Above Normal or Shorted to High Source ...739
Fault Overview...739
Associated Faults...739
Fault Facts...739
Conditions For Clearing The Fault Codes...739
Possible Causes...739
SPN 3031 FMI 4 (Cummins FC 1677) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Below Normal or Shorted to Low Source...741
Fault Overview...741
Associated Faults...741
Fault Facts...741
Conditions For Clearing The Fault Codes...741
Possible Causes...741
SPN 3031 FMI 9 (Cummins FC 4572) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal Update Rate...743
Fault Overview...743
Associated Faults...743
Fault Facts...743
Conditions For Clearing The Fault Codes...743
Special Tools...743
Possible Cause...743
SPN 3031 FMI 11 (Cummins FC 4737) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause Not Known...748
Fault Overview...748
Associated Faults...748
Fault Facts...748
Conditions For Clearing The Fault Codes...748
Possible Causes...748
SPN 3031 FMI 13 (Cummins FC 4731) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out of Calibration...749
Fault Overview...749
Associated Faults...749
Fault Facts...749
Conditions For Clearing The Fault Codes...749
Possible Causes...749
SPN 3364 FMI 2 (Cummins FC 3878) - Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or Incorrect...751
Fault Overview...751
Associated Faults...751
Fault Facts...751
Conditions For Clearing The Fault Codes...751
Possible Causes...751
SPN 3364 FMI 3 (Cummins FC 1686) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Above Normal or Shorted to High Source...752
Fault Overview...752
Associated Faults...752
Fault Facts...752
Conditions For Clearing The Fault Codes...752
Possible Cause...752
SPN 3364 FMI 4 - (Cummins 1685) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Below Normal or Shorted to Low Source...754
Fault Overview...754
Associated Faults...754
Fault Facts...754
Conditions For Clearing The Fault Codes...754
Possible Cause...754
SPN 3364 FMI 9 (Cummins FC 3868) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate...756
Fault Overview...756
Associated Faults...756
Fault Facts...756
Conditions For Clearing The Fault Codes...756
Special Tools...756
Possible Cause...756
SPN 3364 FMI 10 (Cummins FC 4277) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate of Change ...761
Fault Overview...761
Associated Faults...761
Fault Facts...761
Conditions For Clearing The Fault Codes...761
Possible Causes...761
SPN 3364 FMI 11 (Cummins FC 1715) - Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known...764
Fault Overview...764
Associated Faults...764
Fault Facts...764
Conditions For Clearing The Fault Codes...764
Possible Causes...764
SPN 3364 FMI 13 (Cummins FC 1714) - Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration...765
Fault Overview...765
Associated Faults...765
Fault Facts...765
Conditions For Clearing The Fault Codes...765
Possible Causes...765
SPN 3364 FMI 15 (Cummins FC 4842) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal Operating Range - Least Severe Level...767
Fault Overview...767
Associated Faults...767
Fault Facts...767
Conditions For Clearing The Fault Codes...767
Possible Causes...767
SPN 3364 FMI 18 (Cummins FC 3867) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal Operating Range - Moderately Severe Level...769
Fault Overview...769
Associated Faults...769
Fault Facts...769
Conditions For Clearing The Fault Codes...769
Possible Causes...769
SPN 3521 FMI 11 (Cummins FC 4768) - Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known...772
Fault Overview...772
Associated Faults...772
Fault Facts...772
Conditions For Clearing The Fault Codes...772
Possible Causes...772
SPN 3521 FMI 16 (Cummins FC 6765) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above Normal Operating Range - Moderately Severe Level...773
Fault Overview...773
Associated Faults...773
Fault Facts...773
Conditions For Clearing The Fault Codes...773
Possible Causes...773
SPN 3521 FMI 18 (Cummins FC 6766) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below Normal Operating Range - Moderately Severe Level...775
Fault Overview...775
Associated Faults...775
Fault Facts...775
Conditions For Clearing The Fault Codes...775
Possible Causes...775
SPN 3521 FMI 31 (Cummins FC 4235) - Aftertreatment 1 Diesel Exhaust Fluid Property- Condition Exists...777
Fault Overview...777
Associated Faults...777
Fault Facts...777
Conditions For Clearing The Fault Codes...777
Possible Causes...777
SPN 4096 FMI 31 (Cummins FC 3547) - Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition Exists...779
Fault Overview...779
Associated Faults...779
Fault Facts...779
Conditions For Clearing The Fault Codes...779
Possible Causes...779
SPN 5246 FMI 0 (Cummins FC 3712) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Most Severe Level...780
Fault Overview...780
Associated Faults...780
Fault Facts...780
Conditions For Clearing The Fault Codes...780
Possible Causes...780
SPN 5246 FMI 15 (Cummins FC 4134) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Least Severe Level...781
Fault Overview...781
Associated Faults...781
Fault Facts...781
Conditions For Clearing The Fault Codes...781
Possible Causes...781
SPN 5246 FMI 16 (Cummins FC 6254) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Moderately Severe Level...782
Fault Overview...782
Associated Faults...782
Fault Facts...782
Conditions For Clearing The Fault Codes...782
Possible Causes...782
Tests and Inspections...783
Overview...783
DEF Head Unit Coolant Line Routing Inspection...784
Overview...784
Tools Required...784
Equipment Condition...784
Inspection Procedure...784
Expected Outcome...785
DEF Quality Test...786
Overview...786
Tools Required...786
Equipment Condition...786
Test Procedure...786
Expected Outcome...787
DEFTHV Coolant Flow Test...788
Overview...788
Tools Required...788
Equipment Condition...788
Test Setup...788
Test Procedure...788
Expected Outcome...788
Engine Fan...789
Horton Drivemaster...789
Overview...789
Operational Checkout Procedure...793
Engine Fan Always ON...795
Overview...795
Fault Facts...795
Special Tools...795
Possible Causes...795
Engine Fan Always OFF...802
Overview...802
Fault Facts...802
Special Tools...802
Possible Causes...802
Engine Fan Cycles Too Frequently...807
Overview...807
Fault Facts...807
Special Tools...807
Possible Causes...807
Excessive Noise From Engine Fan Drive...810
Overview...810
Fault Facts...810
Special Tools...810
Possible Causes...810
Exhaust Brake...812
Overview...812
Fuel Heater...814
Overview...814
Idle Increment / Decrement...816
Overview...816
Idle Shut Down Indicator...818
13. Exterior Lighting...819
Brake Switch...819
Air...819
Overview...819
Operational Checkout Procedure...824
Special Tools...824
Brake Switch Electrical Test...826
Overview...826
Special Tools...826
Equipment Conditions...826
Test Setup...826
SPN 597 FMI 0 - Brake Switch Input Short to Power...828
Overview...828
Associated Faults...828
Fault Facts...828
Special Tools...828
Possible Causes...828
SPN 597 FMI 1 - Brake Switch Reading Below Normal Range...830
Overview...830
Associated Faults...830
Fault Facts...830
Special Tools...830
Possible Causes...830
SPN 597 FMI 2 - Brake Switch Inputs Do Not Match...831
Overview...831
Associated Faults...831
Fault Facts...831
Special Tools...831
Possible Causes...831
Body Builder Lighting...832
Overview...832
Exterior Light Check...835
Overview...835
Fog Lights...837
Overview...837
Operational Checkout Procedure...841
Overview...841
Special Tools...841
Fog Lights Not Illuminating...843
Overview...843
Special Tools...843
Possible Causes...843
Fog Lights Illuminating When Not Requested...847
Overview...847
Special Tools...847
Possible Causes...847
SPN 2388 FMI 5 - Left Fog Light Open Circuit...849
Overview...849
Associated Faults...849
Fault Facts...849
Special Tools...849
Possible Causes...849
SPN 2388 FMI 6 - Left Fog Light Short to GND...851
Overview...851
Associated Faults...851
Fault Facts...851
Special Tools...851
Possible Causes...851
SPN 4008 FMI 5 - Right Fog Light Open Circuit...852
Overview...852
Associated Faults...852
Fault Facts...852
Special Tools...852
Possible Causes...852
SPN 4008 FMI 6 - Right Fog Light Short to Ground...854
Overview...854
Associated Faults...854
Fault Facts...854
Special Tools...854
Possible Causes...854
Headlights...855
Overview...855
Operational Checkout Procedure...861
Overview...861
Special Tools...861
Low Beam Diagnostics...863
Overview...863
Low Beams Not Illuminating...865
Overview...865
Fault Facts...865
Special Tools...865
Possible Causes...865
Low Beams Illuminating When Not Requested...870
Overview...870
Fault Facts...870
Special Tools...870
Possible Causes...870
SPN 2653 FMI 5 - Left Low Beam Open Circuit...873
Overview...873
Associated Faults...873
Fault Facts...873
Special Tools...873
Possible Causes...873
SPN 2653 FMI 6 - Left Low Beam Short to Ground...875
Overview...875
Associated Faults...875
Fault Facts...875
Special Tools...875
Possible Causes...875
SPN 2655 FMI 5 - Right Low Beam Open Circuit...876
Overview...876
Associated Faults...876
Fault Facts...876
Special Tools...876
Possible Causes...876
SPN 2655 FMI 6 - Right Low Beam Short to GND...878
Overview...878
Associated Faults...878
Fault Facts...878
Special Tools...878
Possible Causes...878
High Beam Diagnostics...879
Overview...879
High Beam Input Diagnostics...881
Overview...881
Fault Facts...881
Special Tools...881
Possible Causes...881
High Beam Output Diagnostics - Not Illuminating...884
Overview...884
Fault Facts...884
Tools Required...884
Possible Causes...884
High Beam Output Diagnostics - Illuminating When Not Requested...888
Overview...888
Fault Facts...888
Special Tools...888
Possible Causes...888
SPN 4011 FMI 5 - Left High Beam Open Circuit...890
Overview...890
Associated Faults...890
Fault Facts...890
Special Tools...890
Possible Causes...890
SPN 4011 FMI 6 - Left High Beam Short to Ground...892
Overview...892
Associated Faults...892
Fault Facts...892
Special Tools...892
Possible Causes...892
SPN 4012 FMI 5 - Right High Beam Open Circuit...893
Overview...893
Associated Faults...893
Fault Facts...893
Special Tools...893
Possible Causes...893
SPN 4012 FMI 6 - Right High Beam Short to Ground...895
Overview...895
Associated Faults...895
Fault Facts...895
Special Tools...895
Possible Causes...895
Lighting Control Module...896
Overview...896
Operational Checkout Procedure...897
Overview...897
Special Tools...897
Lighting Control Module (LCM) Electrical Test...898
Overview...898
Special Tools...898
Equipment Conditions...898
Test Setup...898
Park, Marker, and Clearance Lights...901
Overview...901
Operational Checkout Procedure...907
Overview...907
Special Tools...907
Park Lights Not Illuminating...909
Overview...909
Fault Facts...909
Special Tools...909
Possible Causes...909
Park Lights Illuminating When Not Requested...911
Overview...911
Fault Facts...911
Special Tools...911
Possible Causes...911
SPN 2378 FMI 5 - Park Light Undercurrent...913
Overview...913
Associated Faults...913
Fault Facts...913
Special Tools...913
Possible Causes...913
SPN 2378 FMI 6 - Park Light Overcurrent...915
Overview...915
Associated Faults...915
Fault Facts...915
Special Tools...915
Possible Causes...915
Marker Interrupt Switch...916
Overview...916
SPN 4024 FMI 2 - Marker Light Interrupt Switch Failure...920
Overview...920
Associated Faults...920
Fault Facts...920
Special Tools...920
Possible Causes...920
Reverse Lights...921
Overview...921
Automatic Transmission...922
Manual Transmission...923
Snow Plow Lights...924
Overview...924
Stop / Turn Lights...927
Overview...927
Operational Checkout Procedure...934
Overview...934
Special Tools...936
Hazard Lights Not Illuminating...939
Overview...939
Fault Facts...939
Special Tools...939
Possible Causes...939
Front and Rear Left Turn Lights or Front and Rear Right Turn Lights Not Illuminating...942
Overview...942
Fault Facts...942
Special Tools...942
Possible Causes...942
Front Turn Lights Not Illuminating...946
Overview...946
Fault Facts...946
Special Tools...946
Possible Causes...946
Front Turn Lights Illuminating When Not Requested...950
Overview...950
Fault Facts...950
Special Tools...950
Possible Causes...950
Stop and Rear Turn Lights Not Illuminating...952
Overview...952
Fault Facts...952
Special Tools...952
Possible Causes...952
Stop and Rear Turn Lights Illuminating When Not Requested...956
Overview...956
Fault Facts...956
Special Tools...956
Possible Causes...956
SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps...958
Overview...958
Associated Faults...958
Fault Facts...958
Special Tools...958
Possible Causes...958
SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps...959
Overview...959
Associated Faults...959
Fault Facts...959
Special Tools...959
Possible Causes...959
SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps...960
Overview...960
Associated Faults...960
Fault Facts...960
Special Tools...960
Possible Causes...960
SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps...961
Overview...961
Associated Faults...961
Fault Facts...961
Special Tools...961
Possible Causes...961
SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent ...962
Overview...962
Associated Faults...962
Fault Facts...962
Special Tools...962
Possible Causes...962
SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent ...963
Overview...963
Associated Faults...963
Fault Facts...963
Special Tools...963
Possible Causes...963
SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent ...964
Overview...964
Associated Faults...964
Fault Facts...964
Special Tools...964
Possible Causes...964
SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent...965
Overview...965
Associated Faults...965
Fault Facts...965
Special Tools...965
Possible Causes...965
Work Lights...966
Overview...966
14. Front Suspension...971
Front Air Suspension...971
Overview...971
15. HVAC...973
On-Highway HVAC System...973
Front HVAC System...974
Overview...974
A/C Refrigerant Flow...975
General Operation of HVAC Electrical System...977
Automatic Climate Control...978
Full Automatic Mode...979
Semi Automatic Mode...979
Air Distribution...980
Defrost...981
Temperature...981
Recirculation...981
Panel / Floor...982
Operational Checkout Procedure...985
Overview...985
Special Tools...985
Blower Not Working Properly...988
Overview...988
Fault Facts...988
Special Tools...988
Possible Causes...988
HVAC System Air Not Cool after A/C Turned ON...993
Overview...993
Fault Facts...993
Special Tools...993
Possible Causes...993
HVAC System Air Not Warm After Heat Turned ON...998
Overview...998
Special Tools...998
Possible Causes...998
SPN 170 FMI 3 - Cab Interior Temperature Voltage Above Normal, Or Shorted To High Source...1000
Overview...1000
Associated Faults...1000
Fault Facts...1000
Special Tools...1000
Possible Causes...1000
SPN 170 FMI 4 - Cab Interior Temperature Voltage Below Normal, Or Shorted To Low Source...1002
Overview...1002
Associated Faults...1002
Fault Facts...1002
Special Tools...1002
Possible Causes...1002
SPN 876 FMI 5 - HVAC Compressor Clutch Engagement Undercurrent...1004
Overview...1004
Associated Faults...1004
Fault Facts...1004
Possible Causes...1004
SPN 876 FMI 6 - HVAC Compressor Clutch Engagement Overcurrent...1005
Overview...1005
Associated Faults...1005
Fault Facts...1005
Possible Causes...1005
SPN 1552 FMI 2 - Temperature Door Actuator Data Intermittent or Incorrect...1006
Overview...1006
Associated Faults...1006
Fault Facts...1006
Possible Causes...1006
SPN 1552 FMI 5 - Temperature Door Actuator Current Below Normal Or Open Circuit...1007
Overview...1007
Associated Faults...1007
Fault Facts...1007
Possible Causes...1007
SPN 1552 FMI 6 - Temperature Door Actuator Current Above Normal Or Grounded Circuit...1008
Overview...1008
Associated Faults...1008
Fault Facts...1008
Special Tools...1008
Possible Causes...1008
SPN 2609 FMI 0 - PT Sensor - HVAC Pressure Sensor Reading Above Normal Range...1012
Overview...1012
Associated Faults...1012
Fault Facts...1012
Special Tools...1012
Possible Causes...1012
SPN 2609 FMI 1 - Pressure Sensor - HVAC Pressure Sensor Reading Below Normal Range...1013
Overview...1013
Associated Faults...1013
Fault Facts...1013
Special Tools...1013
Possible Causes...1013
SPN 2609 FMI 15 - PT Sensor - HVAC Low Pressure Protection (A/C Compressor Lockout)...1019
Overview...1019
Associated Faults...1019
Fault Facts...1019
SPN 2609 FMI 16 - PT Sensor - HVAC High Pressure Protection...1020
Overview...1020
Associated Faults...1020
Fault Facts...1020
Possible Causes...1020
SPN 2609 FMI 17- Low Charge Data Valid But Below Normal Operating Range...1022
Overview...1022
Associated Faults...1022
Fault Facts...1022
Possible Causes...1022
SPN 2610 FMI 3 - Solar Intensity Percent Voltage Above Normal, Or Shorted To High Source...1023
Overview...1023
Associated Faults...1023
Fault Facts...1023
Special Tools...1023
Possible Causes...1023
SPN 2610 FMI 4 - Solar Intensity Percent Voltage Below Normal, Or Shorted To Low Source...1025
Overview...1025
Associated Faults...1025
Fault Facts...1025
Special Tools...1025
Possible Causes...1025
SPN 3981 FMI 2 - Defrost Door Actuator Data Intermittent or Incorrect...1027
Overview...1027
Associated Faults...1027
Fault Facts...1027
Possible Causes...1027
SPN 3984 FMI 2 - Recirculation Door Actuator Data Intermittent or Incorrect...1028
Overview...1028
Associated Faults...1028
Fault Facts...1028
Possible Causes...1028
SPN 3984 FMI 5 - Recirculation Door Actuator Current Below Normal Or Open Circuit...1029
Overview...1029
Associated Faults...1029
Fault Facts...1029
Possible Causes...1029
SPN 3984 FMI 6 - Recirculation Door Actuator Current Above Normal Or Grounded Circuit...1030
Overview...1030
Associated Faults...1030
Fault Facts...1030
Special Tools...1030
Possible Causes...1030
SPN 3985 FMI 9 - HVAC Control Module Circuit Failed To Communicate With the Body Control Module...1034
Overview...1034
Associated Faults...1034
Fault Facts...1034
Possible Causes...1034
SPN 516636 FMI 19 - Error or Not Available is transmitted from Front HVAC Control Module ...1035
Overview...1035
Associated Faults...1035
Fault Facts...1035
Special Tools...1035
Possible Causes...1035
SPN 516778 FMI 5 - Freeze Probe Open Circuit...1037
Overview...1037
Associated Faults...1037
Fault Facts...1037
Special Tools...1037
Possible Causes...1037
SPN 516778 FMI 6 - Freeze Probe Short to Ground...1038
Overview...1038
Associated Faults...1038
Fault Facts...1038
Special Tools...1038
Possible Causes...1038
SPN 516825 FMI 2 - Panel Door Actuator Data Intermittent or Incorrect...1039
Overview...1039
Associated Faults...1039
Fault Facts...1039
Possible Causes...1039
SPN 516825 FMI 5 - Panel Door Actuator Current Below Normal Or Open Circuit...1040
Overview...1040
Associated Faults...1040
Fault Facts...1040
Possible Causes...1040
SPN 516825 FMI 6 - Panel Door Actuator Current Above Normal Or Grounded Circuit...1041
Overview...1041
Associated Faults...1041
Fault Facts...1041
Special Tools...1041
Possible Causes...1041
SPN 516826 FMI 2 - Floor Door Actuator Data Intermittent or Incorrect...1045
Overview...1045
Associated Faults...1045
Fault Facts...1045
Possible Causes...1045
SPN 516826 FMI 5 - Floor Door Actuator Current Below Normal Or Open Circuit...1046
Overview...1046
Associated Faults...1046
Fault Facts...1046
Possible Causes...1046
SPN 516826 FMI 6 - Floor Door Actuator Current Above Normal Or Grounded Circuit...1047
Overview...1047
Associated Faults...1047
Fault Facts...1047
Special Tools...1047
Possible Causes...1047
SPN 516827 FMI 3 - Blower Motor Under Voltage Protection...1051
Overview...1051
Associated Faults...1051
Fault Facts...1051
Special Tools...1051
Possible Causes...1051
SPN 516827 FMI 4 - Blower Over Voltage Protection...1053
Overview...1053
Associated Faults...1053
Fault Facts...1053
Special Tools...1053
Possible Causes...1053
SPN 516827 FMI 7 - Blower Motor Not Responding (Blocked Rotor)...1055
Overview...1055
Associated Faults...1055
Fault Facts...1055
Special Tools...1055
Possible Causes...1055
SPN 516827 FMI 31 - Blower Motor Over Temperature...1057
Overview...1057
Associated Faults...1057
Fault Facts...1057
Special Tools...1057
Possible Causes...1057
SPN 520465 FMI 2 - HVAC Control Module - Multiple Actuator Faults...1059
Overview...1059
Associated Faults...1059
Fault Facts...1059
Special Tools...1059
Possible Causes...1059
HVAC Tests...1061
Overview...1061
A/C Compressor Clutch Electrical Test...1062
Overview...1062
Special Tools...1062
Equipment Conditions...1062
Test Setup...1062
Test Procedure...1062
Follow-On Procedure...1063
A/C Compressor Compression Test...1064
Overview...1064
Special Tools...1064
Equipment Conditions...1064
Test Procedure...1064
Follow-On Procedure...1064
A/C Pressure Readings Indicating Problems...1065
Overview...1065
Special Tools...1065
Equipment Conditions...1065
Low-Side Pressure Low, High-Side Pressure Low...1066
Possible Causes...1066
Low-Side Pressure Low, High-Side Pressure Normal or High...1067
Possible Causes...1067
High-Side and Low-Side Pressures Normal or Slightly Low, Duct Output Not Cold...1068
Possible Causes...1068
Low-Side Pressure Normal, High-Side Pressure High...1069
Possible Causes...1069
Low-Side Pressure High, High-Side Pressure Low...1070
Possible Causes...1070
Low-Side Pressure High, High-Side Pressure Normal...1071
Possible Causes...1071
Low-Side Pressure High, High-Side Pressure High...1072
Possible Causes...1072
High-Side Pressure Excessively High or Low...1072
Follow-On Procedure...1072
A/C System Restriction Test...1073
Overview...1073
Special Tools...1073
Equipment Conditions...1073
Test Setup...1073
Test Procedure...1073
Follow-On Procedure...1073
Blower Motor Electrical Input Test...1074
Overview...1074
Special Tools...1074
Equipment Conditions...1074
Test Setup...1074
Test Procedure...1074
Follow-On Procedure...1074
Charge Quantity Measurement Test...1075
Overview...1075
Special Tools...1075
Equipment Conditions...1075
Test Setup...1075
Test Procedure...1075
Follow-On Procedure...1075
Defrost Actuator Electrical Test...1076
Overview...1076
Special Tools...1076
Possible Causes...1076
Procedure...1076
Dynamic Refrigerant Pressure Test...1080
Overview...1080
Special Tools...1080
Equipment Conditions...1080
Test Setup...1081
Test Procedure...1081
Follow-On Procedure...1083
Floor Actuator Electrical Test...1084
Overview...1084
Special Tools...1084
Equipment Conditions...1084
Possible Causes...1084
Freeze Probe Electrical Test...1088
Overview...1088
Special Tools...1088
Equipment Conditions...1088
Test Setup...1088
Test Procedure...1088
Follow-On Procedure...1089
Heater Core Seal Leak Test...1090
Overview...1090
Special Tools...1090
Equipment Conditions...1090
Test Setup...1090
Test Procedure...1090
Follow-On Procedure...1091
HVAC Control Module and Actuator Calibration...1092
Overview...1092
Special Tools...1092
Equipment Conditions...1092
Calibration Procedure...1092
Follow-On Procedure...1092
HVAC Control Module Electrical Tests...1093
Overview...1093
Special Tools...1093
Equipment Conditions...1093
Test Setup...1093
Test Procedure...1093
Follow-On Procedure...1095
HVAC Pressure / Temperature Sensor Electrical Test...1096
Overview...1096
Special Tools...1096
Equipment Conditions...1096
Test Setup...1096
Pressure / Temperature Test Procedure...1096
Follow-On Procedure...1096
HVAC Pressure / Temperature Sensor Functional Test...1097
Overview...1097
Special Tools...1097
Equipment Conditions...1097
Test Setup...1097
Procedure...1097
Follow-On Procedure...1098
Low A/C Pressure Sensor Electrical Test...1099
Overview...1099
Special Tools...1099
Equipment Conditions...1099
Test Setup...1099
Test Procedure...1099
Follow-On Procedure...1099
Panel Actuator Electrical Test...1100
Overview...1100
Special Tools...1100
Possible Causes...1100
Recirculation Actuator Electrical Test...1104
Overview...1104
Special Tools...1104
Equipment Conditions...1104
Possible Causes...1104
Refrigerant Identification Test...1108
Overview...1108
Special Tools...1108
Equipment Conditions...1108
Test Setup...1108
Test Procedure...1108
Follow-On Procedure...1108
Refrigerant Leak Test...1109
Overview...1109
Special Tools...1109
Equipment Conditions...1109
Test Procedure Refrigerant Present...1110
No Refrigerant Present...1111
No Refrigerant Present - High Pressure Nitrogen...1112
Follow-On Procedure...1113
Static Refrigerant Pressure Test...1114
Overview...1114
Special Tools...1114
Equipment Conditions...1114
Test Setup...1114
Test Procedure...1114
Follow-On Procedure...1115
Temperature Actuator Electrical Test...1116
Overview...1116
Special Tools...1116
Equipment Conditions...1116
Possible Causes...1116
HVAC Inspections...1120
HVAC System Inspection...1120
Overview...1120
Special Tools...1120
Equipment Conditions...1120
Inspection Procedure...1120
Follow-On Procedure...1122
A/C System Internal Damage Inspection...1123
Overview...1123
Special Tools...1123
Equipment Conditions...1123
Inspection Procedure...1123
Follow-On Procedure...1124
16. Instrumentation / Gauges...1125
Electronic Gauge Cluster...1125
Overview...1125
Gauge Cluster...1128
EGC Fault Reaction...1128
Virtual Gauges...1128
Auxiliary Gauges...1128
Operational Checkout Procedure...1132
SPN 2023 FMI 11 - Message ignition and switched ignition do not match...1133
Fault Overview...1133
Fault Facts...1133
Special Tools...1133
Possible Causes...1133
SPN 516598 FMI 0 - Cluster Display Control Switch Input is Above Normal Range...1135
Fault Overview...1135
Fault Facts...1135
Special Tools...1135
Possible Causes...1135
SPN 516598 FMI 1 - Cluster Display Control Switch Input is Below Normal Range...1137
Fault Overview...1137
Fault Facts...1137
Special Tools...1137
Possible Causes...1137
Center Panel Location #1...1139
Overview...1139
Center Panel Location Double Din #1...1140
Overview...1140
Gauges...1141
Air Application Gauge...1141
Overview...1141
Air Pressure Gauges Primary / Secondary...1145
Overview...1145
Ambient Temperature...1149
Overview...1149
Ammeter...1151
Overview...1151
Auxiliary Air Pressure Gauge...1152
Overview...1152
Axle Temperature Gauge...1154
Overview...1154
DEF Gauges...1158
Overview...1158
Engine Coolant Temperature...1160
Overview...1160
Engine Oil Pressure...1163
Overview...1163
Engine Oil Temperature...1166
Overview...1166
Fuel Level Gauge...1168
Overview...1168
PTO Hour Meter...1172
Overview...1172
Rear Axle Load Monitor...1173
Overview...1173
Speedometer...1179
Overview...1179
Tachometer...1181
Overview...1181
Transmission Oil Temp Gauge...1183
Overview...1183
Voltmeter...1188
Overview...1188
Indicators...1190
Antilock Brake System (ABS) Indicator...1190
Overview...1190
Allison Range Inhibit Warning...1193
Overview...1193
Battery Disconnect Indicator...1195
Overview...1195
Brake Indicator...1196
Overview...1196
DEF / EXH High Temperature Indicator for Exhaust...1197
Overview...1197
DPF Clogged Indicator...1199
Overview...1199
Economy Mode Indicator (Allison Transmission Only)...1201
Overview...1201
Engine Idle Shutdown Indicator...1202
Overview...1202
Electronic Stability Control (ESC) Indicator...1203
Overview...1203
Low Coolant Level Indicator with Alarm...1206
Overview...1206
Park Brake Indicator...1207
Overview...1207
PTO Indicator...1211
Overview...1211
Traction Control Indicator...1213
Overview...1213
Trailer ABS Indicator...1216
Overview...1216
Wait To Start Indicator...1218
Overview...1218
Instrumentation...1219
Allison PRNDL Display...1219
Overview...1219
Driver Information Display...1222
Overview...1222
Eaton PRNDL Display...1224
Overview...1224
Tire Pressure Monitor...1227
Overview...1227
17. Rear Axle / Suspension...1229
Air Suspension Dump...1229
Overview...1229
Air Suspension Dump (ASD) Switch...1229
Air Suspension System Faults...1229
Differential Locking...1232
Overview...1232
Power Divider Lock (PDL)...1235
Overview...1235
18. Seats...1237
Seatbelt Indicator...1237
Overview...1237
19. Trailer...1238
Auxiliary 7-pin Trailer Socket...1238
Overview...1238
Auxiliary Trailer ABS Socket...1240
Overview...1240
Trailer Auxiliary Circuit Power...1241
Overview...1241
Trailer Lighting...1243
Overview...1243
Operational Checkout Procedure...1245
Overview...1245
Fault Facts...1245
Special Tools...1245
Trailer Marker Lights Not Illuminating...1248
Overview...1248
Fault Facts...1248
Special Tools...1248
Possible Causes...1248
Trailer Tail Lights Not Illuminating...1250
Overview...1250
Fault Facts...1250
Special Tools...1250
Possible Causes...1250
Trailer Left Turn Lights Not Illuminating...1252
Overview...1252
Fault Facts...1252
Special Tools...1252
Possible Causes...1252
Trailer Right Turn Lights Not Illuminating...1254
Overview...1254
Fault Facts...1254
Special Tools...1254
Possible Causes...1254
Trailer Stop Lights Not Illuminating...1256
Overview...1256
Fault Facts...1256
Special Tools...1256
Possible Causes...1256
20. Transmission...1260
Auto Neutral...1260
Overview...1260
Allison...1263
Overview...1263
Operational Checkout Procedure...1266
Overview...1266
Special Tools...1266
Transmission Control Module (TCM) Electrical Test...1267
Overview...1267
Special Tools...1267
Equipment Conditions...1267
Test Setup...1267
SPN 751 FMI 8 - Transmission Primary Shift Selector Abnormal Frequency Or Pulse Width Or Period...1270
Overview...1270
Associated Faults...1270
Fault Facts...1270
Special Tools...1270
Possible Causes...1270
SPN 1855 FMI 2 - Mode Selector Switch Error...1272
Fault Overview...1272
Associated Faults...1272
Fault Facts...1272
Special Tools...1272
Possible Causes...1272
Auxiliary Transmission...1274
Overview...1274
Eaton®...1276
Overview...1276
Operational Checkout Procedure...1279
Overview...1279
Special Tools...1279
Transmission Control Module (TCM) Electrical Test...1280
Overview...1280
Special Tools...1280
Equipment Conditions...1280
Test Setup...1280
SPN 751 FMI 11 - TCM Loss of Communication With Stalk Shifter...1283
Overview...1283
Associated Faults...1283
Fault Facts...1283
Special Tools...1283
Possible Causes...1283
Transmission Hill Start Aid...1284
Overview...1284
Shifter...1287
Stalk Shifter...1287
Overview...1287
Engine Brake Control...1287
Manual Mode...1287
Range Selection...1287
Tech Tips...1288
Operational Checkout Procedure...1289
Overview...1289
Special Tools...1289
Stalk Shifter Electrical Test...1290
Overview...1290
Special Tools...1290
Equipment Conditions...1290
Test Setup...1290
SPN 525 FMI 3 - Stalk Shifter Shorted High...1292
Overview...1292
Associated Faults...1292
Fault Facts...1292
Special Tools...1292
Possible Causes...1292
SPN 525 FMI 4 - Stalk Shifter Shorted Low...1293
Overview...1293
Associated Faults...1293
Fault Facts...1293
Special Tools...1293
Possible Causes...1293
SPN 525 FMI 13 - Transmission Requested Gear : Out Of Calibration...1294
Overview...1294
Associated Faults...1294
Fault Facts...1294
Special Tools...1294
Possible Causes...1294
SPN 2000 FMI 9 - Loss of Communication With ECM...1295
Overview...1295
Associated Faults...1295
Fault Facts...1295
Special Tools...1295
Possible Causes...1295
SPN 2003 FMI 9 - Loss of Communication With TCM...1296
Overview...1296
Associated Faults...1296
Fault Facts...1296
Special Tools...1296
Possible Causes...1296
SPN 2005 FMI 12 - Failure of Non-Volatile Memory or Checksum Fault...1297
Overview...1297
Associated Faults...1297
Fault Facts...1297
Special Tools...1297
Possible Causes...1297
SPN 2033 FMI 9 - Loss of Communication With BCM...1298
Overview...1298
Associated Faults...1298
Fault Facts...1298
Special Tools...1298
Possible Causes...1298
Transfer Case...1299
Overview...1299
Interlocks...1301
21. Windshield Wiper System...1305
Overview...1305
Operational Checkout Procedure...1306
Overview...1306
Special Tools...1306
Windshield Wipers...1308
Overview...1308
Wiper_0_Signal Not Working...1311
Overview...1311
Associated Faults...1311
Fault Facts...1311
Special Tools...1311
Possible Causes...1311
Wiper_1_Signal Not Working...1313
Overview...1313
Associated Faults...1313
Fault Facts...1313
Special Tools...1313
Possible Causes...1313
Wiper_2_Signal Not Working...1315
Overview...1315
Associated Faults...1315
Fault Facts...1315
Special Tools...1315
Possible Causes...1315
Wiper Low Speed Not Working...1317
Overview...1317
Associated Faults...1317
Fault Facts...1317
Special Tools...1317
Possible Causes...1317
Wiper High Speed Not Working...1322
Overview...1322
Associated Faults...1322
Fault Facts...1322
Special Tools...1322
Possible Causes...1322
SPN 2636 FMI 5 - Wiper Motor Relay Undercurrent or Open Circuit...1328
Overview...1328
Associated Faults...1328
Fault Facts...1328
Special Tools...1328
Possible Causes...1328
SPN 2636 FMI 6 - Wipe Motor Relay Over Current...1330
Overview...1330
Associated Faults...1330
Fault Facts...1330
Special Tools...1330
Possible Causes...1330
SPN 2637 FMI 5 - Wiper Variable Speed Relay Undercurrent or High Resistance...1331
Overview...1331
Associated Faults...1331
Fault Facts...1331
Special Tools...1331
Possible Causes...1331
SPN 2637 FMI 6 - Wiper Variable Relay Over Current...1333
Overview...1333
Associated Faults...1333
Fault Facts...1333
Special Tools...1333
Possible Causes...1333
SPN 4057 FMI 5 - Wiper Motor Undercurrent...1334
Overview...1334
Associated Faults...1334
Fault Facts...1334
Special Tools...1334
Possible Causes...1334
SPN 4057 FMI 6 - Wiper Motor Over Current...1340
Overview...1340
Associated Faults...1340
Fault Facts...1340
Special Tools...1340
Possible Causes...1340
Windshield Washer Pump...1343
Overview...1343
Washer Pump and / or Wipers Not Working...1345
Overview...1345
Associated Faults...1345
Fault Facts...1345
Special Tools...1345
Possible Causes...1345
Front End...1349
1. Fender Extensions...1351
Overview...1351
2. Hood / Grille...1352
Grille...1352
Overview...1352
Removal...1353
Overview...1353
Special Tools...1353
Equipment Condition...1353
Removal Procedure...1354
Expected Outcome...1354
Follow-On Procedure...1354
Installation...1355
Overview...1355
Special Tools...1355
Torque Specifications...1355
Equipment Condition...1355
Installation Procedure...1356
Follow-On Procedure...1356
Grill Ember Screen...1357
Overview...1357
Tilting Hood...1358
Overview...1358
Removal...1360
Overview...1360
Special Tools...1360
Equipment Condition...1360
Removal Procedure...1361
Expected Outcome...1364
Follow-On Procedure...1364
Installation...1365
Overview...1365
Special Tools...1365
Torque Specifications...1365
Equipment Condition...1365
Installation Procedure...1366
Expected Outcome...1369
Follow-On Procedure...1369
Alignment...1370
Overview...1370
Special Tools...1370
Equipment Condition...1370
Procedure...1370
Expected Outcome...1371
Follow-On Procedure...1371
Headlight Adjustment...1372
Overview...1372
Special Tools...1372
Equipment Condition...1372
Procedure...1372
Expected Outcome...1373
Follow-On Procedure...1373
Service Hatch...1374
Overview...1374
Fifth Wheel and Misc...1375
1. Fifth Wheel...1377
Fontaine®...1377
Overview...1377
Holland®...1380
Overview...1380
Jost...1382
Overview...1382
2. Fire Extinguisher...1384
Overview...1384
3. Keys...1385
Overview...1385
4. Quarter Fenders...1387
Rear Wheel...1387
Overview...1387
Clutch...1389
1. Clutch Brake...1391
Overview...1391
Adjustment...1392
Overview...1392
Special Tools...1392
Equipment Condition...1392
Procedure...1392
Expected Outcome...1392
Follow-On Procedure...1392
2. Clutch Actuation System...1393
Hydraulic Clutch Actuation...1393
Overview...1393
Hydraulic Clutch Master Cylinder...1394
Removal...1394
Overview...1394
Special Tools...1394
Equipment Condition...1394
Removal Procedure...1394
Expected Outcome...1394
Follow-On Procedure...1394
Installation...1395
Overview...1395
Special Tools...1395
Torque Specifications...1395
Equipment Condition...1395
Installation Procedure...1395
Follow-On Procedure...1395
Hydraulic Clutch Slave Cylinder...1396
Removal...1396
Overview...1396
Special Tools...1396
Equipment Condition...1396
Removal Procedure...1396
Expected Outcome...1396
Follow-On Procedure...1396
Installation...1397
Overview...1397
Special Tools...1397
Torque Specifications...1397
Equipment Condition...1397
Installation Procedure...1397
Follow-On Procedure...1397
Hydraulic Clutch Slave Cylinder Hose...1398
Removal...1398
Overview...1398
Special Tools...1398
Equipment Condition...1398
Removal Procedure...1398
Expected Outcome...1398
Follow-On Procedure...1398
Installation...1399
Overview...1399
Special Tools...1399
Torque Specifications...1399
Equipment Condition...1399
Installation Procedure...1399
Follow-On Procedure...1399
Hydraulic Clutch Bleed Procedure...1400
Overview...1400
Special Tools...1400
Equipment Conditions...1400
Procedure...1401
Follow-On Procedure...1402
Hydraulic Clutch Actuation with Air Assist...1403
Overview...1403
Engines...1405
1. Air Cleaner...1409
Air Cleaner...1409
Overview...1409
2. Block Heater...1410
Overview...1410
3. Cold Start Assist...1412
Intake Heater Cold Start...1412
Engine Control Module (ECM) Control...1412
Overview...1412
4. Cooling System - Navistar® A26...1413
Auxiliary Water Cooler...1413
Overview...1413
Cooling Package...1414
Overview...1414
Coolant System External Cleaning...1416
Overview...1416
Special Tools...1416
Equipment Conditions...1416
Procedure...1417
Expected Outcome...1417
Follow-On Procedure...1417
Deaeration Tank Inspection...1418
Overview...1418
Special Tools...1418
Equipment Conditions...1418
Setup...1419
Procedure...1419
Expected Outcome...1421
Follow-On Procedure...1421
Check Coolant Condition...1422
Overview...1422
Special Tools...1422
Equipment Conditions...1422
Setup...1423
Procedure...1424
Expected Outcome...1424
Follow-On Procedure...1424
Coolant Pressure Check...1425
Overview...1425
Special Tools...1425
Equipment Conditions...1425
Setup...1425
Procedure...1426
Expected Outcome...1427
Follow-On Procedure...1427
Coolant Package Flush...1428
Overview...1428
Special Tools...1428
Equipment Conditions...1428
Preparation...1429
Coolant Filter Flush, if Applicable...1430
Flush Thermostat Housing...1431
Front Heater Core Flush...1432
Rear Heater Core Flush, if Applicable...1433
DEF Heater Core Flush...1434
Front and Rear, if Applicable, Heater Core Rinse...1435
DEF Heater Rinse...1436
Radiator and Engine Rinse...1437
Final Rinse...1438
Expected Outcome...1438
Follow-On Procedure...1438
Coolant Drain...1439
Overview...1439
Special Tools...1439
Equipment Conditions...1439
Setup...1440
Procedure...1441
Expected Outcome...1442
Follow-On Procedure...1442
Deaeration Tank...1443
Removal...1443
Overview...1443
Special Tools...1444
Equipment Conditions...1444
Procedure...1445
Follow-on Procedure...1446
Installation...1447
Overview...1447
Special Tools...1447
Procedure...1448
Follow-on Procedure...1449
Engine Coolant Level (ECL) Sensor...1450
Removal...1450
Overview...1450
Special Tools...1450
Equipment Conditions...1451
Procedure...1452
Follow-On Procedure...1452
Installation...1453
Overview...1453
Special Tools...1453
Torque Specification...1454
Equipment Conditions...1454
Procedure...1455
Follow-On Procedure...1455
Power Steering Fluid Reservoir...1456
Removal...1456
Overview...1456
Special Tools...1456
Equipment Conditions...1456
Procedure...1457
Follow-on Procedure...1457
Installation...1458
Overview...1458
Special Tools...1458
Equipment Conditions...1458
Procedure...1459
Follow-on Procedure...1459
Relocation...1460
Overview...1460
Special Tools...1460
Equipment Conditions...1460
Procedure...1461
Follow-on Procedure...1461
Reinstallation...1462
Overview...1462
Special Tools...1462
Equipment Conditions...1462
Procedure...1463
Follow-on Procedure...1463
Coolant (Radiator) Hose...1465
Overview...1465
Upper Hose...1466
Removal...1466
Overview...1466
Special Tools...1466
Equipment Conditions...1466
Procedure...1467
Follow-on Procedure...1467
Installation...1468
Overview...1468
Special Tools...1468
Torque Specifications...1468
Procedure...1469
Follow-on Procedure...1470
Lower Hose...1471
Replacement...1471
Overview...1471
Special Tools...1471
Special Tools...1472
Equipment Conditions...1472
Radiator-to-Pipe Hose...1473
Removal...1473
Overview...1473
Follow-on Procedure...1473
Installation...1474
Torque Specifications...1474
Follow-on Procedure...1475
Pipe-to-Trans-Cooler Hose...1476
Removal...1476
Overview...1476
Follow-on Procedure...1476
Installation...1477
Torque Specifications...1477
Procedure...1477
Follow-on Procedure...1478
Trans-Cooler-to-Water-Distribution-Housing Hose...1479
Removal...1479
Procedure...1479
Follow-on Procedure...1479
Installation...1480
Torque Specifications...1480
Procedure...1480
Follow-on Procedure...1481
Coolant Package...1482
Removal...1482
Overview...1482
Special Tools...1482
Equipment Conditions...1482
Procedure...1483
Follow-on Procedure...1490
Installation...1491
Overview...1491
Special Tools...1491
Procedure...1492
Follow-on Procedure...1500
Radiator Core...1501
Removal...1501
Overview...1501
Special Tools...1501
Equipment Conditions...1501
Procedure...1502
Installation...1509
Overview...1509
Special Tools...1509
Procedure...1510
Follow-on Procedure...1517
HVAC Condenser...1518
Removal...1518
Overview...1518
Special Tools...1518
Equipment Conditions...1518
Procedure...1519
Follow-on Procedure...1522
Installation...1523
Overview...1523
Special Tools...1523
Equipment Conditions...1523
Procedure...1524
Follow-on Procedure...1526
Relocation...1527
Overview...1527
Special Tools...1527
Equipment Condition...1527
Procedure...1528
Follow-on Procedure...1534
Reinstallation...1535
Overview...1535
Special Tools...1535
Procedure...1536
Follow-on Procedure...1542
Charge Air Cooler...1543
Removal...1543
Overview...1543
Special Tools...1543
Equipment Conditions...1543
Procedure...1544
Follow-on Procedure...1547
Installation...1548
Special Tools...1548
Procedure...1549
Follow-on Procedure...1552
Cummins® Charge Air Cooler (CAC)...1553
Overview...1553
CAC Clean...1554
Overview...1554
Special Tools...1554
Equipment Condition...1554
Setup...1556
Procedure...1557
Expected Outcome...1557
Follow-On Procedure...1557
CAC Flush...1558
Overview...1558
Special Tools...1558
Equipment Condition...1558
Procedure...1560
Expected Outcome...1560
Follow-On Procedure...1560
CAC Pressure Test...1561
Overview...1561
Special Tools...1561
Equipment Condition...1561
Setup...1562
Procedure...1563
Expected Outcome...1565
Follow-On Procedure...1565
Coolant Filter...1568
5. Cooling System - Cummins® L9 and B6.7...1569
Auxiliary Water Cooler...1569
Overview...1569
Cooling Package...1570
Overview...1570
Coolant System External Cleaning...1572
Overview...1572
Special Tools...1572
Equipment Conditions...1572
Procedure...1573
Expected Outcome...1573
Follow-On Procedure...1573
Deaeration Tank Inspection...1574
Overview...1574
Special Tools...1574
Equipment Conditions...1574
Setup...1575
Procedure...1575
Expected Outcome...1577
Follow-On Procedure...1577
Check Coolant Condition...1578
Overview...1578
Special Tools...1578
Equipment Conditions...1578
Setup...1579
Procedure...1580
Expected Outcome...1580
Follow-On Procedure...1580
Coolant Pressure Check...1581
Overview...1581
Special Tools...1581
Equipment Conditions...1581
Setup...1581
Procedure...1582
Expected Outcome...1583
Follow-On Procedure...1583
Coolant Package Flush...1584
Overview...1584
Special Tools...1584
Equipment Conditions...1584
Preparation...1585
Coolant Filter Flush, if Applicable...1586
Flush Thermostat Housing...1587
Front Heater Core Flush...1588
Rear Heater Core Flush, if Applicable...1589
DEF Heater Core Flush...1590
Front and Rear, if Applicable, Heater Core Rinse...1591
DEF Heater Rinse...1592
Radiator and Engine Rinse...1593
Final Rinse...1594
Expected Outcome...1594
Follow-On Procedure...1594
Coolant Drain...1595
Overview...1595
Special Tools...1595
Equipment Conditions...1595
Setup...1596
Procedure...1597
Expected Outcome...1598
Follow-On Procedure...1598
Deaeration Tank...1599
Removal...1599
Overview...1599
Special Tools...1599
Equipment Conditions...1599
Procedure...1600
Follow-on Procedure...1601
Installation...1602
Overview...1602
Special Tools...1602
Procedure...1603
Follow-on Procedure...1604
Engine Coolant Level (ECL) Sensor...1605
Removal...1605
Overview...1605
Special Tools...1605
Equipment Conditions...1606
Procedure...1607
Follow-On Procedure...1607
Installation...1608
Overview...1608
Special Tools...1608
Torque Specification...1609
Equipment Conditions...1609
Procedure...1610
Follow-On Procedure...1610
Coolant (Radiator) Hose...1611
Heat Shrink Clamp Removal...1611
Overview...1611
Special Tools...1611
Procedure...1611
Heat Shrink Clamp Installation...1612
Overview...1612
Special Tools...1612
Procedure...1612
Radiator Hose Locator...1615
Hose Removal...1616
Overview...1616
Special Tools...1616
Equipment Conditions...1616
Procedure...1617
Hose Installation...1619
Overview...1619
Special Tools...1619
Procedure...1620
Follow-on Procedure...1621
Coolant Package...1623
Removal...1623
Overview...1623
Special Tools...1623
Equipment Conditions...1623
Procedure...1624
Follow-on Procedure...1630
Installation...1631
Overview...1631
Special Tools...1631
Procedure...1632
Follow-on Procedure...1639
Radiator Core / Charge Air Cooler (CAC)...1640
Removal...1640
Overview...1640
Special Tools...1640
Equipment Conditions...1640
Procedure...1641
Installation...1646
Overview...1646
Special Tools...1646
Procedure...1647
Follow-on Procedure...1651
HVAC Condenser...1652
Removal...1652
Overview...1652
Special Tools...1652
Equipment Conditions...1652
Procedure...1653
Follow-on Procedure...1656
Installation...1657
Overview...1657
Special Tools...1657
Equipment Conditions...1657
Procedure...1658
Follow-on Procedure...1660
Relocation...1661
Overview...1661
Special Tools...1661
Equipment Conditions...1661
Procedure...1662
Follow-on Procedure...1662
Reinstallation...1663
Overview...1663
Special Tools...1663
Procedure...1664
Follow-on Procedure...1664
Cummins® Charge Air Cooler (CAC)...1666
Overview...1666
CAC Clean...1667
Overview...1667
Special Tools...1667
Equipment Condition...1667
Setup...1669
Procedure...1670
Expected Outcome...1670
Follow-On Procedure...1670
CAC Flush...1671
Overview...1671
Special Tools...1671
Equipment Condition...1671
Procedure...1673
Expected Outcome...1673
Follow-On Procedure...1673
CAC Pressure Test...1674
Overview...1674
Special Tools...1674
Equipment Conditions...1674
Setup...1675
Procedure...1676
Expected Outcome...1678
Follow-On Procedure...1678
Coolant Filter...1681
6. Fan and Shroud...1682
Shroud...1682
Removal...1682
Overview...1682
Special Tools...1682
Equipment Conditions...1682
Follow-On Procedure...1683
Installation...1684
Overview...1684
Special Tools...1684
Torque Specification...1684
Equipment Conditions...1684
Procedure...1684
Follow-On Procedure...1684
Belt Routing Options...1685
Cummins®...1685
Overview...1685
Special Tools...1685
Specifications...1685
Equipment Condition...1685
Procedure...1686
Follow-On Procedure...1686
Navistar®, Inc...1687
Overview...1687
Special Tools...1687
Torque Specifications...1687
Equipment Condition...1687
Procedure...1688
Follow-On Procedure...1689
7. Fan Drive...1690
Horton Drivemaster...1690
Overview...1690
Operational Check...1692
Symptom 1...1694
Overview...1694
Possible Causes...1694
Equipment Conditions...1694
Test Procedure...1694
Symptom 2...1706
Overview...1706
Possible Causes...1706
Equipment Conditions...1706
Test Procedure...1706
Symptom 3...1711
Overview...1711
Possible Causes...1711
Equipment Condition...1711
Test Procedure...1711
Symptom 4...1714
Overview...1714
Possible Causes...1714
Equipment Conditions...1714
Test Procedure...1714
Air Cartridge...1716
Removal...1716
Overview...1716
Special Tools...1716
Equipment Conditions...1716
Removal Procedure...1717
Expected Outcome...1718
Follow-On Procedure...1718
Installation...1719
Overview...1719
Special Tools...1719
Torque Specifications...1719
Equipment Conditions...1719
Installation Procedure...1720
Expected Outcome...1721
Follow-On Procedure...1721
Clutch Pack Seal Face...1722
Removal...1722
Overview...1722
Special Tools...1722
Equipment Conditions...1722
Removal Procedure...1723
Expected Outcome...1723
Follow-On Procedure...1723
Installation...1724
Overview...1724
Special Tools...1724
Equipment Condition...1724
Installation Procedure...1725
Expected Outcome...1725
Follow-On Procedure...1725
Cummins® Fan...1726
Removal...1726
Overview...1726
Special Tools...1726
Equipment Condition...1726
Removal Procedure...1727
Expected Outcome...1727
Follow-On Procedure...1727
Installation...1728
Overview...1728
Special Tools...1728
Equipment Condition...1728
Procedure...1729
Expected Outcome...1729
Follow-On Procedure...1729
Cummins® Fan Drive Assembly...1730
Removal...1730
Overview...1730
Special Tools...1730
Equipment Condition...1730
Removal Procedure...1731
Expected Outcome...1731
Follow-On Procedure...1731
Installation...1732
Overview...1732
Special Tools...1732
Equipment Condition...1732
Installation Procedure...1733
Expected Outcome...1733
Follow-On Procedure...1733
Navistar® Fan...1734
Removal...1734
Overview...1734
Special Tools...1734
Equipment Condition...1734
Removal Procedure...1735
Expected Outcome...1735
Follow-On Procedure...1735
Installation...1736
Overview...1736
Special Tools...1736
Equipment Condition...1736
Installation Procedure...1737
Follow-On Procedure...1737
Navistar® Fan Drive Assembly...1738
Removal...1738
Overview...1738
Special Tools...1738
Equipment Condition...1738
Removal Procedure...1739
Follow-On Procedure...1739
Installation...1740
Overview...1740
Special Tools...1740
Equipment Condition...1740
Installation Procedure...1741
Follow-On Procedure...1742
Pulley Bearing...1743
Removal...1743
Overview...1743
Special Tools...1743
Equipment Conditions...1743
Removal Procedure...1744
Expected Outcome...1744
Follow-On Procedure...1744
Installation...1745
Overview...1745
Special Tools...1745
Torque Specifications...1745
Equipment Condition...1745
Installation Procedure...1746
Expected Outcome...1746
Follow-On Procedure...1746
Fan Override...1747
Overview...1747
8. Oil System...1748
Oil Level Sensor...1748
Oil Recovery System...1749
Oil Sample Valve...1750
9. Engine Features...1751
Power Take-Off (PTO)...1751
Overview...1751
Engine Speed Control...1752
Overview...1752
Transmissions...1755
1. Shifter...1757
Automatic Shifter...1757
Allison Push Button...1757
Overview...1757
Navistar® Stalk Shifter...1758
Overview...1758
Removal...1759
Overview...1759
Special Tools...1759
Equipment Conditions...1759
Removal Procedure...1760
Follow-On Procedure...1760
Installation...1761
Overview...1761
Special Tools...1761
Torque Specifications...1761
Equipment Conditions...1761
Installation Procedure...1762
Follow-On Procedure...1762
Eaton® T-handle...1763
Overview...1763
2. Automated Manual Transmissions...1765
Eaton® Fuller Advantage®...1765
Overview...1765
Eaton® UltraShift® PLUS...1767
Overview...1767
3. Automatic Transmissions...1770
Allison®...1770
Overview...1770
Allison® with Auto Neutral...1774
Overview...1774
4. Manual Transmissions...1776
Fuller...1776
Overview...1776
5. Transmission Oil Cooler...1778
Remote-Mounted Oil Cooler...1778
Overview...1778
Transmission Cooler Hoses...1779
Overview...1779
Transmission Lube Pump for Manual Transmission...1780
Transfer Case Cooler...1781
Overview...1781
6. Transfer Case...1782
Fabco...1782
Overview...1782
Accommodation Package Less Transfer Case...1783
Overview...1783
Interlock Transfer Case...1784
Overview...1784
7. PTO...1785
Dash Mounted PTO Controls...1785
Overview...1785
Transmission Mounted PTO...1786
Overview...1786
PTO Provision...1788
Overview...1788
Rear Axle and Suspension...1789
1. Air Suspensions...1791
Air Suspension Dump Valve...1791
Overview...1791
Suspension Leveling Valve...1792
Overview...1792
Hendrickson®...1793
Single Axle...1793
Overview...1793
Service Information...1793
Tandem Axle...1794
Overview...1794
IROS (International Ride Optimized Suspension)...1795
Single Axle...1795
Overview...1795
Tandem Axle...1798
Overview...1798
Air Ride Spring...1800
Removal...1800
Overview...1800
Special Tools...1800
Equipment Conditions...1800
Removal Procedure...1801
Follow-On Procedure...1801
Installation...1802
Overview...1802
Special Tools...1802
Equipment Conditions...1802
Installation Procedure...1803
Follow-On Procedure...1803
Main Support Bushing...1804
Removal...1804
Overview...1804
Special Tools...1804
Equipment Conditions...1804
Removal Procedure...1805
Follow-On Procedure...1805
Installation...1806
Overview...1806
Special Tools...1806
Torque Specifications...1806
Equipment Conditions...1806
Installation Procedure...1806
Follow-On Procedure...1807
Main Support Member...1808
Removal...1808
Overview...1808
Special Tools...1808
Equipment Conditions...1808
Removal Procedure...1809
Follow-On Procedure...1809
Installation...1810
Overview...1810
Special Tools...1810
Equipment Conditions...1810
Installation Procedure...1811
Follow-On Procedure...1811
Shock Absorber...1813
Removal...1813
Overview...1813
Special Tools...1813
Equipment Conditions...1813
Removal Procedure...1814
Follow-On Procedure...1814
Installation...1815
Overview...1815
Special Tools...1815
Equipment Conditions...1815
Installation Procedure...1816
Follow-On Procedure...1816
Torque Rod...1817
Removal...1817
Overview...1817
Special Tools...1817
Equipment Conditions...1817
Removal Procedure...1817
Follow-On Procedure...1818
Installation...1819
Overview...1819
Special Tools...1819
Torque Specification...1819
Equipment Condition...1819
Installation Procedure...1819
Follow-On Procedure...1820
U-bolt Installation...1821
Overview...1821
Special Tools...1821
Torque Specifications...1821
Equipment Condition...1821
Procedure...1822
Follow-On Procedure...1823
Ride Height Adjustment Procedure...1824
Overview...1824
Special Tools...1824
Specifications...1824
Equipment Conditions...1824
Procedure...1824
Follow-On Procedure...1827
Travel exceeds specification:...1827
Travel is less than specification:...1828
Torque Rod...1829
Overview...1829
2. Axle Controls...1830
Differential Lock Controls...1830
Overview...1830
Service Information...1830
3. Rear Axle...1831
Lift Pusher Axle...1831
Overview...1831
Dana Spicer®...1832
Single Axle...1832
Overview...1832
Single Reduction...1834
Two-Speed...1834
Meritor® Axle...1835
Single Axle...1835
Overview...1835
Single Reduction...1837
Two-Speed...1838
Tandem Axle...1839
Overview...1839
Single Reduction...1840
Two-Speed...1840
Tridem Axle...1841
Overview...1841
Tag Lift Axle...1842
Overview...1842
Fuel System...1843
1. DEF Tank...1845
DEF Tank Filter...1845
Removal...1845
Overview...1845
Special Tools...1845
Equipment Conditions...1845
Removal Procedure...1846
Expected Outcome...1846
Follow-On Procedure...1846
Installation...1847
Overview...1847
Special Tools...1847
Torque Specifications...1847
Equipment Condition...1847
Follow-On Procedure...1848
DEF Tank...1849
Removal...1849
Overview...1849
Special Tools...1849
Equipment Conditions...1849
Removal Procedure...1850
Expected Outcome...1850
Follow-On Procedure...1850
Installation...1851
Overview...1851
Special Tools...1851
Equipment Condition...1851
Installation Procedure...1852
Follow-On Procedure...1852
DEF Head Module...1853
Removal...1853
Overview...1853
Special Tools...1853
Equipment Conditions...1853
Removal Procedure...1854
Expected Outcome...1854
Follow-On Procedure...1854
Installation...1855
Overview...1855
Special Tools...1855
Torque Specifications...1855
Equipment Condition...1855
Installation Procedure...1856
Follow-On Procedure...1856
2. Fuel Cooler...1857
Overview...1857
Removal...1858
Overview...1858
Special Tools...1858
Equipment Condition...1858
Removal Procedure...1859
Expected Outcome...1859
Follow-On Procedure...1859
Installation...1860
Overview...1860
Special Tools...1860
Equipment Condition...1860
Installation Procedure...1861
Follow-On Procedure...1861
3. Fuel Heater...1862
Arctic Fox...1862
Overview...1862
4. Fuel / Water Separator...1863
Fuel / Water Separator...1863
Davco...1863
Overview...1863
Removal...1865
Overview...1865
Special Tools...1865
Equipment Condition...1865
Removal Procedure...1866
Expected Outcome...1866
Follow-On Procedure...1866
Installation...1867
Overview...1867
Special Tools...1867
Torque Specification...1867
Equipment Condition...1867
Installation Procedure...1868
Expected Outcome...1868
Follow-On Procedure...1868
Bleed Procedure...1869
Overview...1869
Required Tools...1869
Equipment Condition...1869
Procedure...1870
Expected Outcome...1870
Follow-On Procedure...1870
Racor...1871
Overview...1871
5. Fuel System...1873
Fuel Tank...1873
Removal...1873
Overview...1873
Special Tools...1873
Equipment Condition...1873
Removal Procedure...1874
Expected Outcome...1874
Follow-On Procedure...1875
Installation...1876
Overview...1876
Special Tools...1876
Equipment Condition...1876
Installation Procedure...1877
Follow-On Procedure...1878
Cleaning...1879
Overview...1879
Special Tools...1879
Equipment Conditions...1879
Procedure...1879
Follow-On Procedure...1879
Sending Unit...1880
Removal...1880
Overview...1880
Special Tools...1880
Equipment Condition...1880
Removal Procedure...1881
Expected Outcome...1881
Follow-On Procedure...1882
Installation...1883
Overview...1883
Special Tools...1883
Equipment Condition...1883
Installation Procedure...1884
Follow-On Procedure...1885
Cab...1887
1. Accessories...1891
Antenna Mounting...1891
Overview...1891
GPS...1892
Overview...1892
Keyless Entry System...1893
Overview...1893
Programming Key Fob...1894
Exiting Learning Process...1894
Mirrors...1895
Aero / Pedestal - Heated / Power Mirror...1895
Overview...1895
Mirror Removal...1898
Overview...1898
Special Tools...1898
Equipment Condition...1898
Procedure...1899
Follow-On Procedure...1899
Mirror Installation...1900
Overview...1900
Special Tools...1900
Torque Specification...1900
Equipment Condition...1900
Procedure...1902
Follow-On Procedure...1902
Mirror Assembly Removal...1903
Overview...1903
Special Tools...1903
Equipment Condition...1903
Procedure...1904
Follow-On Procedure...1904
Mirror Assembly Installation...1905
Overview...1905
Special Tools...1905
Equipment Condition...1905
Procedure...1906
Follow-On Procedure...1906
Tire Pressure Monitor...1907
Overview...1907
2. Cab...1909
Cab...1909
Day Cab...1909
Overview...1909
Crew Cab...1910
Overview...1910
Extended Cab...1911
Overview...1911
Cab Interior Trim...1912
Overview...1912
Cab Interior...1913
Door Vapor Barrier...1913
Removal...1913
Overview...1913
Special Tools...1913
Equipment Conditions...1914
Procedure...1915
Follow-On Procedure...1918
Installation...1919
Overview...1919
Special Tools...1919
Torque Specifications...1919
Equipment Conditions...1920
Procedure...1921
Follow-On Procedure...1923
Engine Cover...1924
Overview...1924
Front Door Panel...1925
Removal...1925
Overview...1925
Special Tools...1925
Equipment Condition...1925
Removal Procedure...1926
Expected Outcome...1926
Follow-On Procedure...1927
Installation...1928
Overview...1928
Special Tools...1928
Torque Specifications...1928
Equipment Condition...1928
Installation Procedure...1929
Expected Outcome...1930
Follow-On Procedure...1930
Cab Rear Suspension...1932
Overview...1932
Cab Sunshade...1933
Overview...1933
Dash...1934
Flat Panel Dash...1934
Removal...1934
Overview...1934
Special Tools...1934
Torque Specifications...1934
Equipment Conditions...1935
Procedure...1936
Follow-On Procedure...1950
Installation...1951
Special Tools...1951
Equipment Conditions...1951
Procedure...1952
Follow-On Procedure...1967
Wing Panel...1968
Overview...1968
Removal...1969
Overview...1969
Special Tools...1969
Equipment Condition...1969
Procedure...1970
Follow-On Procedure...1971
Installation...1972
Overview...1972
Special Tools...1972
Torque Specifications...1972
Equipment Condition...1972
Procedure...1973
Follow-On Procedure...1974
Windshield...1975
Overview...1975
3. HVAC...1976
Overview...1976
Automatic Climate Control...1977
Full Automatic Mode...1978
Semi Automatic Mode...1978
Front HVAC System Repair...1979
HVAC Actuator Overview...1979
Defrost Actuator...1979
Temperature Actuator...1979
Recirculation Actuator...1980
Panel Actuator / Floor Actuator...1980
Defrost Actuator...1981
Removal...1981
Overview...1981
Special Tools...1981
Equipment Conditions...1981
Removal Procedure...1981
Follow-On Procedure...1982
Installation...1983
Overview...1983
Special Tools...1983
Equipment Conditions...1983
Installation Procedure...1984
Follow-On Procedure...1984
Floor Actuator...1985
Removal...1985
Overview...1985
Special Tools...1985
Equipment Conditions...1985
Removal Procedure...1985
Follow-On Procedure...1986
Installation...1987
Overview...1987
Special Tools...1987
Equipment Conditions...1987
Installation Procedure...1988
Follow-On Procedure...1988
Panel Actuator...1989
Removal...1989
Overview...1989
Special Tools...1989
Equipment Conditions...1989
Removal Procedure...1989
Follow-On Procedure...1990
Installation...1991
Overview...1991
Special Tools...1991
Equipment Conditions...1991
Installation Procedure...1992
Follow-On Procedure...1992
Recirculation Actuator...1993
Removal...1993
Overview...1993
Special Tools...1993
Equipment Conditions...1993
Removal Procedure...1993
Follow-On Procedure...1994
Installation...1995
Overview...1995
Special Tools...1995
Equipment Conditions...1995
Installation Procedure...1996
Follow-On Procedure...1996
Temperature Actuator...1997
Removal...1997
Overview...1997
Special Tools...1997
Equipment Conditions...1997
Removal Procedure...1997
Follow-On Procedure...1998
Installation...1999
Overview...1999
Special Tools...1999
Equipment Conditions...1999
Installation Procedure...2000
Follow-On Procedure...2000
Blower Motor...2001
Removal...2001
Overview...2001
Special Tools...2001
Equipment Conditions...2001
Removal Procedure...2002
Follow-On Procedure...2002
Installation...2003
Overview...2003
Special Tools...2003
Equipment Conditions...2003
Installation Procedure...2004
Follow-On Procedure...2004
Cab Evaporator...2005
Removal...2005
Overview...2005
Special Tools...2005
Equipment Conditions...2005
Procedure...2006
Follow-On Procedure...2008
Installation...2009
Overview...2009
Special Tools...2009
Equipment Condition...2009
Procedure...2010
Follow-On Procedure...2012
Cab Thermal Expansion Valve (TXV)...2013
Removal...2013
Overview...2013
Special Tools...2013
Equipment Conditions...2013
Removal Procedure...2014
Follow-On Procedure...2014
Installation...2015
Overview...2015
Special Tools...2015
Equipment Conditions...2015
Installation Procedure...2015
Follow-On Procedure...2016
Compressor...2017
Removal...2017
Overview...2017
Special Tools...2017
Equipment Condition...2017
Removal Procedure...2018
Follow-On Procedure...2019
Installation...2020
Overview...2020
Special Tools...2020
Equipment Condition...2020
Installation Procedure...2021
Follow-On Procedure...2022
Condenser...2023
Removal...2023
Overview...2023
Special Tools...2023
Equipment Condition...2023
Removal Procedure...2024
Follow-On Procedure...2025
Installation...2026
Overview...2026
Special Tools...2026
Equipment Condition...2026
Installation Procedure...2027
Follow-On Procedure...2028
Freeze Probe...2029
Removal...2029
Overview...2029
Special Tools...2029
Equipment Conditions...2029
Removal Procedure...2030
Follow-On Procedure...2030
Installation...2031
Overview...2031
Special Tools...2031
Equipment Conditions...2031
Installation Procedure...2032
Follow-On Procedure...2032
HVAC Control Module...2033
Removal...2033
Overview...2033
Special Tools...2033
Equipment Conditions...2033
Procedure...2033
Follow-On Procedure...2036
Installation...2037
Overview...2037
Special Tools...2037
Torque Specifications...2037
Equipment Conditions...2037
Procedure...2038
Follow-On Procedure...2041
Integrated Temperature Optical Sensor (ITOS)...2042
Removal...2042
Overview...2042
Special Tools...2042
Equipment Conditions...2042
Procedure...2042
Follow-On Procedure...2045
Installation...2046
Overview...2046
Special Tools...2046
Torque Specifications...2046
Equipment Conditions...2046
Procedure...2046
Follow-On Procedure...2049
Receiver Drier...2050
Removal...2050
Overview...2050
Special Tools...2050
Equipment Condition...2050
Removal Procedure...2052
Follow-On Procedure...2052
Installation...2053
Overview...2053
Special Tools...2053
Equipment Condition...2053
Installation Procedure...2054
Follow-On Procedure...2054
Sun Load Sensor...2055
Removal...2055
Overview...2055
Special Tools...2055
Equipment Conditions...2055
Procedure...2055
Follow-On Procedure...2056
Installation...2057
Overview...2057
Special Tools...2057
Torque Specifications...2057
Equipment Conditions...2057
Procedure...2057
Follow-On Procedure...2058
General HVAC System Maintenance...2059
Safety Precautions...2059
General Precautions...2059
Refrigerant Precautions...2059
Discharge A/C System...2063
Overview...2063
Special Tools...2063
Equipment Condition...2063
Recycling Mode...2063
Follow-On Procedure...2064
Evacuate A/C System...2065
Overview...2065
Special Tools...2065
Equipment Condition...2065
Evacuate A/C System...2066
Follow-On Procedure...2067
Charge A/C System...2068
Overview...2068
Special Tools...2068
Equipment Condition...2068
Charge A/C System...2069
Follow-On Procedure...2069
Oil Fill Guidelines...2070
Overview...2070
Special Tools...2070
Equipment Conditions...2070
Procedure...2073
Oil separation during refrigerant recovery...2073
Component replacement...2073
Oil loss due to refrigerant leak...2073
Compressor replacement due to internal compressor failure...2073
Compressor replacement due to clutch failure...2073
Follow-On Procedure...2073
Checking Compressor Oil Level...2074
Overview...2074
Special Tools...2074
Equipment Conditions...2074
Procedure...2075
Follow-On Procedure...2077
Flush and Purge...2078
Evaporator...2078
Overview...2078
Special Tools...2078
Equipment Conditions...2078
Procedure...2081
Follow-On Procedure...2083
Supply and Return Lines...2084
Overview...2084
Special Tools...2084
Equipment Conditions...2084
Procedure...2085
Follow-On Procedure...2089
Condenser...2090
Overview...2090
Special Tools...2090
Equipment Conditions...2090
Procedure...2092
Follow-On Procedure...2095
4. Instrumentation / Gauges...2096
Driver Information Display...2096
Overview...2096
Gauge Cluster...2098
Overview...2098
Removal...2101
Overview...2101
Special Tools...2101
Equipment Conditions...2101
Procedure...2101
Follow-On Procedure...2102
Installation...2103
Overview...2103
Special Tools...2103
Equipment Conditions...2103
Procedure...2103
Follow-On Procedure...2104
5. Seats...2105
National...2105
Overview...2105
Driver...2108
Removal...2108
Overview...2108
Special Tools...2108
Equipment Condition...2108
Removal Procedure...2109
Expected Outcome...2109
Follow-On Procedure...2109
Installation...2110
Overview...2110
Special Tools...2110
Torque Specifications...2110
Equipment Condition...2110
Installation Procedure...2111
Expected Outcome...2111
Follow-On Procedure...2111
Passenger...2112
Removal...2112
Overview...2112
Special Tools...2112
Equipment Condition...2112
Removal Procedure...2113
Expected Outcome...2113
Follow-On Procedure...2113
Installation...2114
Overview...2114
Special Tools...2114
Torque Specifications...2114
Equipment Condition...2114
Installation Procedure...2115
Expected Outcome...2115
Follow-On Procedure...2115
Split Bench...2116
Removal...2116
Overview...2116
Special Tools...2116
Equipment Condition...2116
Removal Procedure...2116
Expected Outcome...2116
Follow-On Procedure...2116
Installation...2117
Overview...2117
Special Tools...2117
Torque Specifications...2117
Equipment Condition...2117
Installation Procedure...2117
Expected Outcome...2117
Follow-On Procedure...2117
Bench...2118
Removal...2118
Overview...2118
Special Tools...2118
Equipment Condition...2118
Removal Procedure...2119
Expected Outcome...2119
Follow-On Procedure...2119
Installation...2120
Overview...2120
Special Tools...2120
Torque Specifications...2120
Equipment Condition...2120
Installation Procedure...2121
Expected Outcome...2121
Follow-On Procedure...2121
Rear...2122
Removal...2122
Overview...2122
Special Tools...2122
Equipment Condition...2122
Removal Procedure...2122
Expected Outcome...2122
Follow-On Procedure...2122
Installation...2123
Overview...2123
Special Tools...2123
Torque Specifications...2123
Equipment Condition...2123
Installation Procedure...2123
Expected Outcome...2123
Follow-On Procedure...2123
National with RollTek®...2124
Drivers...2124
Overview...2124
Passenger...2126
Overview...2126
Driver / Passenger RollTek® Seat with Supplemental Restraint System (SRS)...2128
Removal (Driver and Passenger)...2128
Overview...2128
Required Tools...2128
Equipment Conditions...2128
Procedure...2128
Expected Outcome...2132
Follow-On Maintenance...2132
Installation (Driver and Passenger)...2133
Overview...2133
Required Tools...2133
Equipment Conditions...2133
Procedure...2133
Expected Outcome...2137
Follow-On Maintenance...2137
RollTek® Side Roll Airbag (SRA)...2138
Removal...2138
Overview...2138
Required Tools...2139
Equipment Conditions...2139
Procedure...2139
Expected Outcome...2142
Follow-On Maintenance...2142
Installation...2143
Overview...2143
Required Tools...2144
Torque Specifications...2144
Equipment Conditions...2144
Procedure...2144
Unpacking Replacement SRA Unit...2144
Product Identification...2145
RollTek® Side Roll Air Bag (SRA) - Installation...2146
Expected Outcome...2148
Follow-On Maintenance...2148
RollTek® Supplemental Restraint System (SRS) Module...2149
Removal...2149
Overview...2149
Required Tools...2150
Equipment Conditions...2150
Procedure...2150
Expected Outcome...2155
Follow-On Maintenance...2155
Installation...2156
Overview...2156
Required Tools...2157
Equipment Conditions...2157
Procedure...2157
Expected Outcome...2164
Follow-On Maintenance...2164
Seat Belt Warning Lamp...2165
Overview...2165
6. Windshield Wipers...2166
Windshield Wiper System...2166
Overview...2166
Windshield Wiper Motor...2167
Removal...2167
Overview...2167
Special Tools...2167
Equipment Conditions...2167
Procedure...2168
Follow-On Procedure...2168
Installation...2169
Overview...2169
Special Tools...2169
Equipment Conditions...2169
Procedure...2170
Follow-On Procedure...2170
Washer Pump...2171
Removal...2171
Overview...2171
Special Tools...2171
Equipment Conditions...2171
Procedure...2172
Follow-On Procedure...2172
Installation...2173
Overview...2173
Special Tools...2173
Torque Specifications...2173
Equipment Conditions...2173
Procedure...2174
Follow-On Procedure...2174
Washer Reservoir...2175
Removal...2175
Overview...2175
Special Tools...2175
Equipment Conditions...2175
Procedure...2176
Follow-On Procedure...2176
Installation...2177
Overview...2177
Special Tools...2177
Torque Specifications...2177
Equipment Conditions...2177
Procedure...2178
Follow-On Procedure...2178
tables...31
Torque Specifications...31
Torque Specifications...39
Torque Specifications...47
Service Procedures...51
Service Procedures...53
Torque Specifications...57
Torque Specifications...67
Torque Specifications...82
Service Procedures...109
Torque Specifications...111
Service Procedures...113
Torque Specifications...115
Service Procedures...120
Service Procedures...143
Torque Specifications...158
Torque Specifications...176
Service Procedures...180
Torque Specifications...208
Torque Specifications...214
Specifications...222
Torque Specifications...230
Torque Specification...284
Procedures...302
Torque Specifications...332
Torque Specifications...335
Torque Specifications...337
Diagnostics...340
Battery Type...378
Description...378
Battery Chemistry...378
Description...378
Battery Type...383
Description...383
Battery Chemistry...384
Description...384
Individual Battery Test RESULTS...386
Recommended Action...386
Starting System RESULTS...387
Recommended Action...387
RESULTS...391
Recommended Action...391
Released...422
Intermediate...422
Fully depressed...422
Service Information...539
Test Procedure...604
Specifications...611
CAN Modules Table...620
Approximate Resistance Values...642
Approximate DC voltage readings (Key ON)...644
Service Procedures...792
Tech Tips...823
Base HVAC Tests...1061
HVAC Tests...1061
Refrigerant Charge Quantities...1075
A/C System Dynamic Pressures and Temperatures...1082
Freeze Probe Resistance Chart...1088
R-134a Static Temperature / Pressure Table...1115
Sensor Values...1171
Service Information...1221
Service Information...1223
Service Information...1226
PWM Outputs to TCM...1288
Windshield Wiper Input Switch...1309
Torque Specification...1400
Torque Specifications...1447
Torque Specifications...1458
Torque Specifications...1462
Torque Specifications...1491
Torque Specifications...1509
Torque Specifications...1523
Torque Specifications...1535
Torque Specifications...1548
Torque Specifications...1562
Torque Specifications...1602
Torque Specifications...1619
Torque Specifications...1631
Torque Specifications...1646
Torque Specifications...1657
Torque Specifications...1663
Torque Specifications...1675
Torque Specifications...1724
Torque Specification...1728
Torque Specifications...1732
Torque Specifications...1736
Torque Specifications...1740
Service Procedures...1797
Service Procedures...1799
Torque Specifications...1802
Torque Specifications...1810
Torque Specifications...1815
Torque Specifications...1851
Torque Specifications...1860
Service Information...1864
Torque Specifications...1876
Torque Specifications...1883
Torque Specifications...1905
Torque Specifications...1951
Torque Specifications...1983
Torque Specifications...1987
Torque Specifications...1991
Torque Specifications...1995
Torque Specifications...1999
Torque Specifications...2003
Torque Specifications...2009
Torque Specifications...2015
Torque Specifications...2020
Torque Specifications...2026
Torque Specifications...2031
Torque Specifications...2053
Refrigerant Charge Quantities...2068
Oil Capacity Specifications by Component...2070
Torque Specifications...2070
Torque Specifications...2074
Torque Specifications...2103
Torque Specifications...2133
Torque Specifications...2157
Torque Specifications...2169
4328687 - Interactive Schematics User Guide...2180
toc...2182
Table of Contents...2182
SAFETY INFORMATION...2184
Safety Terminology...2184
Work Area...2184
Protective Measures...2184
Vehicle...2184
Safety Equipment...2185
Engine...2185
Fire Prevention...2185
Batteries...2185
Introduction...2186
What is Interactive Schematics?...2186
Features...2186
Why Interactive?...2186
Benefits...2186
Getting Started...2187
Opening Interactive Schematics...2187
User Interface...2188
The Navigation Menu...2188
Menu Headings...2190
Using the Search Function...2191
Finding the Diagram for a Desired Feature...2191
Finding Schematics Containing a Specific Device...2192
Topics that Have Multiple Schematics...2193
Layout View...2194
Symbols...2196
Working with Devices...2197
Finding Other Schematics in which the Device is Used...2198
Finding the Physical Location of a Device...2199
Finding the Part Number for the Device...2201
Working with Connectors...2202
Finding Other Schematics that the Connector is Used In...2203
Displaying the Connector View...2204
Viewing Connector Attributes...2206
Finding Connector Part Numbers...2206
Finding the Part Number for a Connector Housing...2207
Finding the Terminal Splice Part Number and Seal / Sleeve Part Number...2208
Working with Inline Connectors...2211
Finding Other Schematics that the Inline is Used In...2212
Finding the Physical Location of an Inline...2213
Displaying the End View for an Inline Connector...2215
Viewing Attributes for Inline Connectors...2217
Working with Wires...2218
Circuit Identification...2218
Circuit Name...2219
Wire Color by System...2220
Cable Colors for Ground Circuits...2220
Finding Other Schematics that the Wire is Used In...2221
Viewing Attributes for Wires...2222
Working with Power and Grounds...2223
Power and Ground Wires...2223
Tracing a Ground Wire to the Ground Stud...2224
Tracing a Power Wire to the Source...2226
Ground Studs...2229
Finding the Physical Location of a Ground Stud...2230
Tracing from Ground to Feature Diagram...2231
Power Distribution ...2233
Finding the Physical Location of a Power Distribution Module (PDM)...2234
Tracing from Power Distribution to Feature Diagram...2235
CAN Systems...2236
Finding the CAN Layout Schematic...2237
Product Feedback and Technical Support...2238
Opening a Technical Publications Feedback Case...2238
Procedure...2238
Information to Provide...2238
Accessing Online Training for Interactive Schematics...2238
International HVHD-Series, HVMD-Series Repair Service Manual 2018-2020
