International/Navistar Trucks DuraStar and WorkStar Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for International/Navistar Trucks DuraStar (4000-Series) and WorkStar (7000-Series), with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
International/Navistar Trucks Models DuraStar and WorkStar workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 29,126 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 13.pdf
0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 4.pdf
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Revision 1 (Supersedes 0000001601, 0000001843 & 0000002222) Service Manual.pdf
S13008 - 6 Speed Transmissions Eaton Series FS-5106 and FS-6206 Supersedes CTS-5179 (June 1996) Service Manual.pdf
0000002601 - 3200, RXT, DuraStar, TranStar, TranStar Natural Gas, WorkStar Series Built May 17, 2010 and Later Electrical Circuit Diagrams (Supersedes S08343).pdf
S082503 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built Before 05_20_2003.pdf
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10 Service Manual.pdf
CTS-5122T - 2000, 4000, 8000 Series Built After February 1, 1996 Electrical Circuit Diagrams.pdf
S13016 7 - Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual.pdf
S082504 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models 05_20_2003 to 02_28_2007.pdf
1087481R1 - 1000 Through 4000, 7000, 8000 Series Electrical Circuit Diagrams CTS-4417Circuit Diagrams.pdf
S082503A - Electrical System Troubleshooting Guide Models Built After 05_20_2003 (Apr 2004) Serice Manualpdf
S082504 - Electrical System Troubleshooting Guide Models Built 05_20_2003 to 02_28_2007 (Jan 2008) Service Manual.pdf
S082503 - Electrical System Troubleshooting Guide Models Built 10_16_2000 to 05_20_2003 (Jan 2008) Service Manual.pdf
0000002601 - 4000 Series (Oct 2014) Wiring Diagrams.pdf
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual.pdf
S08322 - 4000 Series (March 2007 to March 2008) Wiring Diagrams.pdf
0000017581 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Series Built March 11, 2004 to September 30, 2005 Electrical Circuit Diagrams (Supersedes S082854).pdf
S08322 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600, RXT Models Built March 1, 2007 to March 18, 2008 Electrical Circuit Diagrams.pdf
S08315 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, MXT, RXT Models Built Oct. 1, 2005 to Feb. 28, 2007 Electrical Circuit Diagrams.pdf
0000003922 - 4000 Series (Nov 2010) Wiring Diagrams.pdf
S10024 - Eaton Hybrid System Service Manual (Oct 2009).pdf
S08300 - Body Builder Electrical Data Book for Models Built January 2001 to February 28, 2007 Supersedes PBB-73000B (Aug 2008) Service Manual.pdf
0000002842 - 3200, DuraStar, TranStar, WorkStar, and RXT Models Built March, 2008 to May 16, 2010 Electrical Circuit Diagrams (Supersedes S08337) .pdf
S08323A - (2007) 3000 4000 7000 8000 BE CE DuraStar WorkStar TranStar - Body Builder Data Book.pdf
S08230 - Electrical System Troubleshooting Guide, Supersedes CTS-5300 (July 1999) Service Manual.pdf
S082854 - 4000 Series (2004 to 2005) Wiring Diagrams.pdf
CTS-5122K - 2000 , 4000 and 8000 Series September 1993 and Later Electrical Circuit Diagrams.pdf
0000002322 - DuraStar and TerraStar Cab Service Manual (Supersedes S16026).pdf
0000001844 WorkStar Radiator _ Cooling System (Supersedes S12026) Service Manual.pdf
S082853 - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built September 16, 2003 to March 10, 2004 Electrical Circuit Diagrams.pdf
0000001844 - Radiator, Cooling System Cooling System Service Manual 2013.pdf
S08186X - 2000, 4000, 8000 Models Built October 1, 1999 and After Electrical Circuit Diagrams.pdf
S08186 - 2000, 4000, 8000 Models Built October 1, 1998 To September 30, 1999 Electrical Circuit Diagrams.pdf
S13006H - 6 Speed Transmissions International Model ES52-7A and ESO65-7A 6-Plus Service Manual.pdf
0000003922 - DuraStar, WorkStar, TranStar Series Models Built From November 22, 2010 Electrical Circuit Diagrams (Supersedes S08353) (Latin America _ Mexico).pdf
0000002324 - SERVICE MANUAL CAB TranStar, WorkStar.pdf
S13009 - 5 Speed Transmissions Spicer ES43-5 and ES53-5 Supersedes CTS-5181 (March 1996) Service Manual.pdf
S16034 - HEAT VENTILATION AIR CONDITIONING (HVAC), TXV System, March 2007 - 2009 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Models, CXT, DuraStar, TranStar, WorkStar and RXT.pdf
0000002842 - 4000 Series (March 2008 to May 2010) Wiring Diagrams.pdf
0000018561 - DuraStar with Cummins Euro 5 ISB Engine Electrical Circuit Diagram Manual (for Latin America and Mexico).pdf
S160263 - CAB 4100, 4200, 4300, 4400, DuraStar, TerraStar 4100, 4200, 4300, 4400, DuraStar, TerraStar Service Manual.pdf
S16046 - 3200 Bus, DuraStar, TerraStar, TranStar, WorkStar Models Heat Ventilation Air Conditioning (HVAC) for 2010 Service Manual.pdf
S08359 - 4400 LHD Euro III Model Built After July, 2011 Electrical Circuit Diagrams (Brazil Market) Circuit Diagrams.pdf
CTS4425 - Electrical System Troubleshooting Guide - U-HAUL 4600UH Service Manual.pdf
S11003 - Spicer 14-Inch (355.6 mm) Stamped Angle-Spring Clutch Supersedes CTS-5140 (March 1996) Service Manual.pdf
S16055 - HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 HVAC DuraStar Vehicle Service Manual.pdf
S082852 - 4000 Series (Jan 2002 to Sep 2002) Wiring Diagrams.pdf
S082852 - 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600 Models Built January 1, 2002 To September 30, 2002 Electrical Circuit Diagrams (Jan 2002) Service Manual.pdf
S16025 - HEAT VENTILATION AIR CONDITIONING (HVAC), Orifice Tube System, Pre-March 2007 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Service Manual.pdf
S08324 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, CXT, DuraStar, RXT, TranStar, and WorkStar Models Built After March 01, 2007 Electrical System Troubleshooting Guide.pdf
0000003046 - Radiator_Cooling System DuraStar Cooling System Service Manual.pdf
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES Built October 1, 2002 and After ELECTRICAL CIRCUIT DIAGRAMS.pdf
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built October 1, 2002 to September 15, 2003 Electrical Circuit Diagrams (Oct 2002) Manual.pdf
S16053 - Heat Ventilation Air Conditioning (HVAC) for 2010 - South Africa _ 7000 RHD AND 8000 RHD Service Manual.pdf
S08361 - DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — DuraStar, TerraStar, TranStar, and WorkStar Built May 2010 and Later.pdf
S12022 - Radiator _ Cooling System (Aug 2010) Service Manual.pdf
S09016 - 2010 Hood Grille Fenders Bumper WorkStar, TranStar Service Manual.pdf
S02014 - Carraro Axle Repair Manual (Feb 2009) Service Manual.pdf
S16054 - SERVICE MANUAL CAB MANUALModel DuraStar Vehicle.pdf
S04038 - EC-17 Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Technical Manual.pdf
S08285 - 4200, 4300, 4400 Models Built October 16, 2000 to December 31, 2001 Electrical Circuit Diagrams (Jan 2001).pdf
0000680131 - DuraStar Radiator _ Cooling System (Euro V Latin American Market ) Service Manual.pdf
S04051 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual.pdf
S09002 - Hood, Grille, and Fenders - 2000, 4000, 8000 (Supersedes CTS-5269) (Feb 1999) Service Manual.pdf
S16038 - CAB_ 7300, 7400, 7500, 7600, 7700, 8500, 8600, TranStar, and WorkStar Models Service Manual.pdf
S12036 - Radiator_Cooling System 2010 Service Manual.pdf
S09007 - Hood, Grille, Fenders and Bumper - 7000 (Oct 2002) Service Manual.pdf
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Manual.pdf
S11004 - Spicer 14 Inch (350 mm) Solo Clutch Supersedes CTS-5256 (March 1996) Service Manual.pdf
S09014 - Hood Grille Fenders Bumper Service Manual (Dec 2011).pdf
S04050 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual.pdf
S11014 - Hydraulic Clutch Service Manual (2010) Service Manual.pdf
S14019 - LIFT AXLE SYSTEMS (7400, 7500 7600 Models) Service Manual.pdf
S02012 - Meritor Medium Duty Front Drive Steer Axle (Dec 2001) Service Manual.pdf
S08357 - 2011 DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE Model 4400.pdf
S040393 - Lucas Varity _ TRW Hydraulic Antilock Brake System (Dec 2003) Technical Manual.pdf
4328434 - New Truck Processing Technical Manual.pdf
S04016K - Caliper Disc Brakes, Supersedes CTS-5009K (March 1996) Service Manual.pdf
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual.pdf
S04045 - Meritor _ WABCO Hydraulic ABS for Medium-Duty Trucks, Buses and Motor Home Chassis (June 2000) Technical Manual.pdf
S08155X - Instruments (New Data Link Driven Instrument Cluster), Supersedes CTS-5228 (Oct 1999) Technical Manual.pdf
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual.pdf
S09018 - 2011 Hood Grille Fenders Bumper Service Manual.pdf
S12038 - 2011 Cooling System Service Manual.pdf
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual.pdf
S16016 - Air Conditioning - Heater System_ 2000, 4000, and 8000 - 12_06_1994 and After Formerly (CTS-5227) Service Manual.pdf
S04055 - MCAC 465 Air Compressor (Dec 2010) Service Manual.pdf
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual.pdf
S09003 - Hood, Grille, and Fenders (March 2001) Service Manual.pdf
S09003 - 2001 Hood Grille Fender Bumper Service Manual.pdf
S04053 - ECE-13 Brake System (2010) Service Manual.pdf
S12010 - Radiator, Removal and Replacement (April 2003) Service Manual.pdf
S05021 - Steering Wheel and Steering Column Assembly (July 2012) Service Manual.pdf
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual.pdf
S08034X - Instruments, Supersedes CTS-5088K (Oct 1999) Service Manual.pdf
S04004 - Air Compressor_ Bendix 2150, Supersedes CTS-5058 (March 1996) Service Manual.pdf
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual.pdf
S16027 - SERVICE CAB 4100, 4200, 4300, 4400 SERVICE MANUAL .pdf
S04033 - Antilock Brakes_Traction Control_ Bendix - Troubleshooting, Supersedes CTS-5250 (June 1996) Service Manual.pdf
S12008 - Radiator, Removal and Replacement (2012) Service Manual.pdf
S13037 - OMSI PFT-PCV_3000 Split Shaft PTO Service Manual.pdf
s04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual.pdf
S04018W - Reconditioning Rotors, Supersedes CTS-5086W (June 1998) Service Manual.pdf
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual.pdf
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual.pdf
S04011 - Air Compressor_ Midland Models EL-1300 and EL-1600, Supersedes CTS-5146 (March 1996) Service Manual.pdf
S05022 - Steering Wheel _ Column Assembly _ Power Steering Reservoir (Jan 2011) Brazilian Market Service Manual.pdf
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual.pdf
S04010 - Air Compressor_ Bendix TU-FLO 501, Supersedes CTS-5145 (March 1996) Service Manual.pdf
S08308 - Diamond Logic PowerPack 3 Dynamic Power System Service _ Troubleshooting Guide (Feb 2006) Service Manual.pdf
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual.pdf
S04020X - DCM and DDM Drum Type Parking Brake, Supersedes CTS-5135TA (July 1997) Service Manual.pdf
S04017Y - Hydro-Max Brake Booster and Master Cylinder, Supersedes CTS-5018K (Dec 2000) Service Manual.pdf
S16017X - Air Conditioning Compressor and Clutch, Two Cylinder Reciprocating Type - After 01_01_1993 (R-134A) (Formerly CTS-5241) Service Manual.pdf
S08333 - 4300 Eaton Hybrid Drive System Built November 2006 through February 2007 Electrical Circuit Diagrams.pdf
S05013 - Steering Column Assembly, Standard and Tilt, Supersedes CTS-5168 (April 1996) Service Manual.pdf
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual.pdf
S08327 - 2007-2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual.pdf
S11002 - Spicer 13-Inch (310 mm) and 14-Inch (350 mm) Angle-Ring Single Plate Push-Type Clutch Supersedes CTS-5057 Service Manual.pdf
S04044 - Bosch Parking Brake_ Manual or Power Brake (Oct 2008) Service Manual.pdf
S05025 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual.pdf
s12005 - Radiator Shutters, Supersedes CTS-5084 (March 1996) Service Manual.pdf
S05016 - Steering Wheel Removal and Installation (Sept 2010) Service Manual.pdf
S11006R - Clutch Control Linkage Supersedes CTS-5053R (Oct 2002) Service Manual.pdf
S05012 - Steering Column Assembly, Tilt_Telescoping Supersedes CTS-5167 (May 1996) Service Manual.pdf
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual.pdf
S10020 - USPS International 4400 Master Index (June 2005) Service Manual.pdf
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes (June 2005) Service Manual.pdf
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual.pdf
MAIN SECTIONS
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10 Service Manual....1
toc....3
Summary of Changes....3
1. Description....9
1.1. Theory of Operation....15
Aftertreatment regeneration burns soot to ash when excess soot buildup occurs. For regeneration to occur, the Engine Control Module (ECM) must detect a DPF restriction by monitoring temperature and pressure sensors.....15
1.2. Switchback / Horizontal....16
1.3. Vertical / Vertical....17
1.4. In-Line....18
2. General Service Information....19
2.1. Exhaust Aftertreatment System Modifications....20
2.2. Gaskets and Fasteners....21
2.3. Diesel Particulate Filter (DPF) Indexing....21
2.4. DPF and DOC Cleaning....21
2.5. DPF General Inspection....22
DPF Inspection Points....23
2.6. DOC General Inspection....26
DOC Inspection Points....26
2.7. DPF / DOC Thread Repair....30
12 MM Thread Replacement....30
14 MM Thread Replacement....34
2.8. DOC and DPF Reuse Guidelines....38
General Information....38
Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted....39
Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged....40
Diesel Particulate Filter (DPF) Inlet / Outlet – New....41
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1)....42
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2)....43
Diesel Particulate Filter (DPF) Inlet – Clean....44
Diesel Particulate Filter (DPF) Inlet – Gouged....45
Diesel Particulate Filter (DPF) Inlet – Ash....46
Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings....47
Diesel Particulate Filter (DPF) Outlet – Soot Stains....48
Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process....49
Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains ....50
Diesel Particulate Filter (DPF) Outlet – Face Cracked....51
Diesel Particulate Filter (DPF) Outlet – Coolant Staining....52
Diesel Particulate Filter (DPF) Outlet – Melted....53
2.9. Decomposition Reactor Tube Cleaning....54
2.10. Diesel Exhaust Fluid (DEF) Dosing Valve cleaning....55
2.11. DEF Supply Module Filter Inspection....57
2.12. Diesel Exhaust Fluid (DEF) System Contamination....59
2.13. DEF System Decontamination Procedure....62
2.14. Diesel Exhaust Fluid (DEF) Refractometer Tool....63
Using the DEF Refractometer....63
DEF Refractometer Maintenance....65
2.15. Diesel Exhaust Fluid (DEF) Dosing System Reuse Guidelines....66
2.16. Diesel Exhaust Fluid (DEF) Tank Draining....69
3. Switchback / Horizontal....70
3.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....70
Switchback / Horizontal – Removal....70
Switchback / Horizontal – Installation....72
Diesel Exhaust Fluid (DEF) Dosing Valve – Removal....73
Diesel Exhaust Fluid (DEF) Dosing Valve – Installation....74
Decomposition Reactor Tube – Removal....75
Decomposition Reactor Tube – Installation....76
Aftertreatment Assembly Mounting Bracket – Removal....77
Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly Mounting Bracket – Installation....78
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal....79
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation....79
Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal....81
Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation....81
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped)....83
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped)....83
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal....84
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation....84
(DPF) Temperature Sensors and Module – Removal....86
Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation....86
Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal....88
Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation....89
Diesel Particulate Filter (DPF) High Pressure Tube – Removal....90
Diesel Particulate Filter (DPF) High Pressure Tube – Installation....90
Diesel Particulate Filter (DPF) Low Pressure Tube – Removal....91
Diesel Particulate Filter (DPF) Low Pressure Tube – Installation....91
4. Vertical / Vertical ....92
4.1. Navistar® N13 Engine....92
Vertical / Vertical....92
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal....93
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Installation....93
Power Distribution Module (PDM) – Removal....94
Power Distribution Module (PDM) – Installation....94
Aftertreatment Control Module (ACM) – Removal....95
Aftertreatment Control Module (ACM) – Installation....95
5. In–Line....96
5.1. Cummins ISB6.7 or Navistar® N9 and N10 Engines....96
In-Line....96
6. Diesel Exhaust Fluid (DEF) System....97
6.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....97
Diesel Exhaust Fluid (DEF) Tank – Removal....97
Diesel Exhaust Fluid (DEF) Tank – Installation....100
Power Distribution Module (PDM) – Removal....101
Power Distribution Module (PDM) – Installation....101
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal....102
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation....105
Diesel Exhaust Fluid (DEF) Tank Lines – Removal....106
Diesel Exhaust Fluid (DEF) Tank Lines – Installation....108
Diesel Exhaust Fluid (DEF) Supply Module – Removal....109
Diesel Exhaust Fluid (DEF) Supply Module – Installation....110
Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal....111
Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation....111
Aftertreatment Control Module (ACM) – Removal....112
Aftertreatment Control Module (ACM) – Installation....113
Diesel Exhaust Fluid (DEF) Tank Bracket – Removal....114
Diesel Exhaust Fluid (DEF) Tank Bracket – Installation....115
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal....116
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation....117
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal....118
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation....119
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal....120
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation....122
Diesel Exhaust Fluid (DEF) System....123
7. Acronym List....124
tables....20
Table 2Minimum Clearance Between Exhaust System Components and Other Chassis Components.....20
Table 32Acronym List.....124
Table 33Torque Chart.....125
0000001844 - Radiator, Cooling System Cooling System Service Manual 2013....126
toc....128
Summary of Changes....128
1. Description....134
1.1. Deaeration Tank....135
1.2. Fan Shroud....136
1.3. A/C Condenser....136
1.4. Radiator....136
1.5. Charge Air Cooler....136
1.6. Low-Temperature Radiator....136
1.7. Transmission Oil Cooler....136
1.8. Fuel Cooler....136
2. Removal and Installation....137
2.1. Cooling Package Cleaning Procedures....138
Cleaning Cooling Package (MaxxForce® 9, 10, and DT Engines)....138
Cleaning Cooling Package (Navistar® 11 and 13 Engines)....139
2.2. Coolant Drain, Pressure Test, and Fill Procedures....142
Coolant Drain Procedure (Recommended)....144
Pressure Test Procedure (Recommended)....146
Coolant Fill Procedure (Recommended)....147
Coolant Drain Procedure (Optional)....149
Coolant Fill Procedure (MaxxForce® DT, 9, and 10 Engines) (Optional)....150
Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....151
2.3. Grille....154
Grille (Standard) – Removal....154
Grille (Standard) – Installation....154
Grille (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....155
Grille (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....155
Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....156
Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....156
2.4. Splash Panel....157
Splash Panel (Standard) – Removal....157
Splash Panel (Standard) – Installation....158
Splash Panel (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....158
Splash Panel (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....159
Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....159
Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....160
2.5. Deaeration Tank....160
Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....160
Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....162
Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....162
Deaeration Tank (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....164
Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....164
Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....166
2.6. A/C Condenser....167
A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....167
A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....168
A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....169
A/C Condenser (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....170
A/C Condenser (Navistar® 11 and 13 Engines) – Removal....171
A/C Condenser (Navistar® 11 and 13 Engines) – Installation....172
2.7. Fan Shroud....173
Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....173
Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....176
Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal ....176
Fan Shroud (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....177
Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....178
Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....180
Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....180
Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....183
Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....184
Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....186
2.8. Radiator Fan....187
Radiator Fan (Standard) – Removal....187
Radiator Fan (Standard) – Installation....187
Radiator Fan (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal ....188
Radiator Fan (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....189
Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....189
Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....190
2.9. Radiator Hose....191
Heat Shrink Clamp – Removal....191
Heat Shrink Clamp – Installation....192
Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....194
Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....195
Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....196
Radiator Hose (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....198
Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....199
Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....200
Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....200
Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....203
2.10. Charge Air Cooler....204
Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....204
Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....207
Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....207
Charge Air Cooler (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....207
Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....208
Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....211
Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....212
Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....214
Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....214
Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....216
Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....217
Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....218
2.11. Low-Temperature Radiator....219
Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....219
Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....221
Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal....222
Low-Temperature Radiator (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation....222
Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....223
Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....225
2.12. Radiator Core....227
Radiator Core (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....227
Radiator Core (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....232
Radiator Core (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Removal ....233
Radiator Core (MaxxForce® 9, 10, and DT Engines) (Enhanced Vision) – Installation ....241
Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....242
Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....244
Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....245
Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....248
2.13. Transmission Oil Cooler....249
Transmission Oil Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Removal....249
Transmission Oil Cooler (MaxxForce® 9, 10, and DT Engines) (Standard) – Installation....250
Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....251
Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....252
Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....252
Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....253
2.14. Fuel Cooler....254
Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....254
Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....254
tables....256
Table 2Torque Chart....256
0000001844 WorkStar Radiator _ Cooling System (Supersedes S12026) Service Manual....260
toc....262
Summary of Changes....262
1. Description....270
1.1. Surge Tank (If Equipped)....272
1.2. Deaeration Tank....272
1.3. Fan Shroud....272
1.4. Fan Drive....272
1.5. A / C Condenser....272
1.6. Radiator....272
1.7. Charge Air Cooler....272
1.8. Cross-Member....272
1.9. Low-Temperature Radiator....273
1.10. Low Temperature Radiator (LTR) Thermostat....273
1.11. Fuel Cooler....273
1.12. Transmission Oil Cooler....273
2. Removal and Installation....274
2.1. Coolant Drain, Pressure Test, and Fill Procedures....275
2.1.1. Coolant Drain Procedure (Recommended)....277
2.1.2. Pressure Test Procedure (Recommended)....280
2.1.3. Coolant Fill Procedure (Recommended)....284
2.1.4. Coolant Gravity Drain Procedure (Optional)....288
2.1.5. Coolant Fill Procedure (MaxxForce® DT, 9, and 10 Engines) (Optional)....289
2.1.6. Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....290
2.1.7. Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....293
2.2. Grille....297
2.2.1. Grille (Standard) – Removal....297
2.2.2. Grille (Standard) – Installation....298
2.2.3. Grille (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....298
2.2.4. Grille (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....299
2.2.5. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....299
2.2.6. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....300
2.3. Splash Panel....301
2.3.1. Splash Panel (Standard) – Removal....301
2.3.2. Splash Panel (Standard) – Installation....301
2.3.3. Splash Panel (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....302
2.3.4. Splash Panel (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....302
2.3.5. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....303
2.3.6. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....304
2.4. Surge Tank (if equipped)....305
2.4.1. Surge Tank (with Cummins® ISB6.7 Engine) – Removal....305
2.4.2. Surge Tank (with Cummins® ISB6.7 Engine) – Installation....306
2.5. Deaeration Tank....307
2.5.1. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....307
2.5.2. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....308
2.5.3. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....308
2.5.4. Deaeration Tank (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....310
2.5.5. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....310
2.5.6. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....312
2.5.7. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Removal ....313
2.5.8. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Installation....316
2.6. A/C Condenser....317
2.6.1. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....317
2.6.2. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....318
2.6.3. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....319
2.6.4. A/C Condenser (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....320
2.6.5. A/C Condenser (Navistar® 11 and 13 Engines) – Removal....321
2.6.6. A/C Condenser (Navistar® 11 and 13 Engines) – Installation....322
2.6.7. A/C Condenser (ISB6.7) Engine – Removal....322
2.6.8. A / C Condenser (ISB6.7 Engine) – Installation....324
2.7. Fan Belts....325
2.7.1. Fan Belt with A / C (Cummins® ISB6.7 Engine) - Removal ....325
2.7.2. Fan Belt with A / C (Cummins® ISB6.7 Engine) – Installation ....326
2.8. Fan Shroud....327
2.8.1. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....327
2.8.2. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....330
2.8.3. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal ....330
2.8.4. Fan Shroud (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....331
2.8.5. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....332
2.8.6. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....334
2.8.7. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....334
2.8.8. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....337
2.8.9. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....338
2.8.10. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....340
2.8.11. Fan Shroud (Cummins® ISB6.7 Engine) 7 similar - Removal....341
2.8.12. Fan Shroud - Installation....341
2.9. Fan and Fan Drive Assembly....342
2.9.1. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Removal....342
2.9.2. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Installation....343
2.9.3. Fan Removal – (12THZ and 12THT Horton DA) (optional)....344
2.9.4. Fan Installation – (12THZ and 12THT Horton DA) (optional)....345
2.9.5. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....346
2.9.6. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....348
2.9.7. 12THT Horton (DMA) Serviceable Fan Drive – Removal....349
2.9.8. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....356
2.9.9. 12THT Pulley Bearing – Removal....357
2.9.10. 12THT Pulley Bearing – Installation....357
2.9.11. 12THT Fan Drive Friction Liner– Removal....358
2.9.12. 12THT Fan Drive Friction Liner – Installation....363
2.9.13. 12THT Clutch Pack Seal Face – Removal....364
2.9.14. 12THT Clutch Pack Seal Face – Installation....364
2.9.15. 12THT Air Cartridge – Removal....365
2.9.16. 12THT Air Cartridge – Installation....367
2.9.17. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Removal....370
2.9.18. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Installation....373
2.10. Radiator Fan....374
2.10.1. Radiator Fan (Standard) – Removal....374
2.10.2. Radiator Fan (Standard) – Installation....375
2.10.3. Radiator Fan (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal ....376
2.10.4. Radiator Fan (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....377
2.10.5. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....378
2.10.6. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....379
2.11. Radiator Hose....379
2.11.1. Heat Shrink Clamp – Removal....379
2.11.2. Heat Shrink Clamp – Installation....381
2.11.3. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....384
2.11.4. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....386
2.11.5. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....387
2.11.6. Radiator Hose (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....389
2.11.7. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....390
2.11.8. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....391
2.11.9. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....392
2.11.10. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....394
2.12. Coolant Package....395
Overview....395
2.12.1. Coolant Package – Removal....395
2.12.2. Coolant Package – Installation....402
2.13. Charge Air Cooler....404
2.13.1. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....404
2.13.2. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....406
2.13.3. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....406
2.13.4. Charge Air Cooler (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....406
2.13.5. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....407
2.13.6. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....411
2.13.7. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....412
2.13.8. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....413
2.13.9. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....413
2.13.10. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....415
2.13.11. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....416
2.13.12. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....417
2.14. Low-Temperature Radiator....418
2.14.1. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....418
2.14.2. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....420
2.14.3. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal....421
2.14.4. Low-Temperature Radiator (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation....421
2.14.5. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....422
2.14.6. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....425
2.15. Low Temperature Radiator (LTR) Thermostat....426
2.15.1. Low Temperature Radiator (LTR) Thermostat – Removal....426
2.15.2. Low Temperature Radiator (LTR) Thermostat – Installation....427
2.16. Radiator Core....428
2.16.1. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....428
2.16.2. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....433
2.16.3. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Removal ....434
2.16.4. Radiator Core (MaxxForce® DT, 9, and 10 Engines) (Enhanced Vision) – Installation ....442
2.16.5. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....443
2.16.6. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....445
2.16.7. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....446
2.16.8. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....449
2.17. Transmission Oil Cooler....450
2.17.1. Transmission Oil Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Removal....450
2.17.2. Transmission Oil Cooler (MaxxForce® DT, 9, and 10 Engines) (Standard) – Installation....451
2.17.3. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....452
2.17.4. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....453
2.17.5. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....453
2.17.6. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....454
2.18. Fuel Cooler....455
2.18.1. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....455
2.18.2. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....456
2.19. Low Temperature Radiator Hoses....457
2.19.1. Low Temperature Radiator Hoses – Removal....457
2.19.2. Low Temperature Radiator (LTR) Thermostat Hose – Installation....461
3. Cooling Package Cleaning Procedures....462
3.1. Cooling Package Cleaning Procedures....462
3.1.1. Cleaning Cooling Package (MaxxForce® DT, 9, and 10 Engines)....463
3.1.2. Cleaning Cooling Package (Navistar® 11 and 13 Engines)....463
4. Inspection Procedures....466
4.1. Deaeration Tank and Cap Inspection Procedures....466
4.1.1. Deaeration Tank....466
4.1.2. Deaeration Tank Cap Vacuum Relief Check....468
4.2. Fan Drive Pulley and Pulley Groove Inspection Procedures....469
4.2.1. Pulley Crack Inspection....469
4.2.2. Pulley Nick Inspection....470
4.3. 12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....471
4.3.1. Fan Drive Movement....471
4.4. 12THT Horton Drivemaster Advantage Fan Drive Inspection Procedures....472
4.4.1. Fan Drive Movement....472
4.4.2. Clutch Pack Face Seal....474
4.4.3. Cartridge Assembly Seal and Spring....475
4.4.4. Friction Liner Measurement....476
4.4.5. Fan Drive Bearing Measurement and Inspection....477
4.5. 12TTD Borg – Warner 842B Visctronics Inspection Procedure....478
4.5.1. Fan Drive Movement....478
4.6. Fuel Cooler Valve (FCV) Inspection Procedure....479
4.6.1. Fuel Cooler Valve (FCV) Filter Screen – Removal....479
4.6.2. Fuel Cooler Valve (FCV) Filter Screen – Installation....480
5. 12THT and 12THZ Horton DriveMaster Advantage (DMA) Fan Drive System Diagnostics....481
5.1. Start Diagnostics here: 12THT and 12THZ Horton DriveMaster Advantage (DMA) System Operational Checks....481
Overview....481
Tools Required....481
Operational Checks – Start Fan Drive Diagnostics Here.....481
Visual Air Leak Check....481
5.2. Symptom 1: Fan Always On....484
5.3. Symptom 2: Fan Always Off....503
5.4. Symptom 3: Cycles Too Frequently....511
5.5. Symptom 4: Excessive Noise From Fan Drive....513
6. 12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics....516
6.1. Start Diagnostics here: 12TTD Borg-Warner 842B Visctronic Fan Drive....516
Overview....516
Tools Required....516
Operational Checks – Start Fan Drive Diagnostics Here....516
6.2. Symptom 1: Fan Always ON....518
6.3. Symptom 2: Fan Always OFF....524
6.4. Symptom 3: Cycles Too Frequently....542
6.5. Symptom 4: Excessive Noise From Fan Drive....545
7. 12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....548
7.1. Start Diagnostics Here: 12TSY Borg-Warner SA85 Fan Drive Assembly....548
Overview....548
Tools Required....548
8. Abbreviations and Acronyms....550
9. Terminology....551
tables....554
Table 88Torque Chart....554
0000002322 - DuraStar and TerraStar Cab Service Manual (Supersedes S16026)....558
toc....560
Summary of Changes....560
1. DESCRIPTION....572
1.1. Standard Cab, Extended Cab and Crew Cab....572
1.2. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION....573
1.3. ELECTRIC WINDSHIELD WIPERS....574
1.4. WINDSHIELD WASHER....575
2. OPERATION....578
2.1. Electric Windshield Wipers....578
2.2. WINDSHIELD WASHER....578
3. MAINTENANCE....579
3.1. Windshield Washer....579
4. REMOVE....580
4.1. ONE PIECE ENCAPSULATED WINDSHIELD....580
Remove One Piece Encapsulated Windshield on Standard Cab, Extended Cab and Crew Cab for all Models....580
4.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY....586
Remove Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....586
4.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY....589
Remove Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....589
4.4. HOOD SEAL....597
Remove Hood Seal on Standard Cab, Extended Cab and Crew Cab for All Models....597
4.5. SUNSHADE....598
Remove Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models....598
4.6. SUN VISOR AND CLIP....598
Remove Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models....598
4.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER....600
Remove Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models....601
Remove Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models....603
4.8. INSTRUMENT PANEL....605
Remove Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models....605
4.9. CAB DOORS....609
Remove Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models....609
Remove Rear Cab Door on Crew Cab for All Models....613
4.10. Cab Door Hinge....618
Remove Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....618
Remove Rear Cab Door Hinge on Crew Cab for all Models....619
4.11. CAB DOOR STRIKER PIN....621
Remove Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for All Models....621
Remove Rear Cab Door Striker Pin on Crew Cab for all Models....622
4.12. CAB DOOR CHECK BRACKET....623
Remove Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models....623
Remove Crew Cab rear Door Check Bracket on Crew Cab for all Models....624
4.13. CAB DOOR CHECK LINK....624
Remove Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models....624
Remove Rear Door Check Link on Crew Cab for all Models....625
4.14. CAB DOOR TRIM PANEL....627
Remove Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....627
Remove Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....629
Remove Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for all Models....631
Remove Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for all Models....633
4.15. CAB DOOR INNER DOOR PANEL WATER SHIELD....635
Remove Front Cab Door Inner Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for all Models....635
Remove Rear Cab Door Inner Panel Water Shield on Crew Cab for all Models....637
4.16. CAB DOOR WINDOW SLIDE BLOCK....638
Remove Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models....638
Remove Rear Cab Door Window Slide Block on Crew Cab for all Models....639
4.17. CAB DOOR GLASS....641
Remove Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models....641
Remove Rear Cab Door Glass on Crew Cab for all Models....645
4.18. MODULAR DOOR HARDWARE ASSEMBLY....649
Remove Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....649
Remove Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models....653
4.19. CAB DOOR VENT WINDOW....656
Remove Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models....656
4.20. CAB DOOR VENT WINDOW HINGE....657
Remove Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....657
4.21. CAB DOOR VENT WINDOW SEAL....659
Remove Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models....659
4.22. CAB DOOR LOCK CYLINDER....659
Remove Cab Door Lock Cylinder on Front Cab Door of Standard Cab or Extended Cab Models and on Front and Rear Cab Doors of Crew Cab Models....659
4.23. CAB DOOR WINDOW ELECTRIC MOTOR....661
Remove Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for all Models....661
Remove Rear Cab Door Window Electric Motor on Crew Cab for all Models....662
4.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY....663
Remove Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....663
Remove Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models....667
4.25. OUTER CAB DOOR HANDLE....668
Remove Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....668
Remove Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models....672
4.26. CAB DOOR LATCH....673
Remove Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models....673
Remove Rear Cab Door Latch on Crew Cab for all Models....675
4.27. INNER CAB DOOR HANDLE....676
Remove Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....676
Remove Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models....678
4.28. CAB DOOR WINDOW RUN CHANNELS....679
Remove Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for all Models....679
Remove Rear Cab Door Window Run Channels on Crew Cab for all Models....682
4.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH....683
Remove Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and Crew Cab for all Models....683
Remove Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models....684
4.30. CAB DOOR ELECTRIC MIRROR SWITCH....685
Remove Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all Models....685
4.31. SEATS....686
Remove Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models....686
Remove Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models....688
Remove Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....690
Remove Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....690
Remove Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models....690
4.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER....692
Remove Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab and Crew Cab for all Models....692
4.33. EXTENDED CAB BUNK/STORAGE UNIT....693
Remove Bunk/Storage Unit on Extended Cab for all Models....693
4.34. SIDE AND CORNER INTERIOR TRIM PANEL....694
Remove Side and Corner Interior Trim Panel on Standard Cab for all Models....694
Remove Side and Corner Interior Trim Panel on Extended Cab for all Models....695
Remove Side and Corner Interior Trim Panel on Crew Cab for all Models....696
4.35. Extended Cab Rear Side Window....698
Remove Rear Side Window on Extended Cab for all Models....698
Remove Rear Side Window Latch from Rear Side Window on Extended Cab for all Models....700
4.36. REAR INTERIOR TRIM PANEL....701
Remove Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models....701
4.37. HEADER CONSOLE PANEL....701
Remove Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models....701
4.38. HEADLINER TRIM PANEL....705
Remove Headliner Trim Panel on Standard Cab for all Models....705
Remove Front Headliner Trim Panel on Extended Cab for all Models....706
Remove Rear Headliner Trim Panel on Extended Cab for all Models....708
Remove Front Headliner Trim Panel on Crew Cab for all Models....708
Remove Rear Headliner Trim Panel on Crew Cab for all Models....711
4.39. Crew Cab B - Pillar Trim Panel....712
Remove B - Pillar Trim Panel on Crew Cab for all Models....712
4.40. Cab Door Opening Weather Seals....712
Remove Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for all Models....712
Remove Rear Cab Door Opening Weather Seals on Crew Cab for all Models....713
4.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....714
Remove Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....714
4.42. CAB COWL TRAY....715
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September 2000....715
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September 2000....717
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002....719
4.43. WINDSHIELD WIPER ASSEMBLY....721
Remove Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....721
4.44. ELECTRIC WINDSHIELD WIPER MOTOR....723
Remove Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models....723
4.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR....725
Remove Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for all Models....725
4.46. Engine Cover And Cup Holder....729
Remove Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models....729
Remove Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models....729
4.47. CAB....732
General Procedures for Cab Removal....732
Remove Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....733
Cab with Low Mount Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....734
Cab with Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....736
Remove Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab before January 2003....737
Remove Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models before January 2003....737
Remove Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....737
Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003....738
Cab with Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....739
Remove Low Mount Rear Cab Air Suspension for all Crew Cab Models....740
Remove Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models....740
Remove Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....740
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....741
Remove Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications....742
Remove Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City Tractor Applications....743
5. INSTALL....744
5.1. ONE PIECE ENCAPSULATED WINDSHIELD....744
Install One Piece Encapsulated Windshield using Two Part U216 Urethane Adhesive (adhesive A and curative B) on Standard Cab, Extended Cab and Crew Cab for all Models....744
Install One Piece Encapsulated Windshield using One Part U400HV Urethane Adhesive on Standard Cab, Extended Cab and Crew Cab for all Models....760
5.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY....765
Install Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....765
5.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY....780
Install Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....780
5.4. HOOD SEAL....799
Install Hood Seal on Standard Cab, Extended Cab and Crew Cab for all Models....799
5.5. SUNSHADE....799
Install Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models....799
5.6. SUN VISOR AND CLIP....800
Install Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models....800
5.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER....800
Install Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models....800
Install Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models....801
5.8. INSTRUMENT PANEL....801
Install Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models....801
5.9. CAB DOORS....804
Install Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models....804
Install Rear Cab Door on Crew Cab for all Models....804
5.10. CAB DOOR HINGE....806
Install Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....806
Install Rear Cab Door Hinge on Crew Cab for all Models....806
5.11. CAB DOOR STRIKER PIN....807
Install Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for all Models....807
Install Rear Cab Door Striker Pin on Crew Cab for all Models....807
5.12. CAB DOOR CHECK BRACKET....807
Install Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models....807
Install Crew Cab Rear Door Check Bracket on Crew Cab for all Models....807
5.13. CAB DOOR CHECK LINK....808
Install Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models....808
Install Crew Cab Rear Door Check Link on Crew Cab for all Models....808
5.14. CAB DOOR TRIM PANEL....808
Install Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....808
Install Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....809
Install Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for all Models....809
Install Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for all Models....810
5.15. CAB DOOR INNER DOOR PANEL WATER SHIELD....811
Install Front Cab Door Inner Door Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for all Models....811
Install Rear Cab Door Inner Door Panel Water Shield on Crew Cab for all Models....811
5.16. CAB DOOR WINDOW SLIDE BLOCK....811
Install Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models....811
Install Rear Cab Door Window Slide Block on Crew Cab for all Models....813
5.17. CAB DOOR GLASS....814
Install Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models....814
Install Rear Cab Door Glass on Crew Cab for all Models....818
5.18. MODULAR DOOR HARDWARE ASSEMBLY....822
Install Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....822
Install Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models....823
5.19. CAB DOOR VENT WINDOW....825
Install Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models....825
5.20. CAB DOOR VENT WINDOW HINGE....825
Install Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....825
5.21. CAB DOOR VENT WINDOW SEAL....825
Install Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models....825
5.22. CAB DOOR LOCK CYLINDER....826
Install Cab Door Lock Cylinder on Front Cab Door on Standard Cab, Extended Cab and Crew Cab Models and Rear Cab Doors on Crew Cab Models....826
5.23. CAB DOOR WINDOW ELECTRIC MOTOR....826
Install Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for all Models....826
Install Rear Cab Door Window Electric Motor on Crew Cab for all Models....827
5.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY....827
Install Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....827
Install Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models....829
5.25. OUTER CAB DOOR HANDLE....831
Install Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....831
Install Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models....832
5.26. CAB DOOR LATCH....834
Install Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models....834
Install Rear Cab Door Latch on Crew Cab for all Models....835
5.27. INNER CAB DOOR HANDLE....835
Install Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....835
Install Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models....836
5.28. CAB DOOR WINDOW RUN CHANNELS....838
Install Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for all Models....838
Install Rear Cab Door Window Run Channels on Crew Cab for all Models....839
5.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH....840
Install Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and Crew Cab for all Models....840
Install Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models....840
5.30. CAB DOOR ELECTRIC MIRROR SWITCH....840
Install Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all Models....840
5.31. SEATS....841
Install Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models....841
Install Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models....841
Install Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....841
Install Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....842
Install Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models....842
5.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER....842
Install Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab and Crew Cab for all Models....842
5.33. EXTENDED CAB BUNK/STORAGE UNIT....843
Install Bunk/Storage Unit on Extended Cab for all Models....843
5.34. SIDE AND CORNER INTERIOR TRIM PANEL....843
Install Side and Corner Interior Trim Panel on Standard Cab for all Models....843
Install Side and Corner Interior Trim Panel on Extended Cab for all Models....844
Install Side and Corner Interior Trim Panel on Crew Cab for all Models....844
5.35. Extended Cab Rear Side Window....845
Install Rear Side Window Latch onto Rear Side Window on Extended Cab for all Models....845
Install Rear Side Window on Extended Cab for all Models....845
5.36. REAR INTERIOR TRIM PANEL....847
Install Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models....847
5.37. HEADER CONSOLE PANEL....847
Install Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models....847
5.38. HEADLINER TRIM PANEL....848
Install Headliner Trim Panel on Standard Cab for all Models....848
Install Front Headliner Trim Panel on Extended Cab for all Models....849
Install Rear Headliner Trim Panel on Extended Cab for all Models....849
Install Front Headliner Trim Panel on Crew Cab for all Models....850
Install Rear Headliner Trim Panel on Crew Cab for all Models....850
5.39. Crew Cab B - Pillar trim panel....851
Install B - Pillar Trim Panel on Crew Cab for all Models....851
5.40. Cab Door Opening Weather Seals....852
Install Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for all Models....852
Install Rear Cab Door Opening Weather Seals on Crew Cab for all Models....852
5.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....853
Install Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....853
5.42. CAB COWL TRAY....853
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September 2000....853
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September 2000....854
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002....855
5.43. WINDSHIELD WIPER ASSEMBLY....855
Install Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....855
5.44. ELECTRIC WINDSHIELD WIPER MOTOR....856
Install Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models....856
5.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR....857
Install Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for all Models....857
5.46. Engine Cover And Cup Holder....857
Install Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models....857
Install Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models....858
5.47. CAB....859
Cab Squaring....859
Install Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....859
Install Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models Before January 2003....859
Install Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models Before January 2003....860
Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models....860
Install Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....861
Install Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models....861
Install Low Mount Rear Cab Air Suspension for all Crew Cab Models....861
Cab with Low Mount Front Cab Mounting for all Crew Cab Models and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models....861
Install Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....862
Install Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City Tractor Applications....862
Install Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications....862
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications....863
General Procedures for Cab Installation....863
6. TROUBLESHOOTING....865
6.1. Electric Windshield Wiper Motor....865
6.2. WASHER PUMP MOTOR....866
7. LUBRICATION....867
7.1. 4000 Miles (6000 Km) Or Monthly....867
7.2. AS REQUIRED....867
8. ADJUSTMENTS....868
8.1. Cab Door....868
8.2. HINGE AT CAB HINGE PILLAR....868
8.3. STRIKER PIN AT LOCK PILLAR....869
8.4. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....871
8.5. CAB AIR SUSPENSION....872
9. FORMS....875
9.1. Bonded Windshield Replacement Report....875
10. Torque....877
10.1. Torque Chart....877
tables....865
Table 2Electric Windshield Wiper Motor....865
Table 3Washer Pump Motor....866
Table 4Torque Chart....877
0000002324 - SERVICE MANUAL CAB TranStar, WorkStar....884
toc....886
Summary of Changes....886
1. DESCRIPTION....892
1.1. Standard Cab and extended cab....892
1.2. Cab Interior Trim Panels....892
1.3. VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS....893
1.4. WINDSHIELD....894
1.5. ELECTRIC WINDSHIELD WIPERS....895
1.6. WINDSHIELD WASHER....895
1.7. IGNITION SWITCH CYLINDER....896
1.8. Rear CAB AIR SUSPENSION system....897
2. REMOVAL AND INSTALLATION....898
2.1. Windshield....899
Windshield - Removal....899
Windshield - Installation....903
2.2. Rear Window Glass....914
Rear Window Glass (Unobstructed Access) – Removal....914
Rear Window Glass (Unobstructed Access) – Installation....916
Rear Window Glass (Obstructed Access) – Removal....926
Rear Window Glass (Obstructed Access) – Installation....931
2.3. Rear Side Window....946
Rear Side Window – Removal....946
Latch – Removal....947
Latch – Installation....947
Rear Side Window – Installation....948
2.4. Hood Seal....950
Hood Seal – Removal....950
Hood Seal – Installation ....950
2.5. Cab Cowl Tray....951
Cab Cowl Tray – Removal....951
Cab Cowl Tray – Installation....951
2.6. Windshield Wiper Arm and Blade Assembly....952
Windshield Wiper Arm and Blade Assembly – Removal....952
Windshield Wiper Arm and Blade Assembly – Installation....953
2.7. Windshield Wiper Assembly....953
Windshield Wiper Assembly – Removal....953
Windshield Wiper Assembly – Installation....954
2.8. Windshield Washer Bottle With Pump Motor....955
WorkStar® Windshield Washer Bottle With Pump Motor – Removal....955
WorkStar® Windshield Washer Bottle With Pump Motor – Installation....956
TranStar® Windshield Washer Bottle With Pump Motor – Removal....957
TranStar® Windshield Washer Bottle With Pump Motor – Installation ....958
2.9. Windshield Washer Pump Motor....959
Windshield Washer Pump Motor – Removal....959
Windshield Washer Pump Motor – Installation....960
2.10. Electric Windshield Wiper Motor....960
Electric Windshield Wiper Motor – Removal....960
Electric Windshield Wiper Motor – Installation....961
2.11. Cab Doors....962
Cab Doors – Removal....962
Cab Doors – Installation....965
2.12. Door Hinge....966
Door Hinge – Removal....966
Door Hinge – Installation....967
2.13. Door Striker Pin....967
Door Striker Pin – Removal....967
Door Striker Pin – Installation....968
2.14. Door Check Bracket....968
Door Check Bracket – Removal....968
Door Check Bracket – Installation....969
2.15. Door Check Link....969
Door Check Link – Removal....969
Door Check Link – Installation....970
2.16. Door Trim Panel....971
Door Trim Panel – Removal....971
Door Trim Panel – Installation....972
2.17. Door Vapor Barrier....973
Door Vapor Barrier – Removal....973
Door Vapor Barrier – Installation....973
2.18. Window Slide Block....974
Window Slide Block – Removal....974
Window Slide Block – Installation....975
2.19. Door Glass....975
Door Glass – Removal....975
Door Glass – Installation....977
2.20. Modular Door Hardware Assembly....978
Modular Door Hardware Assembly – Removal....978
Modular Door Hardware Assembly – Installation....981
2.21. Vent Window, Latch, And Seal....983
Vent Window, Latch, And Seal – Removal....983
Vent Window, Latch, And Seal – Installation....984
2.22. Door Lock Cylinder....985
Door Lock Cylinder – Removal....985
Door Lock Cylinder – Installation....986
2.23. Window Electric Motor....987
Window Electric Motor – Removal....987
Window Electric Motor – Installation....987
2.24. Regulator Arm Assembly....988
Regulator Arm Assembly – Removal....988
Regulator Arm Assembly – Installation....992
2.25. Outer Door Handle....993
Outer Door Handle – Removal....993
Outer Door Handle – Installation....995
2.26. Door Latch....996
Door Latch – Removal....996
Door Latch – Installation....997
2.27. Inner Door Handle....997
Inner Door Handle – Removal....997
Inner Door Handle – Installation....998
2.28. Window Run Channels....999
Window Run Channels – Removal....999
Window Run Channels – Installation....1001
2.29. Electric Window And Door Lock Switch....1002
Electric Window And Door Lock Switch – Removal....1002
Electric Window And Door Lock Switch – Installation....1003
2.30. Electric Mirror Switch....1003
Electric Mirror Switch – Removal....1003
Electric Mirror Switch – Installation....1004
2.31. Weather Seals....1004
Weather Seals – Removal....1004
Weather Seals – Installation....1004
2.32. Scuff Plate and Seat Belt Retractor Cover....1005
Scuff Plate and Seat Belt Retractor Cover – Removal....1005
Scuff Plate and Seat Belt Retractor Cover – Installation....1005
2.33. Sunshade....1006
Sunshade – Removal....1006
Sunshade – Installation....1006
2.34. Sun Visor and Clip....1007
Sun Visor and Clip – Removal....1007
Sun Visor and Clip – Installation....1007
2.35. Ignition Switch And Ignition Switch Cylinder....1008
Ignition Switch – Removal....1008
Ignition Switch – Installation....1009
Ignition Switch Cylinder – Removal....1010
Ignition Switch Cylinder – Installation....1011
2.36. INSTRUMENT Panel....1012
Gauge Cluster – Removal....1012
Gauge Cluster – Installation....1013
Instrument Panel – Removal....1013
Instrument Panel – Installation....1016
2.37. Front Seats....1018
Front Seats – Removal....1018
Front Seats – Installation....1019
2.38. Rear Bench Seat....1020
Rear Bench Seat – Removal....1020
Rear Bench Seat – Installation....1020
2.39. Corner and Side Interior Trim Panel....1021
Corner and Side Interior Trim Panel – Removal....1021
Corner and Side Interior Trim Panel – Installation....1021
2.40. Rear Interior Trim Panel....1022
Rear Interior Trim Panel – Removal....1022
Rear Interior Trim Panel – Installation....1022
2.41. Header Console Panel....1023
Header Console Panel – Removal....1023
Header Console Panel – Installation....1027
2.42. Headliner Trim Panel (Standard Cab)....1027
Headliner Trim Panel (Standard Cab) – Removal....1027
Headliner Trim Panel (Standard Cab) – Installation....1029
2.43. Headliner Trim Panel (Extended Cab)....1029
Headliner Trim Panel (Extended Cab) Front – Removal....1029
Headliner Trim Panel (Extended Cab) Front – Installation....1031
Headliner Trim Panel (Extended Cab) Rear – Removal....1032
Headliner Trim Panel (Extended Cab) Rear – Installation....1033
2.44. Engine Cover And Cup Holder....1034
Cup Holder and Ashtray – Removal....1034
Cup Holder and Ashtray – Installation....1034
Engine Cover – Removal....1035
Engine Cover – Installation....1035
2.45. Cab....1035
Initial Procedures Before Cab Removal....1035
Cab – Removal....1038
Cab – Installation....1039
Final Procedures After Cab Installation....1040
2.46. Rear Cab Air Suspension Assembly....1041
Rear Cab Air Suspension Assembly – Removal....1041
Rear Cab Air Suspension Assembly – Installation....1042
2.47. Front Cab Mounting Bushings....1043
Front Cab Mounting Bushings – Removal....1043
Front Cab Mounting Bushings – Installation....1044
2.48. Rear Cab Air Suspension System....1045
Height Control Valve – Removal....1045
Height Control Valve – Installation....1046
Shock Absorber – Removal....1047
Shock Absorber – Installation....1048
Suspension Air Spring (Bag) – Removal....1048
Suspension Air Spring (Bag) – Installation....1050
Lateral Control Rod – Removal....1050
Lateral Control Rod – Installation....1051
Jounce Bumper – Removal....1052
Jounce Bumper – Installation....1052
3. TROUBLESHOOTING....1053
3.1. ELECTRIC WINDSHIELD WIPER MOTOR....1053
3.2. WASHER PUMP MOTOR....1054
3.3. Rear CAB AIR SUSPENSION SYSTEM....1054
4. LUBRICATION....1055
4.1. 4,000 MILES (6,000 km) OR MONTHLY....1055
4.2. AS REQUIRED....1055
5. ADJUSTMENTS....1056
5.1. CAB SQUARING....1056
5.2. CAB DOOR....1057
5.3. Door HINGE....1057
5.4. STRIKER PIN....1058
5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....1059
5.6. Rear Cab Air Suspension....1060
Ride Height....1060
tables....1062
Table 5Torque....1062
0000002601 - 3200, RXT, DuraStar, TranStar, TranStar Natural Gas, WorkStar Series Built May 17, 2010 and Later Electrical Circuit Diagrams (Supersedes S08343)....1064
0000002601 - 4000 Series (Oct 2014) Wiring Diagrams....2101
0000002842 - 3200, DuraStar, TranStar, WorkStar, and RXT Models Built March, 2008 to May 16, 2010 Electrical Circuit Diagrams (Supersedes S08337) ....2821
0000002842 - 4000 Series (March 2008 to May 2010) Wiring Diagrams....3229
0000003046 - Radiator_Cooling System DuraStar Cooling System Service Manual....3629
toc....3631
Summary of Changes....3631
Table of Contents....3633
1. DESCRIPTION....3635
1.1. DEAERATION TANK....3636
1.2. FAN SHROUD....3636
1.3. FAN DRIVE....3636
1.4. A/C CONDENSER....3636
1.5. RADIATOR/Charge Air Cooler ASSEMBLY....3636
1.6. Cross-Member....3636
1.7. Low Temperature Radiator (LTR)....3636
1.8. Low Temperature Radiator (ltr) Thermostat....3636
1.9. TRANSMISSION OIL COOLER....3636
2. Removal and Installation....3637
2.1. Coolant Drain, Pressure Test, and Fill procedures....3638
Coolant Drain Procedure (Recommended)....3640
Pressure Test Procedure (Recommended)....3643
Coolant Fill Procedure (Recommended)....3644
Coolant Drain Procedure (Optional)....3646
Coolant Fill Procedure (Optional Navistar® Engines)....3647
Coolant Fill Procedure (Optional Cummins® ISB Engine)....3649
2.2. Splash panel....3651
Splash Panel – Removal....3651
Splash Panel – Installation....3651
2.3. DEAERATION TANK....3652
Deaeration Tank (Radiators with Single Mega Bracket) - Removal....3652
Deaeration Tank (Radiators with Single Mega Bracket) - Installation....3653
Deaeration Tank (Radiators with Dual Mega Bracket) – Removal....3654
Deaeration Tank (Radiators with Dual Mega Bracket) – Installation....3655
2.4. A/C CONDENSER....3656
A/C Condenser - Removal....3656
A/C Condenser - Installation....3657
2.5. Radiator Fan and Fan Drive Assembly....3658
Horton Drivemaster (optional) - Removal....3658
Horton Drivemaster (optional) - Installation....3659
Viscous Fan and Two Speed Fan Drive - Removal....3659
Viscous Fan and Fan Drive - Installation....3661
2.6. FAN SHROUD....3662
Fan Shroud - Removal....3662
Fan Shroud - Installation....3664
2.7. Low Temperature Radiator....3666
Low Temperature Radiator - Removal....3666
Low Temperature Radiator - Installation....3667
2.8. RADIATOR HOSE....3668
Heat Shrink Clamp - Removal....3668
Heat Shrink Clamp - Installation....3669
Radiator Hoses - Removal....3671
Radiator Hoses - Installation....3672
2.9. LTR Thermostat....3673
LTR Thermostat – Removal....3673
LTR Thermostat – Installation....3674
2.10. Coolant Package....3675
Coolant Package - Removal....3675
Coolant Package - Installation....3681
2.11. RADIATOR CORE/CAC ASSEMBLY....3683
Radiator Core/CAC Assembly - Removal....3683
Radiator Core/CAC Assembly - Installation....3685
tables....3686
Table 2Torque Chart....3686
0000003922 - 4000 Series (Nov 2010) Wiring Diagrams....3688
0000003922 - DuraStar, WorkStar, TranStar Series Models Built From November 22, 2010 Electrical Circuit Diagrams (Supersedes S08353) (Latin America _ Mexico)....4170
0000017581 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Series Built March 11, 2004 to September 30, 2005 Electrical Circuit Diagrams (Supersedes S082854)....4662
toc....4664
Table of Contents....4664
INSTRUCTIONS AND CHARTS (Chapter 1)....4670
2.1. Circuit Number Identification and Location Chart, p. 1....4670
2.2. Circuit Number Identification and Location Chart, p. 2....4671
2.3. Circuit Number Identification and Location Chart, p. 3....4672
2.4. Circuit Number Identification and Location Chart, p. 4....4673
2.5. Circuit Number Identification and Location Chart, p. 5....4674
2.6. NAVPAK/ECM I6 Engine Controller Connector Pin Number Identi....4675
2.7. Circuit Diagram Instructions, p. 7....4676
2.8. Circuit Diagram Instructions, p. 8....4677
2.9. Schematic Symbol Chart, p. 9....4678
2.10. Relay Functions, p. 10....4679
2.11. Lamp Bulb Chart, p. 11....4680
2.12. International V8 and I6 ECM Controller Connectors Pin Numb....4681
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....4682
3.1. Accessory, p. 1....4682
3.2. Battery Feeds, Cab, p. 2....4683
3.3. Battery, p. 3....4684
3.4. 1708 Data Link Chassis, p. 4....4685
3.5. Switch Data Link, p. 5....4686
3.6. Drivetrain 1939 Data Link (Cab), p. 6....4687
3.7. Drivetrain 1939 Data Link (Chassis), p. 7....4688
3.8. Grounds Chassis, p. 8....4689
3.9. Grounds Chassis, p. 9....4690
3.10. Grounds IP, p. 10....4691
3.11. Grounds IP, p. 11....4692
3.12. Ignition Cab, p. 12....4693
3.13. Ignition Cab, p. 13....4694
3.14. Ignition Feeds, Chassis, p. 14....4695
3.15. Start, p. 15....4696
CAB ACCESSORIES (Chapter 3)....4697
4.1. Cigar Lighter and Power Feeds, p. 1....4697
4.2. CB Power, p. 2....4698
4.3. Compass and Temperature Display, p. 3....4699
4.4. Front Doors Windows and Locks (Power), p. 4....4700
4.5. Crew Doors Windows and Locks (Power), p. 5....4701
4.6. Horn, Dual Electric, p. 6....4702
4.7. Mirrors (Heated, Lighted and Power), p. 7....4703
4.8. Radio (Entertainment), Speakers, p. 8....4704
4.9. Windshield Wiper and Washer Pump, p. 9....4705
4.10. 2–Way Radio, p. 10....4706
4.11. Switch Pack, Optional Gauge Pack, p. 11....4707
4.12. Lighted Air Shield, p. 12....4708
4.13. Roof Aux. Load, p. 13....4709
4.14. Satellite Communication Qualcomm-MCT and IMCT Systems, p. ....4710
4.15. Self Contained Air Seat, p. 15....4711
4.16. Digital Clock PTC, p. 16....4712
4.17. Transmission Allison LCT Column Shifter, p. 17....4713
4.18. Heated Seats for 7700 Models Only, p. 18....4714
4.19. Backup Camera, p. 19....4715
4.20. XATA Computer, p. 20....4716
4.21. Keyless Ignition System, p. 21....4717
12V CHARGING + CRANKING SYSTEM (Chapter 4)....4718
5.1. I6 EGR Engines, p. 1....4718
5.2. V8 AVNT Engines, p. 2....4719
5.3. Caterpillar, Cummins ISM Engines, p. 3....4720
5.4. I6 HEUI Engines, p. 4....4721
5.5. Caterpillar Engines, Cummins ISM and with Eaton Ultrashift/....4722
5.6. I6 EGR Engines with Air Start, p. 6....4723
FANS AND ENGINE ACCESSORIES (Chapter 5)....4724
6.1. Fan Wiring, p. 1....4724
6.2. Ether Start, p. 2....4725
6.3. Snow Valve, p. 3....4726
6.4. Fan Wiring, Caterpillar and Cummins, p. 4....4727
ELECTRONIC ENGINES (Chapter 6)....4728
7.1. Electronic Engine Controls, I6–EGR Engines, p. 1....4728
7.2. Electronic Engine Controls, I6-EGR Engine Cruise Control an....4729
7.3. Electronic Engine Controls, (V8–AVNT) Engines, p. 3....4730
7.4. Electronic Engine Controls, V8–AVNT Engine Cruise Control a....4731
7.5. Caterpillar C10, C11, C12, and C13 Engines, p. 5....4732
7.6. Cummins ISM Engine, p. 6....4733
7.7. I6 HEUI Engine, p. 7....4734
7.8. I6 HEUI Engine Cruise Control and Body Builder Connections ....4735
GAUGES WITH AND WITHOUT INTEGRAL WARNING LIGHT (Chapter 7)....4736
8.1. IP/Gauge List, p. 1....4736
8.2. Warning Light List, p. 2....4737
8.3. Warning Lights Controlled by Engine, Transmission, ABS Cont....4738
8.4. Engine Oil Pressure and Temp, Speedometer, Tach, Voltmeter ....4739
8.5. IP/Gauges and Warning Lights — Gauge Cluster, p. 5....4740
8.6. Air Pressure Input Circuit, p. 6....4741
8.7. Axle Temperature, FWD Rear and Rear Axles, Gauge Input Circ....4742
8.8. Fuel Gauge Input Circuit (Single Tank) Differential Lock Wa....4743
8.9. Gauges and Warning Lights — Fuel Filter Restriction and Wat....4744
8.10. Gauges and Warning Lights — Park Brake Light and Transmiss....4745
8.11. Gauges and Warning Lights — Ammeter, p. 11....4746
8.12. Engine Oil Temperature Gauge With Caterpillar, p. 12....4747
8.13. Front Axle Engagement Lamp, p. 13....4748
LIGHTS (Chapter 8)....4749
9.1. Back Up Lights, p. 1....4749
9.2. Light Systems — Clearance, Marker, Park, Tail, Turn and Sto....4750
9.3. Light Systems — Clearance, Marker, Park, Tail, Turn and Sto....4751
9.4. Light Systems — Turn Signal and Stop Switches, p. 4....4752
9.5. Dome Light, Map Light, p. 5....4753
9.6. Dome Light, Map Light (Cont.), p. 6....4754
9.7. Fog Light and Work Light, p. 7....4755
9.8. Headlights, p. 8....4756
9.9. Aux. Headlights, Aux. Park, Aux. Turn, p. 9....4757
9.10. Panel Lights, p. 10....4758
CHASSIS ACCESSORIES (Chapter 9)....4759
10.1. Air Dryer and Heated Drain Valve, p. 1....4759
10.2. Antilock Brake System (ABS), Air, p. 2....4760
10.3. Antilock Brake System (ABS), Air, Traction Control, p. 3....4761
10.4. Antilock Brake System (ABS), Hydraulic, p. 4....4762
10.5. Antilock Brake System (ABS), Hydraulic (Cont.), p. 5....4763
10.6. Antilock Brake System (ABS), Hydraulic (Cont.), p. 6....4764
10.7. Two Speed Axle Switch With Manual Transmission and I6 HEUI....4765
10.8. Brake System, Hydraulic, p. 8....4766
10.9. Fuel Transfer Pump, p. 9....4767
10.10. Back of Cab Body Builder and Trailer Stop, Tail, Marker, ....4768
10.11. Body Builder and Trailer Turns, Center Pin ABS, Center Pi....4769
10.12. Body Builder and Trailer Socket Back of Cab Sockets, p. 1....4770
10.13. Body Builder and Trailer Socket End of Frame (EOF) Socket....4771
10.14. Air Solenoid 4–Way Pack, p. 14....4772
10.15. Remote Power Units, Solenoid Packs, Remote Engine Speed C....4773
10.16. HYD Power Park, p. 16....4774
10.17. Air Suspension, p. 17....4775
10.18. Aux. Trailer, Acc Controlled, p. 18....4776
10.19. Aux. Trailer, Battery Controlled, p. 19....4777
10.20. Lift Axles (Non-Steerable), p. 20....4778
10.21. Lift Axles (Steerable), p. 21....4779
10.22. Air Actuated Park Brake, p. 22....4780
10.23. Antilock Brake System, WABCO Air, p. 23....4781
10.24. Antilock Brake System, WABCO Air, p. 24....4782
10.25. Lift Axles, With Non-Steerable for SS Models, p. 25....4783
10.26. Fuel / Water Separator With 12VDC Fuel Preheater, p. 26....4784
10.27. Electronic Trailer Brake Accommodation, p. 27....4785
10.28. Lectrashift Accommodation, p. 28....4786
10.29. Auxiliary 40 Amp Circuit, p. 29....4787
10.30. Hourmeter, Customer Mounted PTO, p. 30....4788
10.31. Remote Start/ Stop, p. 31....4789
10.32. Lift Axle with 14RAR, p. 32....4790
10.33. Lift Gate, p. 33....4791
10.34. Lift Axle Multiplex, p. 34....4792
TRANSMISSIONS (Chapter 10)....4793
11.1. Allison LCT Transmission or Allison 1000, 2000, 2400, p. 1....4793
11.2. Allison MD Transmission, p. 2....4794
11.3. Allison MD Transmission (WTEC), p. 3....4795
11.4. Allison MD Transmission (Cont.), p. 4....4796
11.5. Transmission, WTEC MD W/Auto Neutral, p. 5....4797
11.6. Eaton Autoshift Transmission, p. 6....4798
11.7. Eaton Autoshift Transmission (Cont.), p. 7....4799
11.8. Eaton Lightning Transmission, p. 8....4800
11.9. Allison HD Transmission, p. 9....4801
11.10. Allison HD Transmission, p. 10....4802
11.11. Allison HD Transmission, p. 11....4803
11.12. Allison HD Transmission With Auto Neutral, p. 12....4804
11.13. Allison HD Transmission With Auto Neutral and with 0013WU....4805
11.14. Allison LCT Transmission (Allison 1000, 2000, 2400) with ....4806
11.15. Transmission Retarder Control Wiring with MD Xmsn, Hard W....4807
11.16. Transmission Retarder Control Wiring with MD Xmsn, Hard W....4808
AIR CONDITIONING (Chapter 11)....4809
12.1. HVAC Systems, p. 1....4809
12.2. Air Conditioning (Only), p. 2....4810
12.3. Autotherm Systems, p. 3....4811
CONNECTOR COMPOSITES (Chapter 12)....4812
13.1. Connector Composites (10M), (71), (72), (345F), p. 1....4812
13.2. Connector Composites (420F), (420M), (520), (521), (522), ....4813
13.3. Connector Composites (1002), (1003), (1010), p. 3....4814
13.4. Connector Composite (1011), p. 4....4815
13.5. Connector Composite (1012), p. 5....4816
13.6. Connector Composite (1013), p. 6....4817
13.7. Connector Composite (1014), p. 7....4818
13.8. Connector Composites (1018), (1019M), (1020M), (1021M), (1....4819
13.9. Connector Composites (1027M, F), (1100), (1101A), (1101), ....4820
13.10. Connector Composites (1104), (1106), (1200), (1210), p. 1....4821
13.11. Connector Composites (1300), (1301), (1400), (1402), (141....4822
13.12. Connector Composites (1553), (1554F), (1555), (1600), (16....4823
13.13. Connector Composites (1652), (1657M), (1658), (1659), (18....4824
13.14. Connector Composites (1804), (1807), (1808), (1809), (181....4825
13.15. Connector Composites (1820), (1822), (1823), (1824), (182....4826
13.16. Connector Composites (1918), (1935), (1920), (2000), (200....4827
13.17. Connector Composites (2006M), (2007F), (2021F), (2021M), ....4828
13.18. Connector Composites (2304M), (2305M), (2306M), (2307F), ....4829
13.19. Connector Composites (2601M, F), (2602M, F), (3000M), (30....4830
13.20. Connector Composites (3204M, F), (3209), (3210M), (3211M)....4831
13.21. Connector Composite (4001), p. 21....4832
13.22. Connector Composite (4002), p. 22....4833
13.23. Connector Composite (4003), p. 23....4834
13.24. Connector Composites (4004), (4007), (4008), p. 24....4835
13.25. Connector Composite (4014), p. 25....4836
13.26. Connector Composite (4014/1700), p. 26....4837
13.27. Connector Composites (4015), (4017), (4018), (4019), (402....4838
13.28. Connector Composites (4024), (4030), (4031), (4032), (403....4839
13.29. Connector Composites (4070), (4071), (4087), (4098), (410....4840
13.30. Connector Composite (4103), p. 30....4841
13.31. Connector Composites (4105), (4111), (4120), (4301), p. 3....4842
13.32. Connector Composites (4305), (4410), (4410B), (4410C), (4....4843
13.33. Connector Composites (4411A), (4411B), (4412), (4415), (4....4844
13.34. Connector Composite (4705), p. 34....4845
13.35. Connector Composites (4810), (4712F), (4820), (4713F), (4....4846
13.36. Connector Composites (4900), (4910), (4950), (4951), p. 3....4847
13.37. Connector Composites (6007), (6011), p. 37....4848
13.38. Connector Composites (6013M), (6014), p. 38....4849
13.39. Connector Composites (6015), (6020), (6021), p. 39....4850
13.40. Connector Composites (6200), (6316), (6323), (6332), (633....4851
13.41. Connector Composites (6550), (6703), (6704), (6708), (710....4852
13.42. Connector Composites (7200), (7202), (7203), p. 42....4853
13.43. Connector Composites (7204), (7205), (7206), (7211), (72....4854
13.44. Connector Composites (7214), (7300), (7301), p. 44....4855
13.45. Connector Composites (7302), (7304), (7305), (7306), (750....4856
13.46. Connector Composites (7603), (7604), (7605), (7606), (760....4857
13.47. Connector Composites (7800), (7801M), (7803), (7900), (79....4858
13.48. Connector Composites (7905), (7906), (8000), (8001), (810....4859
13.49. Connector Composites (8201), (8301), (8310), (8311), (831....4860
13.50. Connector Composites (8503), (8503A), (8505), (8506), (85....4861
13.51. Connector Composites (8700), (8701), (8800), (8801), (880....4862
13.52. Connector Composites (9001), (9002), (9100), (9101), (910....4863
13.53. Connector Composites (9260), (9261), (9262), (9263), (926....4864
13.54. Connector Composites (9405), (9501), (9502), (9503), (950....4865
13.55. Connector Composites (9507), (9508), (9509), (9510), (951....4866
13.56. Connector Composites (9516), (9517), (9518), (9519), p. 5....4867
13.57. Connector Composite (9700), p. 57....4868
13.58. Connector Composite (9700), p. 58....4869
13.59. Connector Composites (9715), (9715A), (9715B), p. 59....4870
13.60. Connector Composites (9716), (9716A), (9716B), p. 60....4871
13.61. Connector Composites (9717A), (9717B), p. 61....4872
13.62. Connector Composites (9718), (9719), (9720), (9733), (973....4873
13.63. Connector Composites (9777), (9778), (9800), p. 63....4874
13.64. Connector Composites (9870), (9871), (9811), (9812), (981....4875
13.65. Connector Composites (9913B), (9914), (4100), (4109), (41....4876
0000018561 - DuraStar with Cummins Euro 5 ISB Engine Electrical Circuit Diagram Manual (for Latin America and Mexico)....4877
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Revision 1 (Supersedes 0000001601, 0000001843 & 0000002222) Service Manual....5063
toc....5065
Table of Contents....5065
1. Description....5077
1.1. Cooling Package Visual Inspection....5082
2. Cooling Package Cleaning Procedures....5083
2.1. Cleaning Cooling Package (MaxxForce® 9, and 10 Engines) ....5084
2.2. Cleaning Cooling Package (Navistar® 11 and 13 Engines) ....5085
2.3. Charge Air Cooler Cleaning Procedure....5088
Overview....5088
Tools Required....5089
Service Parts....5089
2.3.1. Charge Air Cooler Cleaning Procedure Setup....5089
2.3.2. Off-chassis Pressure Test....5090
2.3.3. Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation....5092
2.3.4. Charge Air Cooler Cleaning Procedure....5094
2.3.5. Flushing Procedure....5095
2.3.6. Cleaning Management System (CMS) Removal Procedure....5096
3. PayStar® and 9900....5098
3.1. PayStar® and 9900 Description ....5104
3.1.1. Deaeration Tank ....5104
3.1.2. Fan Shroud ....5104
3.1.3. A/C Condenser ....5104
3.1.4. Transmission Oil Cooler ....5104
3.1.5. Radiator ....5104
3.1.6. Charge Air Cooler ....5104
3.1.7. Low-Temperature Radiator ....5104
3.1.8. Fan Drive....5105
3.2. Coolant Drain and Pressure Test Procedures....5107
3.2.1. Coolant Drain Procedure (Recommended)....5109
3.2.2. Pressure Test (Recommended)....5111
3.2.3. Coolant Fill Procedure (Recommended)....5113
3.2.4. Coolant Gravity Drain Procedure (Optional)....5116
3.2.5. Coolant Fill Procedure (Optional) Cummins® ISB6.7 Engine)....5117
3.2.6. Coolant Fill Procedure – MaxxForce 11 Liter, 13 Liter, 15 Liter (Optional)....5119
3.2.7. Coolant Fill Procedure – Cummins® ISX 15 Engines (Optional)....5122
3.3. PayStar® and 9900 Removal and Installation....5124
3.3.1. Splash Panel – Removal....5125
3.3.2. Splash Panel – Installation....5125
3.3.3. Grille – Removal....5126
3.3.4. Grille Installation....5126
3.3.5. Surge Tank (Cummins® ISB6.7 Engine) – Removal....5127
3.3.6. Surge Tank (Cummins® ISB6.7 Engine) – Installation....5127
3.3.7. Deaeration Tank – Removal....5129
3.3.8. Deaeration Tank – Installation....5130
3.3.9. A/C Condenser (N13 Engine) – Removal....5131
3.3.10. A/C Condenser (N13 Engine) – Installation....5132
3.3.11. A/C Condenser (Cummins® ISX) – Removal....5132
3.3.12. A/C Condenser (Cummins® ISX) – Installation....5133
3.3.13. Upper Fan Shroud (N13 Engine) – Removal....5134
3.3.14. Upper Fan Shroud (N13) – Installation....5136
3.3.15. Lower Fan Shroud (N13) – Removal ....5137
3.3.16. Lower Fan Shroud (N13) – Installation....5140
3.3.17. Fan Shroud (Two and Three Piece) Cummins® ISX15 Engines – Removal....5141
3.3.18. Fan Shroud (Two Piece) Cummins® ISX15 Engines – Installation ....5144
3.3.19. Fan Belt N13 – Removal....5145
3.3.20. Fan Belt (N13) – Installation....5146
3.3.21. Fan Belt (MaxxForce® 15 Engine) – Removal....5146
3.3.22. Fan Belt (MaxxForce® 15) – Installation....5148
3.3.23. Alternator Fan Belt (MaxxForce® 15) – Removal....5148
3.3.24. Alternator Fan Belt (MaxxForce® 15) – Installation....5149
3.3.25. Fan Belt (Cummins®ISX15) – Removal....5150
3.3.26. Fan Belt (Cummins® ISX15) – Installation....5151
3.3.27. Transmission Oil Cooler (Cross-member Mounted) – Removal....5152
3.3.28. Transmission Oil Cooler (Cross-member mounted) – Installation....5153
3.3.29. Transmission Oil Cooler (Front Mounted) – Removal....5154
3.3.30. Transmission Oil Cooler (Front Mounted) – Installation....5154
3.3.31. Radiator Hose Heat Shrink Clamp – Removal and Installation....5156
Heat Shrink Clamp – Removal....5156
Heat Shrink Clamp – Installation....5157
3.3.32. Radiator Hose (N13) – Removal....5159
3.3.33. Radiator Hose (N13) – Installation....5162
3.3.34. Radiator Hose (Series 9900 with Cummins® ISX15) – Removal ....5163
3.3.35. Radiator Hose (Series 9900 with Cummins® ISX15) – Installation....5166
3.3.36. Front Charge Air Cooler (N13) – Removal....5167
3.3.37. Front Charge Air Cooler (N13) – Installation....5168
3.3.38. Rear Charge Air Cooler (N13) – Removal....5169
3.3.39. Rear Charge Air Cooler (N13) – Installation....5169
3.3.40. Charge Air Cooler (Cummins® ISX15) – Removal....5170
3.3.41. Charge Air Cooler (Cummins®ISX15) – Installation....5171
3.3.42. Low-Temperature Radiator – Removal....5172
3.3.43. Low-Temperature Radiator – Installation....5174
3.3.44. Radiator Assembly (N13) – Removal....5175
3.3.45. Radiator Assembly (N13) – Installation ....5178
3.3.46. Radiator Assembly (Cummins®ISX15) – Removal....5179
3.3.47. Radiator Assembly (Cummins®ISX15) – Installation....5184
3.3.48. Recirculation Seals (MaxxForce® 11 or 13 L) – Removal....5187
3.3.49. Recirculation Seals (MaxxForce® 11 or 13 L) – Installation....5188
3.3.50. Recirculation Seals (MaxxForce® 15 L) – Removal ....5189
3.3.51. Recirculation Seals (MaxxForce® 15) – Installation ....5192
3.3.52. Radiator Core (MaxxForce® 11 L or 13 L) – Removal....5192
3.3.53. Radiator Core (MaxxForce® 11 L or 13 L) – Installation....5194
3.3.54. Radiator Core (MaxxForce® 15 L) – Removal....5194
3.3.55. Radiator Core (MaxxForce® 15 L) – Installation....5196
3.3.56. Radiator Core- Removal – (Cummins® ISX15) ....5197
3.3.57. Radiator Core Installation – (Cummins® ISX15) ....5200
3.3.58. Power Steering Oil Cooler (Cummins® ISX15) – Removal....5201
3.3.59. Power Steering Oil Cooler (Cummins® ISX15) – Installation....5201
3.4. PayStar® Inspection Procedures....5202
3.4.1. Deaeration Tank Inspection Procedure....5202
3.4.2. Deaeration Tank Cap Vacuum Relief Check....5203
3.4.3. Fan Drive Pulley Crack Inspection....5204
3.4.4. Fan Drive Pulley Nick Inspection....5204
3.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....5205
Fuel Cooler Valve (FCV) Filter Screen – Removal....5205
Fuel Cooler Valve (FCV) Filter Screen – Installation....5206
3.5. Torque Chart....5207
4. ProStar®....5209
4.1. ProStar®General Description....5215
4.1.1. Deaeration Tank....5215
4.1.2. Fan Shroud....5215
4.1.3. A/C Condenser....5215
4.1.4. Transmission Oil Cooler....5215
4.1.5. Radiator....5215
4.1.6. Charge Air Cooler....5215
4.1.7. Low-Temperature Radiator....5215
4.1.8. Fan Drive....5215
4.1.9. Power Steering Oil Cooler....5216
4.2. ProStar® Coolant Drain, Pressure Test, and Fill procedures ....5217
4.2.1. Coolant Drain Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....5221
4.2.2. Pressure Test Procedure – Navistar® 11, 13, 15, and Cummins® ISX15 (Recommended)....5223
4.2.3. Coolant Fill Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....5224
4.2.4. Coolant Drain Procedure – Navistar® 11, 13, 15, Cummins® ISX15 (Optional)....5227
4.2.5. Coolant Fill Procedure – Navistar® 11, 13, 15 (Optional)....5228
4.2.6. Coolant Fill Procedure – Cummins® ISX Engines (Optional)....5231
4.3. ProStar ® Removal and Installation....5233
4.3.1. Grille – Removal....5234
4.3.2. Grille – Installation....5234
4.3.3. Deaeration Tank Removal – Navistar® 11, 13, 15....5234
4.3.4. Deaeration Tank – Installation Navistar® 11, 13, N13, 15....5235
4.3.5. Deaeration Tank Removal – Cummins® ISX15....5236
4.3.6. Deaeration Tank Installation – Cummins® ISX15....5237
4.3.7. A/C Condenser Removal – MaxxForce® 11, 13 and N13....5238
4.3.8. A/C Condenser Installation – MaxxForce® 11, 13 or N13 ....5241
4.3.9. A/C Condenser Removal – Navistar® 15 L ....5242
4.3.10. A/C Condenser Installation – Navistar® 15 L ....5243
4.3.11. A/C Condenser Removal – Cummins® ISX15 ....5244
4.3.12. A/C Condenser Installation – Cummins® ISX15....5245
4.3.13. Fan Shroud Removal – MaxxForce® 11, 13, N13....5246
4.3.14. Fan Shroud Installation – MaxxForce® 11, 13 L and N13....5252
4.3.15. Fan Shroud Removal – (Three-Piece Upper) Navistar® 15 ....5252
4.3.16. Fan Shroud Installation – (Three-Piece Upper) Navistar® 15 ....5254
4.3.17. Fan Shroud Removal – (Three-Piece Lower) Navistar® 15 ....5255
4.3.18. Fan Shroud Installation – (Three-Piece Lower) Navistar® 15....5255
4.3.19. Fan Shroud (One-Piece) Removal – Navistar® 15....5256
4.3.20. Fan Shroud Installation – (One-Piece) Navistar® 15....5257
4.3.21. Fan Shroud Removal – (Two-Piece) Cummins® ISX15....5258
4.3.22. Fan Shroud Installation – (Two-Piece) Cummins® ISX15....5262
4.3.23. Radiator Fan Removal – Navistar® 11, 13....5262
4.3.24. Radiator Fan Installation – Navistar® 11, 13 ....5263
4.3.25. Radiator Fan Removal (With Three-Piece Fan Shroud) – Navistar® 15....5263
4.3.26. Radiator Fan Installation (With Three-Piece Fan Shroud) – Navistar® 15....5264
4.3.27. Radiator Fan Removal (With One-Piece Fan Shroud) – Navistar® 15....5264
4.3.28. Radiator Fan Installation (With One-Piece Fan Shroud) – Navistar® 15....5265
4.3.29. Radiator Fan Removal – Cummins® ISX15....5266
4.3.30. Radiator Fan Installation – Cummins® ISX15....5266
4.3.31. Fan Drive Removal – Navistar® 11, 13....5267
4.3.32. Fan Drive Installation – Navistar® 11, 13....5269
4.3.33. Fan Drive Removal – Navistar® 15....5269
4.3.34. Fan Drive Installation – Navistar® 15....5270
4.3.35. Fan Drive Assembly Removal – Cummins® ISX15 (Horton)....5270
4.3.36. Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ....5273
4.3.37. Fan Belt Removal – Navistar® 11, 13....5274
4.3.38. Fan Belt Installation – Navistar® 11, 13....5275
4.3.39. Fan Belt Removal – Navistar® 15 ....5275
4.3.40. Fan Belt Installation – Navistar® 15....5277
4.3.41. Alternator Fan Belt Removal – Navistar® 15 ....5277
4.3.42. Alternator Fan Belt Installation – Navistar® 15 ....5279
4.3.43. Fan Belt Removal – Cummins® ISX15 ....5279
4.3.44. Fan Belt Installation – Cummins® ISX15....5281
4.3.45. Radiator Hose Heat Shrink Clamp Removal and Installation....5281
Heat Shrink Clamp Removal....5281
Heat Shrink Clamp Installation....5282
4.3.46. Radiator Hose Removal – Navistar® 11, 13 ....5286
4.3.47. Radiator Hose Installation – Navistar® 11, 13....5287
4.3.48. Radiator Hose Removal – Navistar® 15 ....5288
4.3.49. Radiator Hose Installation – Navistar® 15....5289
4.3.50. Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Removal – Navistar® N13....5290
4.3.51. Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Installation – Navistar® N13....5292
4.3.52. Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Removal – Navistar® 15 ....5295
4.3.53. Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Installation – Navistar® 15....5297
4.3.54. Radiator Hose Removal – Cummins® ISX15....5300
4.3.55. Radiator Hose Installation – Cummins® ISX15 ....5302
4.3.56. Recirculation Seals Removal – Navistar® 11, 13....5303
4.3.57. Recirculation Seals Installation – Navistar® 11, 13 ....5304
4.3.58. Recirculation Seals Removal – Navistar® 15 ....5304
4.3.59. Recirculation Seals Installation – Navistar® 15....5305
4.3.60. Charge Air Cooler Removal – Navistar® 11, 13, 15....5306
4.3.61. Charge Air Cooler Installation – Navistar® 11, 13, 15....5307
4.3.62. Charge Air Cooler Removal – Cummins® ISX15....5307
4.3.63. Charge Air Cooler Installation – Cummins® ISX15....5311
4.3.64. Hood-Tilt Assist Cylinder – Removal....5312
4.3.65. Hood-Tilt Assist Cylinder – Installation....5314
4.3.66. Low-Temperature Radiator Removal – Navistar® 11, 13....5315
4.3.67. Low-Temperature Radiator Installation – Navistar® 11, 13....5317
4.3.68. Low-Temperature Radiator Removal – Navistar® 15....5318
4.3.69. Low-Temperature Radiator Installation – Navistar® 15....5322
4.3.70. Radiator Assembly Removal – Navistar® 11, 13....5323
4.3.71. Radiator Assembly Installation – Navistar® 11, 13....5324
4.3.72. Radiator Assembly Removal – Navistar® 15....5326
4.3.73. Radiator Assembly Installation – Navistar® 15....5328
4.3.74. Radiator Assembly Removal – Cummins® ISX15....5329
4.3.75. Radiator Assembly Installation – Cummins® ISX15....5335
4.3.76. Radiator Core Removal – Navistar® 11, 13....5337
4.3.77. Radiator Core Installation – Navistar® 11, 13....5340
4.3.78. Radiator Core Removal – Navistar® 15....5341
4.3.79. Radiator Core Installation – Navistar® 15....5343
4.3.80. Radiator Core- Removal – Cummins® ISX15 ....5344
4.3.81. Radiator Core Installation – Cummins® ISX15 ....5348
4.3.82. Power Steering Oil Cooler – Removal....5349
4.3.83. Power Steering Oil Cooler – Installation....5351
4.3.84. Transmission Oil Cooler Removal (Cummins® ISX15 ONLY)....5351
4.3.85. Transmission Oil Cooler – Installation....5352
4.4. ProStar® Inspection Procedures....5354
4.4.1. Deaeration Tank Inspection Procedure....5354
4.4.2. Deaeration Tank Cap Vacuum Relief Check....5355
4.4.3. Fan Drive Pulley Crack Inspection....5356
4.4.4. Fan Drive Pulley Nick Inspection....5356
4.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....5357
Fuel Cooler Valve (FCV) Filter Screen – Removal....5357
Fuel Cooler Valve (FCV) Filter Screen – Installation....5358
4.5. Torque Chart Navistar® Engines....5359
5. TranStar®....5362
5.1. TranStar® General Description....5367
5.1.1. Deaeration Tank....5367
5.1.2. Fan Shroud....5367
5.1.3. A/C Condenser....5367
5.1.4. Transmission Oil Cooler....5367
5.1.5. Radiator....5367
5.1.6. Charge Air Cooler....5367
5.1.7. Low-Temperature Radiator....5367
5.1.8. Fan Drive....5367
5.2. TranStar® Coolant Drain, Pressure Test, and Fill procedures....5368
5.2.1. Coolant Drain, Pressure Test, and Fill procedures (Recommended)....5371
5.2.2. Pressure Test Procedure (Recommended)....5373
5.2.3. Coolant Fill Procedure (Recommended)....5376
5.2.4. Coolant Drain Procedure (Optional)....5379
5.3. TranStar® Removal and Installation....5380
5.3.1. Grille – Removal....5381
5.3.2. Grille – Installation....5381
5.3.3. Deaeration Tank – Removal....5381
5.3.4. Deaeration Tank – Installation....5382
5.3.5. A/C Condenser – Removal....5384
5.3.6. A/C Condenser – Installation....5386
5.3.7. Fan Shroud – Removal....5387
5.3.8. Fan Shroud – Installation....5390
5.3.9. Radiator Fan – Removal....5390
5.3.10. Radiator Fan – Installation....5391
5.3.11. Fan Clutch – Removal....5392
5.3.12. Fan Clutch – Installation....5393
5.3.13. Fan Belt – Removal....5394
5.3.14. Fan Belt – Installation....5396
5.3.15. Heat Shrink Clamp Removal and Installation....5396
Heat Shrink Clamp Removal....5396
Heat Shrink Clamp Installation....5397
5.3.16. Radiator Hose – Removal....5400
5.3.17. Radiator Hose – Installation....5404
5.3.18. Charge Air Cooler – Removal....5405
5.3.19. Charge Air Cooler – Installation....5407
5.3.20. Low-Temperature Radiator – Removal....5408
5.3.21. Low-Temperature Radiator – Installation....5409
5.3.22. Radiator Assembly – Removal....5410
5.3.23. Radiator Assembly – Installation....5412
5.3.24. Radiator Core – Removal....5413
5.3.25. Radiator Core – Installation....5415
5.3.26. Transmission Oil Cooler (Crossmember mounted) – Removal....5416
5.3.27. Transmission Oil Cooler (Crossmember mounted) – Installation....5416
5.4. TranStar® Inspection Procedures....5418
5.4.1. Deaeration Tank Inspection Procedure....5418
5.4.2. Deaeration Tank Cap Vacuum Relief Check....5419
5.4.3. Fan Drive Pulley Crack Inspection....5420
5.4.4. Fan Drive Pulley Nick Inspection....5420
5.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....5421
Fuel Cooler Valve (FCV) Filter Screen – Removal....5421
Fuel Cooler Valve (FCV) Filter Screen – Installation....5422
5.5. Torque Chart....5423
6. WorkStar®....5424
6.1. WorkStar® and 9900 Description....5430
6.1.1. Surge Tank (If Equipped) ....5430
6.1.2. Deaeration Tank....5430
6.1.3. Fan Shroud....5430
6.1.4. Fan Drive....5430
6.1.5. A/C Condenser....5430
6.1.6. Radiator....5430
6.1.7. Charge Air Cooler....5430
6.1.8. Cross-Member....5430
6.1.9. Low-Temperature Radiator....5431
6.1.10. Low Temperature Radiator (LTR) Thermostat....5431
6.1.11. Fuel Cooler....5431
6.1.12. Transmission Oil Cooler....5431
6.2. WorkStar® Coolant Drain, Pressure Test, and Fill procedures....5432
6.2.1. Coolant Drain Procedure (Recommended)....5435
6.2.2. Pressure Test Procedure (Recommended)....5437
6.2.3. Coolant Fill Procedure (Recommended)....5440
6.2.4. Coolant Gravity Drain Procedure (Optional)....5443
6.2.5. Coolant Fill Procedure (MaxxForce® 9, and 10 Engines) (Optional)....5444
6.2.6. Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....5446
6.2.7. Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....5448
6.3. WorkStar® Removal and Installation....5451
6.3.1. Grille (Standard) – Removal....5452
6.3.2. Grille (Standard) – Installation....5452
6.3.3. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5452
6.3.4. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5453
6.3.5. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5453
6.3.6. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5454
6.3.7. Splash Panel (Standard) – Removal....5454
6.3.8. Splash Panel (Standard) – Installation....5455
6.3.9. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5455
6.3.10. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5456
6.3.11. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5456
6.3.12. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5457
6.3.13. Surge Tank (with Cummins® ISB6.7 Engine) – Removal....5457
6.3.14. Surge Tank (with Cummins® ISB6.7 Engine) – Installation....5458
6.3.15. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5458
6.3.16. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5459
6.3.17. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5460
6.3.18. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5461
6.3.19. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....5461
6.3.20. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....5462
6.3.21. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Removal ....5463
6.3.22. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Installation....5465
6.3.23. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5465
6.3.24. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5466
6.3.25. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5467
6.3.26. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5468
6.3.27. A/C Condenser (Navistar® 11 and 13 Engines) – Removal....5468
6.3.28. A/C Condenser (Navistar® 11 and 13 Engines) – Installation....5469
6.3.29. A/C Condenser (ISB6.7) Engine – Removal....5470
6.3.30. A/C Condenser (ISB6.7 Engine) – Installation....5470
6.3.31. Fan Belt with A/C (Cummins® ISB6.7 Engine) - Removal ....5471
6.3.32. Fan Belt with A/C (Cummins® ISB6.7 Engine) – Installation ....5471
6.3.33. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5473
6.3.34. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5475
6.3.35. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....5476
6.3.36. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5477
6.3.37. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....5477
6.3.38. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....5479
6.3.39. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5480
6.3.40. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5482
6.3.41. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5482
6.3.42. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....5484
6.3.43. Fan Shroud (Cummins® ISB6.7 Engine) 7 similar - Removal....5484
6.3.44. Fan Shroud - Installation....5485
6.3.45. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Removal....5485
6.3.46. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Installation....5486
6.3.47. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Removal....5486
6.3.48. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Installation....5488
6.3.49. Radiator Fan (Standard) – Removal....5489
6.3.50. Radiator Fan (Standard) – Installation....5490
6.3.51. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....5490
6.3.52. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5491
6.3.53. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5492
6.3.54. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5492
6.3.55. Heat Shrink Clamp Removal and Installation....5493
Heat Shrink Clamp Removal....5493
Heat Shrink Clamp Installation....5494
6.3.56. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5496
6.3.57. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5498
6.3.58. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5498
6.3.59. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5501
6.3.60. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....5502
6.3.61. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....5504
6.3.62. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5504
6.3.63. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5508
6.3.64. Coolant Package – Removal....5509
Overview....5509
6.3.65. Coolant Package – Installation....5513
6.3.66. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5515
6.3.67. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5516
6.3.68. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5517
6.3.69. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5517
6.3.70. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....5518
6.3.71. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....5521
6.3.72. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5522
6.3.73. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5523
6.3.74. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....5524
6.3.75. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....5526
6.3.76. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5526
6.3.77. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5527
6.3.78. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5528
6.3.79. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5530
6.3.80. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....5530
6.3.81. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....5531
6.3.82. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....5531
6.3.83. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....5534
6.3.84. Low Temperature Radiator (LTR) Thermostat – Removal....5535
6.3.85. Low Temperature Radiator (LTR) Thermostat – Installation....5536
6.3.86. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5538
6.3.87. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5542
6.3.88. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....5544
6.3.89. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation ....5550
6.3.90. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....5553
6.3.91. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....5555
6.3.92. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5556
6.3.93. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5558
6.3.94. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....5559
6.3.95. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....5560
6.3.96. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....5561
6.3.97. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....5562
6.3.98. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5562
6.3.99. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5563
6.3.100. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....5563
6.3.101. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....5564
6.3.102. Low Temperature Radiator Hoses – Removal....5564
6.3.103. Low Temperature Radiator (LTR) Thermostat Hose – Installation....5566
6.4. WorkStar® Inspection Procedures....5568
6.4.1. Deaeration Tank Inspection Procedure....5568
6.4.2. Deaeration Tank Cap Vacuum Relief Check....5569
6.4.3. Fan Drive Pulley Crack Inspection....5570
6.4.4. Fan Drive Pulley Nick Inspection....5570
6.4.5. 12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....5571
6.4.6. 12TTD Borg – Warner 842B Visctronics Inspection Procedure....5572
6.4.7. Fuel Cooler Valve (FCV) Inspection Procedure....5572
Fuel Cooler Valve (FCV) Filter Screen – Removal....5572
Fuel Cooler Valve (FCV) Filter Screen – Installation....5574
6.5. Torque Chart....5575
7. 12THT Horton DriveMaster Fan Drive System....5579
7.1. 12THT Horton Drivemaster Fan Drive System Removal and Installation....5579
7.1.1. 12THT Radiator Fan (N13) – Removal....5579
7.1.2. 12THT Radiator Fan (N13) – Installation....5579
7.1.3. 12THT Radiator Fan (Cummins® ISX15) – Removal....5580
7.1.4. 12THT Radiator Fan Cummins® ISX15 – Installation....5580
7.1.5. Fan Removal – (12THZ and 12THT Horton DA) (optional)....5581
7.1.6. Fan Installation – (12THZ and 12THT Horton DA) (optional)....5581
7.1.7. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....5582
7.1.8. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....5583
7.1.9. 12THT Horton (DMA) Serviceable Fan Drive – Removal....5583
7.1.10. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....5587
7.1.11. 12THT Pulley Bearing – Removal....5588
7.1.12. 12THT Pulley Bearing – Installation....5588
7.1.13. 12THT Fan Drive Friction Liner– Removal....5589
7.1.14. 12THT Fan Drive Friction Liner – Installation....5591
7.1.15. 12THT Clutch Pack Seal Face – Removal....5592
7.1.16. 12THT Clutch Pack Seal Face – Installation....5592
7.1.17. 12THT Air Cartridge – Removal....5592
7.1.18. 12THT Air Cartridge – Installation....5593
7.2. 12THT Horton Drivemaster Fan Drive System Inspection Procedures....5595
7.2.1. Fan Drive Movement / Clutch Pack Bearing Check....5595
7.2.2. Clutch Pack Face Seal....5596
7.2.3. Cartridge Assembly Seal and Spring....5597
7.2.4. Friction Liner Measurement....5598
7.2.5. Fan Drive Bearing Measurement and Inspection....5599
7.3. 12THT Horton Drivemaster Fan Drive System Diagnostics....5600
7.3.1. 12THT Horton DriveMaster Fan Drive Operational Checks....5600
Overview....5600
Tools Required....5600
Operational Checks – Start Fan Drive Diagnostics Here.....5600
Visual Air Leak Check....5600
7.3.2. Symptom 1: Fan Always On....5603
7.3.3. Symptom 2: Fan Always Off....5619
7.3.4. Symptom 3: Cycles Too Frequently....5625
7.3.5. Symptom 4: Excessive Noise From Fan Drive....5627
8. 12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics ....5629
8.1. Start Diagnostics here: 12TTD Borg-Warner 842B Visctronic Fan Drive....5629
Overview....5629
Tools Required....5629
Operational Checks – Start Fan Drive Diagnostics Here....5629
8.2. Symptom 1: Fan Always ON....5631
8.3. Symptom 2: Fan Always OFF....5637
8.4. Symptom 3: Cycles Too Frequently....5654
8.5. Symptom 4: Excessive Noise From Fan Drive....5657
9. 12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....5659
9.1. Start Diagnostics Here: 12TSY Borg-Warner SA85 Fan Drive Assembly....5659
Overview....5659
Tools Required....5659
10. 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly....5661
10.1. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly Removal and Installation....5661
Tools Required....5661
10.1.1. 12TKY Borg-Warner Fan Drive Clutch Lining – Removal....5661
10.1.2. 12TKY Borg-Warner Fan Drive Clutch Lining – Installation....5661
10.1.3. 12TKY Borg-Warner Fan Drive and Hub Assembly – Removal....5662
10.1.4. 12TKY Borg-Warner Fan Drive and Hub Assembly – Installation....5662
10.2. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Inspection....5664
10.2.1. 12TKY Borg-Warner Fan Drive Clutch Friction Lining Inspection....5664
10.3. Start Diagnostics here: 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Diagnostics....5665
Overview....5665
Tools Required....5665
Operational Checks – Start Fan Drive Diagnostics here.....5665
10.4. Symptom 1: Fan Always On....5667
10.5. Symptom 2: Fan Always Off....5668
10.6. Symptom 3: Fan Cycles Too Frequently....5669
10.7. Clutch Will Not Engage....5669
10.8. Clutch Will Not Disengage....5670
10.9. Air Leak In Drive....5671
10.10. Symptom 4: Excessive Noise From Fan Drive....5672
11. 12THX Horton Stratis V-Master-Ultra Viscous Fan Drive Assembly System....5675
11.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly Removal and Installation....5675
11.1.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Removal....5675
11.1.2. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Installation....5676
11.2. 12THX Horton Stratis Viscous Fan Drive Assembly System Diagnostics....5677
11.2.1. 12THX Horton Stratis Viscous Fan Drive Assembly Diagnostics – Operations Checks....5677
Overview....5677
Tools Required....5677
Operational Checks – Start Fan Drive Diagnostics here.....5677
Visual Air Leak Check....5677
11.3. 12THX Horton Stratis Fan Drive Inspection, Pin Point Test, and ServiceMaxx™ Engine Fan Test....5680
11.3.1. Fan Drive Inspection....5680
11.3.2. Fan Drive Pin Point Test....5681
11.4. ServiceMaxx Engine Fan Test™....5681
11.5. Engine Fan Test Results....5684
11.5.1. Engine Fan Test Overview....5684
11.5.2. Properly Working Fan Hub Assembly....5684
11.6. Fan Engages Prematurely....5685
11.7. Symptom 1: Fan Always On....5685
11.8. Symptom 2: Fan Always Off....5686
11.9. Symptom 3: Fan Cycles Too Frequently....5687
11.10. Symptom 4: Excessive Noise From Fan Drive....5688
12. Abbreviations and Acronyms....5690
13. Terminology....5691
tables....5207
Table 7Torque Chart....5207
Table 13Torque Chart Navistar® Engines....5359
Table 14Torque Chart Cummins® ISX15 Engine....5361
Table 20Torque Chart....5423
Table 28Torque Chart....5575
0000680131 - DuraStar Radiator _ Cooling System (Euro V Latin American Market ) Service Manual....5694
toc....5696
Table of Contents....5696
1. DESCRIPTION....5698
1.1. DEAERATION TANK....5699
1.2. A/C CONDENSER....5699
1.3. FAN AND FAN DRIVE....5699
1.4. FAN SHROUD....5699
1.5. RADIATOR / CHARGE AIR COOLER ASSEMBLY....5699
2. Removal and Installation....5700
2.1. COOLING PACKAGE CLEANING PROCEDURE....5701
2.2. COOLANT DRAIN, PRESSURE TEST, AND FILL PROCEDURES....5704
2.2.1. Coolant Drain Procedure (Recommended)....5706
2.2.2. Pressure Test Procedure (Recommended)....5710
2.2.3. Coolant Fill Procedure (Recommended)....5712
2.2.4. Coolant Drain Procedure (Optional)....5714
2.2.5. Coolant Fill Procedure (Optional)....5715
2.3. SPLASH PANEL....5717
2.3.1. Splash Panel – Removal....5717
2.3.2. Splash Panel – Installation....5717
2.4. DEAERATION TANK....5718
2.4.1. Deaeration Tank – Removal....5718
2.4.2. Deaeration Tank – Installation....5719
2.5. A/C CONDENSER....5720
2.5.1. A/C Condenser – Removal....5720
2.5.2. A/C Condenser – Installation....5721
2.6. FAN AND ACCESSORY BELTS....5722
2.6.1. Fan and Accessory Belts – Removal....5722
2.6.2. Fan and Accessory Belts – Installation....5723
2.7. FAN AND FAN DRIVE....5724
2.7.1. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....5724
2.7.2. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....5725
2.7.3. 12THT Horton (DMA) Serviceable Fan Drive – Removal....5725
2.7.4. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....5729
2.7.5. 12THT Pulley Bearing – Removal....5730
2.7.6. 12THT Pulley Bearing – Installation....5730
2.7.7. 12THT Fan Drive Friction Liner– Removal....5730
2.7.8. 12THT Fan Drive Friction Liner – Installation....5733
2.7.9. 12THT Clutch Pack Seal Face – Removal....5734
2.7.10. 12THT Clutch Pack Seal Face – Installation....5734
2.7.11. 12THT Air Cartridge – Removal....5734
2.7.12. 12THT Air Cartridge – Installation....5735
2.8. FAN SHROUD....5737
2.8.1. Fan Shroud – Removal....5737
2.8.2. Fan Shroud – Installation....5737
2.9. RADIATOR HOSES....5738
2.9.1. Radiator Hoses – Removal....5738
2.9.2. Radiator Hoses – Installation....5739
2.10. RECIRCULATION SEALS....5740
2.10.1. Recirculation Seals – Removal....5740
2.10.2. Recirculation Seals – Installation....5740
2.11. COOLING PACKAGE....5741
2.11.1. Cooling Package – Removal....5741
2.11.2. Cooling Package – Installation....5745
2.12. RADIATOR / CHARGE AIR COOLER....5746
2.12.1. Radiator / Charge Air Cooler – Removal....5746
2.12.2. Radiator / Charge Air Cooler – Installation....5747
3. 12THT Horton Drivemaster Fan Drive System Inspection Procedures....5748
3.1. Fan Drive Movement / Clutch Pack and Pulley Bearing Check....5748
3.2. Clutch Pack Face Seal....5749
3.3. Cartridge Assembly Seal and Spring....5750
3.4. Friction Liner Measurement....5751
3.5. Fan Drive Bearing Measurement and Inspection....5752
4. 12THT Horton Drivemaster Fan Drive System Diagnostics....5753
Overview....5753
4.1. 12THT Horton DriveMaster Fan Drive Operational Checks....5754
4.2. Symptom 1: Fan Always On....5755
4.3. Symptom 2: Fan Always Off....5756
4.4. Symptom 3: Cycles Too Frequently....5757
4.5. Symptom 4: Excessive Noise From Fan Drive....5757
5. Abbreviations and Acronyms....5761
6. Terminology....5762
tables....5764
Table 13Torque Chart....5764
0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 13....5765
toc....5767
Table of Contents....5767
Safety Terminology....5770
Safety Instructions....5770
Work Area....5770
Safety Equipment....5770
Protective Measures....5770
Vehicle....5770
Engine....5771
Fire Prevention....5771
Batteries....5771
Compressed Air....5771
Tools....5771
Fluids Under Pressure....5772
Fuel....5772
Removal of Tools, Parts, and Equipment....5772
Frame....5773
Front Axle....5777
Front Suspension....5781
Brakes....5785
1. Air Brakes - Foundation....5787
Service Brakes....5787
Overview....5787
Brake Chambers....5788
Removal....5788
Overview....5788
Special Tools....5788
Equipment Conditions....5788
Removal Procedure....5788
Follow-On Procedure....5790
Installation....5791
Overview....5791
Special Tools....5791
Equipment Conditions....5791
Installation Procedure....5791
Follow-On Procedure....5793
Adjustment....5794
Overview....5794
Special Tools....5794
Equipment Conditions....5794
Adjustment Procedure (Preferred)....5794
Adjustment Procedure (Alternate)....5795
Follow-On Procedure....5798
Foot Valve....5799
Removal....5799
Overview....5799
Special Tools....5799
Equipment Conditions....5799
Removal Procedure....5800
Follow-On Procedure....5800
Installation....5801
Overview....5801
Special Tools....5801
Torque Specifications....5801
Equipment Conditions....5801
Installation Procedure....5802
Follow-On Procedure....5802
Rod Stroke Sensor....5803
Removal....5803
Overview....5803
Special Tools....5803
Equipment Conditions....5803
Removal Procedure....5804
Follow-On Procedure....5806
Installation....5807
Overview....5807
Special Tools....5807
Equipment Conditions....5807
Installation Procedure....5807
Follow-On Procedure....5808
Park (Spring) Brakes....5809
Spring Brake Modulator Valve....5809
Overview....5809
Slack Adjusters....5810
Front Axle....5810
Overview....5810
Clevis Types....5812
Rear Axle....5818
Overview....5818
Clevis Types....5820
Inspection....5825
Overview....5825
Special Tools....5825
Equipment Conditions....5825
Minor Inspection Procedure....5825
Major Inspection Procedure....5825
Follow-On Procedure....5827
Removal....5828
Overview....5828
Special Tools....5828
Equipment Conditions....5828
Removal Procedure....5828
Follow-On Procedure....5829
Installation....5830
Overview....5830
Special Tools....5830
Equipment Conditions....5830
Installation Procedure....5830
Follow-On Procedure....5836
Disassembly....5837
Overview....5837
Special Tools....5837
Equipment Conditions....5837
Disassembly Procedure....5837
Follow-On Procedure....5843
Assembly....5844
Overview....5844
Special Tools....5844
Equipment Conditions....5844
Assembly Procedure....5844
Follow-On Procedure....5851
Cleaning....5852
Overview....5852
Special Tools....5852
Equipment Conditions....5852
Cleaning Metal Parts with Polished Surfaces....5853
Cleaning Non-Metal Parts....5853
Follow-On Procedure....5853
2. Air Brakes - Bendix....5854
ABS / ATC / ESC....5854
Overview....5854
ABS....5857
ATC....5858
ESC....5860
ABS Module....5862
Removal....5862
Overview....5862
Special Tools....5862
Equipment Conditions....5862
Removal Procedure....5862
Follow-On Procedure....5862
Installation....5863
Overview....5863
Special Tools....5863
Torque Specifications....5863
Equipment Conditions....5863
Installation Procedure....5863
Follow-On Procedure....5863
Modulator Valve....5864
Removal....5864
Overview....5864
Special Tools....5864
Equipment Conditions....5864
Removal Procedure....5865
Follow-On Procedure....5865
Installation....5866
Overview....5866
Special Tools....5866
Torque Specifications....5866
Equipment Conditions....5866
Installation Procedure....5867
Follow-On Procedure....5867
Steering Angle Sensor....5868
Removal....5868
Overview....5868
Special Tools....5868
Equipment Conditions....5868
Removal Procedure....5868
Follow-On Procedure....5870
Installation....5871
Overview....5871
Special Tools....5871
Equipment Conditions....5871
Installation Procedure....5871
Follow-On Procedure....5873
Traction Relay Valve....5874
Front Removal....5874
Overview....5874
Special Tools....5874
Equipment Conditions....5874
Removal Procedure....5875
Follow-On Procedure....5875
Front Installation....5876
Overview....5876
Special Tools....5876
Torque Specifications....5876
Equipment Conditions....5876
Installation Procedure....5877
Follow-On Procedure....5877
Rear Removal....5878
Overview....5878
Special Tools....5878
Equipment Conditions....5878
Removal Procedure....5879
Follow-On Procedure....5879
Rear Installation....5880
Overview....5880
Special Tools....5880
Torque Specifications....5880
Equipment Conditions....5880
Installation Procedure....5881
Follow-On Procedure....5881
Wheel Speed Sensor....5882
Removal....5882
Overview....5882
Special Tools....5882
Equipment Conditions....5882
Removal Procedure....5883
Follow-On Procedure....5883
Installation....5884
Overview....5884
Special Tools....5884
Torque Specifications....5884
Equipment Conditions....5884
Installation Procedure....5885
Follow-On Procedure....5885
Yaw Rate Sensor....5886
Removal....5886
Overview....5886
Special Tools....5886
Equipment Conditions....5886
Removal Procedure....5887
Follow-On Procedure....5887
Installation....5888
Overview....5888
Special Tools....5888
Equipment Conditions....5888
Installation Procedure....5889
Follow-On Procedure....5889
3. Hydraulic Brakes - Foundation....5890
Disc Brakes....5890
Overview....5890
Front Brake Caliper....5892
Removal....5892
Overview....5892
Special Tools....5892
Equipment Condition....5892
Procedure....5893
Follow-On Procedure....5897
Installation....5898
Overview....5898
Special Tools....5898
Equipment Condition....5899
Procedure....5899
Follow-On Procedure....5902
Rear Brake Caliper....5903
Removal....5903
Overview....5903
Special Tools....5903
Equipment Condition....5903
Procedure....5904
Follow-On Procedure....5908
Installation....5909
Overview....5909
Special Tools....5909
Equipment Condition....5910
Procedure....5910
Follow-On Procedure....5913
Park Brakes....5914
Tech Tips....5915
Park Brake Cable Adjustment....5916
Overview....5916
Special Tools....5917
Equipment Conditions....5917
Adjustment Procedure....5917
Follow-On Procedure....5919
Park Brake System Inspection....5920
Overview....5920
Special Tools....5920
Equipment Conditions....5920
Inspection Procedure....5920
Follow-On Procedure....5921
Park Brake Shoe Adjustment....5922
Overview....5922
Special Tools....5922
Equipment Conditions....5922
Adjustment Procedure (Drum OFF)....5923
Adjustment Procedure (Drum ON)....5924
Follow-On Procedure....5924
4. Hydraulic Brakes - Wabco....5925
SmartTrac ABS / ATC with Hydro-Max....5925
Overview....5925
ABS....5927
ATC....5927
ABS Unit....5930
Removal....5930
Overview....5930
Special Tools....5930
Equipment Conditions....5930
Procedure....5931
Follow-On Procedure....5934
Installation....5935
Overview....5935
Special Tools....5935
Equipment Conditions....5935
Procedure....5936
Follow-On Procedure....5939
Wheel Speed Sensor....5940
Removal....5940
Overview....5940
Special Tools....5940
Equipment Conditions....5940
Procedure....5941
Follow-On Procedure....5941
Installation....5942
Overview....5942
Special Tools....5942
Torque Specifications....5942
Equipment Conditions....5942
Procedure....5943
Follow-On Procedure....5943
Brake Bleeding....5944
Overview....5944
Special Tools....5944
Equipment Conditions....5944
Procedure....5944
Follow-On Procedure....5945
Manual Brake Bleeding....5946
Overview....5946
Special Tools....5946
Equipment Conditions....5946
Procedure....5947
Follow-On Procedure....5948
Full Power ABS / ATC....5949
Overview....5949
Standard Features....5949
Optional Features....5949
System Layout....5952
System Components....5953
Master Cylinder and Reservoir....5953
Normal Operation (Brakes Not Applied)....5954
Service Brakes (Normal Braking)....5956
Normal Operation (Brakes Applied)....5957
Anti-lock Brake System (ABS)....5958
ABS Decrease Pressure Stage....5959
ABS Hold Stage....5960
ABS Increase Pressure Stage....5961
Automatic Traction Control (ATC) System (Optional)....5962
ATC Inactive (ATC Circuit Operation with No ATC Event Occurring)....5962
ATC Active (ATC Circuit Operation while Experiencing an ATC Event)....5964
Tire Size Range....5966
Tech Tips....5966
Safety Precautions....5967
General Warnings / Cautions for Servicing the Full Power Brake System....5967
Asbestos Fibers Warning....5971
Hazard Summary....5971
Recommended Work Practices....5971
Regulatory Guidance....5972
Non-Asbestos Fibers Warning....5973
Hazard Summary....5973
Recommended Work Practices....5973
Regulatory Guidance....5974
Pressure Bleeding Procedure....5975
Overview....5975
Special Tools....5975
Equipment Conditions....5976
Master Cylinder Bleeding Procedure....5977
Brake Caliper Bleeding Procedure....5980
Follow-On Procedure....5982
ABS Electronic Control Unit (ECU)....5983
Removal....5983
Overview....5983
Special Tools....5983
Equipment Conditions....5983
Removal Procedure....5984
Follow-On Procedure....5986
Installation....5987
Overview....5987
Special Tools....5987
Equipment Conditions....5987
Installation Procedure....5988
Follow-On Procedure....5989
Accumulator....5990
Removal....5990
Overview....5990
Special Tools....5990
Equipment Conditions....5990
Removal Procedure....5992
Follow-On Procedure....5993
Installation....5994
Overview....5994
Special Tools....5994
Equipment Conditions....5994
Installation Procedure....5996
Follow-On Procedure....5997
Disposal....5998
Overview....5998
Special Tools....5998
Equipment Conditions....5998
Disposal Procedure....5998
Follow-On Procedure....5999
Brake Light Switch (Mounted on MC)....6000
Removal....6000
Overview....6000
Special Tools....6000
Equipment Conditions....6000
Removal Procedure....6000
Follow-On Procedure....6001
Installation....6002
Overview....6002
Special Tools....6002
Equipment Conditions....6002
Installation Procedure....6002
Follow-On Procedure....6002
Brake Lines (General)....6003
Removal....6003
Overview....6003
Special Tools....6003
Equipment Conditions....6003
Removal Procedure....6004
Follow-On Procedure....6005
Installation....6006
Overview....6006
Special Tools....6006
Equipment Conditions....6006
Installation Procedure....6007
Follow-On Procedure....6007
Hydraulic Compact Unit (HCU)....6008
Removal....6008
Overview....6008
Special Tools....6008
Equipment Conditions....6008
Removal Procedure....6010
Follow-On Procedure....6014
Installation....6015
Overview....6015
Special Tools....6015
Equipment Conditions....6015
Installation Procedure....6017
Follow-On Procedure....6019
HCU Reservoir....6020
Removal....6020
Overview....6020
Special Tools....6020
Equipment Conditions....6020
Removal Procedure....6020
Follow-On Procedure....6021
Installation....6022
Overview....6022
Special Tools....6022
Equipment Conditions....6022
Installation Procedure....6023
Follow-On Procedure....6023
HCU Pumps....6024
Primary HCU Pump Removal....6024
Overview....6024
Special Tools....6024
Equipment Conditions....6024
Removal Procedure....6025
Follow-On Procedure....6027
Primary HCU Pump Installation....6028
Overview....6028
Special Tools....6028
Equipment Conditions....6028
Installation Procedure....6030
Follow-On Procedure....6030
Secondary HCU Pump Removal....6031
Overview....6031
Special Tools....6031
Equipment Conditions....6031
Removal Procedure....6032
Follow-On Procedure....6036
Secondary HCU Pump Installation....6037
Overview....6037
Special Tools....6037
Equipment Conditions....6037
Installation Procedure....6039
Follow-On Procedure....6042
Fluid Level Switch (Mounted on MC Reservoir)....6044
Removal....6044
Overview....6044
Special Tools....6044
Equipment Conditions....6044
Removal Procedure....6044
Follow-On Procedure....6044
Installation....6045
Overview....6045
Special Tools....6045
Torque Specifications....6045
Equipment Conditions....6045
Installation Procedure....6045
Follow-On Procedure....6045
Low Pressure Hose....6046
Removal....6046
Overview....6046
Special Tools....6046
Equipment Conditions....6046
Removal Procedure....6047
Follow-On Procedure....6051
Installation....6052
Overview....6052
Special Tools....6052
Torque Specifications....6052
Equipment Conditions....6052
Installation Procedure....6053
Follow-On Procedure....6053
Master Cylinder (MC)....6054
Removal....6054
Overview....6054
Special Tools....6054
Equipment Conditions....6054
Removal Procedure....6054
Follow-On Procedure....6060
Installation....6061
Overview....6061
Special Tools....6061
Equipment Conditions....6061
Installation Procedure....6062
Follow-On Procedure....6065
Master Cylinder Reservoir....6066
Removal....6066
Overview....6066
Special Tools....6066
Equipment Conditions....6066
Removal Procedure....6066
Follow-On Procedure....6069
Installation....6070
Overview....6070
Special Tools....6070
Equipment Conditions....6070
Installation Procedure....6071
Follow-On Procedure....6072
Relay Valve Assembly....6073
Removal....6073
Overview....6073
Special Tools....6073
Equipment Conditions....6073
Removal Procedure....6074
Follow-On Procedure....6078
Installation....6079
Overview....6079
Special Tools....6079
Equipment Conditions....6079
Installation Procedure....6081
Follow-On Procedure....6084
Wheel Speed Sensor....6085
Removal....6085
Overview....6085
Special Tools....6085
Equipment Conditions....6085
Removal Procedure....6086
Follow-On Procedure....6086
Installation....6087
Overview....6087
Special Tools....6087
Torque Specifications....6087
Equipment Conditions....6087
Installation Procedure....6088
Follow-On Procedure....6089
Steering....6091
1. Steering Wheel and Steering Column Assembly....6093
Description....6093
Steering Wheel....6093
Clock Spring....6093
Steering Column....6094
Remove and Install Procedures....6095
Equipment Conditions....6095
Steering Wheel....6096
Overview....6096
Removal....6097
Installation....6099
Clock Spring....6101
Removal....6101
Installation....6104
Steering Column....6106
Overview....6106
Removal....6106
Installation....6107
Checks and Adjustments....6109
Steering Wheel....6109
Check....6109
Adjust....6109
Torque....6110
2. Power Steering Gear: Sheppard M-Series....6111
Identification....6111
Operation....6114
OIL FLOW THROUGH THE GEAR....6115
Steering System Diagnostics....6117
Diagnostic Overview....6117
Define the Concern....6117
Perform Visual Inspection....6117
Inspect Mechanical Components....6117
Hydraulic Diagnosis....6117
Oil Flow and Pressure Recommendations....6120
Common Complaints....6120
Troubleshooting....6123
Symptoms Table....6123
Re-phasing Column....6126
Troubleshooting Checklist....6127
Preventative Maintenance....6128
Fluid and Filter Change....6128
Input Shaft Seal Replacement — Disassembly....6130
Input Shaft Seal Replacement — Assembly....6134
Bleeding....6137
Single Gear System....6137
Dual Steering Gears....6139
Set Relief Plungers....6142
Pitman Arm....6143
Remove....6143
Install....6145
Steering Gear Disassembly....6152
Sub-assembly Repair....6167
M-SERIES - OPTIONAL INTEGRAL RELIEF VALVE....6167
Clean....6169
Inspect....6170
Parts Discolored (Blue)....6170
Broken Housing....6170
Housing or Piston Scoring....6170
Sector Shaft Roller (Bearing Wear)....6170
Actuating Shaft....6171
Thrust Bearings....6171
Actuating Shaft Thread Wear....6171
Piston Rings Cut, Pinched, Sheered or Worn....6171
Reassemble....6172
Dual Steering System....6188
Description....6188
Operation....6188
Integral Slave Gear....6191
Adjustments....6193
Final....6193
Axle Stop....6193
Specifications....6194
Torque....6194
Special Tools....6195
Glossary of Terms and Definitions....6195
3. Power Steering Gear with Hydro-Max® Brake System....6198
Overview....6198
Cummins ISB with TRW....6199
Cummins ISB with Sheppard....6199
N9 with TRW....6199
Power Steering Fluid Flow Test....6200
Overview....6200
Special Tools....6200
Equipment Conditions....6200
Procedure....6201
Follow-On Procedure....6202
Drivelines....6203
Exhaust....6207
1. Exhaust System....6209
Single Can Aftertreatment - DuraStar....6209
Overview....6209
Single Can Aftertreatment - WorkStar....6211
Overview....6211
Electrical / Software....6215
1. Diagnostic Trouble Code (DTC) List....6225
2. Electronic Service Tools (EST)....6229
Diamond Logic® Builder....6229
Overview....6229
Selecting an Interface Cable....6231
Overview....6231
Special Tools....6231
Equipment Conditions....6231
Selection Procedure....6231
Follow-On Procedure....6232
Connecting to a Vehicle....6233
Overview....6233
Special Tools....6233
Equipment Conditions....6233
Connection Procedure....6233
Follow-On Procedure....6234
Activating Diagnostic Mode....6235
Overview....6235
Special Tools....6235
Equipment Conditions....6235
Activation Procedure....6235
Follow-On Procedure....6236
Starting a Session....6237
Overview....6237
Special Tools....6237
Equipment Conditions....6237
Starting Procedure....6237
Follow-On Procedure....6238
Viewing Fault Codes....6239
Overview....6239
Special Tools....6239
Equipment Conditions....6239
Viewing Procedure....6239
Follow-On Procedure....6239
Clearing Fault Codes....6240
Overview....6240
Special Tools....6240
Equipment Conditions....6240
Clearing Procedure....6240
Follow-On Procedure....6240
Modifying Signals Tab....6241
Overview....6241
Special Tools....6241
Equipment Conditions....6241
Modify Watched Signal Columns....6241
Modify Watched Signals....6242
Follow-On Procedure....6242
Programming Modules....6243
Overview....6243
Special Tools....6243
Equipment Conditions....6243
Programming Procedure....6244
Follow-On Procedure....6247
Input Not Recognized by Body Control Module....6248
Overview....6248
Special Tools....6248
Equipment Conditions....6248
Troubleshooting Procedure....6248
Follow-On Procedure....6249
Output Not Commanded by Body Control Module....6250
Overview....6250
Special Tools....6250
Equipment Conditions....6250
Troubleshooting Procedure....6250
Follow-On Procedure....6251
3. General Electrical Repair....6252
Electrical Connector Cleaning....6252
Overview....6252
Special Tools....6252
Specifications....6252
Equipment Conditions....6252
Cleaning Procedure....6252
Follow-On Procedure....6252
4. 12 Volt Electrical System....6253
Battery Box - DuraStar....6253
Overview....6253
Battery Box - WorksStar....6254
Overview....6254
Battery Box....6255
Overview....6255
Battery Disconnect....6258
Special Tools....6258
Torque Specifications....6258
Equipment Conditions....6258
Disconnect Procedure....6259
Follow-On Procedure....6259
Battery Reconnect....6260
Special Tools....6260
Torque Specifications....6260
Equipment Conditions....6260
Reconnect Procedure....6261
Follow-On Procedure....6261
Battery Terminal Cleaning....6262
Overview....6262
Special Tools....6262
Equipment Conditions....6262
Cleaning Procedure....6263
Follow-On Procedure....6263
Battery Disconnect Switch....6264
Overview....6264
Brake Switch....6265
Overview....6265
SPN 597 FMI 0 – Brake Switch reading above normal range....6268
Overview....6268
Associated Faults....6268
Fault Facts....6268
Tools Required....6268
Possible Causes....6268
SPN 597 FMI 1 – Brake Switch reading below normal range....6271
Overview....6271
Associated Faults....6271
Fault Facts....6271
Possible Causes....6271
CAN Systems....6273
Overview....6273
Faults....6273
Short....6273
Terminating Resistor Failure....6273
Backbone Open....6273
Node Open....6274
Tests....6275
Module Communication Test....6275
Overview....6275
Tools Required....6275
Equipment Condition....6275
Test Setup....6275
Test Procedure....6276
Follow-On Procedure....6276
Remote Start / Stop....6277
Overview....6277
500K....6279
Overview....6279
Operational Checkout Procedure....6280
Overview....6280
Not Operating....6281
Fault Overview....6281
Fault Facts....6281
Possible Causes....6281
Pin-Point Test - Remote Start / Stop Not Operating with 500K....6288
Tools Required....6288
250K....6289
Overview....6289
Operational Checkout Procedure....6291
Charging and Starting System....6292
Operational Checkout Procedure....6293
Electrical System Operational Checkout Procedure....6293
Starting System....6294
System Overview....6294
Battery Pack....6294
Starter....6294
Control....6294
No Click No Crank....6295
Overview....6295
Possible Causes....6295
Click No Crank....6297
Overview....6297
Possible Causes....6297
Low Cranking Speed....6299
Overview....6299
Possible Causes....6299
250K Input Diagnostics....6300
Overview....6300
Navistar Starter Input Diagnostics....6301
Navistar Starter Input Pinpoint Tests....6304
Cummins Starter Input Diagnostics....6310
Cummins Starter Input Pinpoint Tests....6314
500K Input Diagnostics....6317
Overview....6317
Key Switch and Grid Control....6317
Crank Inhibit....6317
GridCtrl_CrankInhibit....6317
Crank_Inhibit_Reason....6317
Lower_Clutch_Signal....6318
Neutral_Status_TCM....6318
Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal)....6318
Hood_Switch....6318
500K Input Operational Checkout Procedure....6320
Overview....6320
Charging System....6324
Overview....6324
Battery Pack....6324
Alternator....6324
Red Battery Warning Light....6325
Overview....6325
Possible Causes....6325
Repeated Jump Starts....6327
Overview....6327
Possible Causes....6327
Battery Gauge Reading High....6329
Overview....6329
Possible Causes....6329
Battery Gauge Reading Low / Fluctuating....6330
Overview....6330
Possible Causes....6330
Tests....6332
Individual Battery Test....6332
Overview....6332
Special Tools....6332
Equipment Condition....6332
Test Setup....6332
Test Procedure....6333
Expected Outcome....6335
Follow-On Procedure....6335
Electrical System Test....6336
Overview....6336
Special Tools....6336
Equipment Condition....6337
Test Setup....6337
Battery Pack Test Procedure....6339
Starter System Test Procedure....6342
Charging System Test Procedure....6344
Expected Outcome....6347
Follow-On Procedure....6347
Cable Drop Test....6348
Overview....6348
Special Tools....6348
Equipment Condition....6348
Test Setup....6348
Test Procedure....6348
Expected Outcome....6351
Follow-On Procedure....6351
Parasitic Draw Test....6352
Overview....6352
Tools Required....6352
Equipment Condition....6352
Test Setup....6352
Test Procedure....6352
Expected Outcome....6355
Follow-On Procedure....6355
Manual Engine Bar Test....6356
Overview....6356
Tools Required....6356
Equipment Condition....6356
Test Setup....6356
Test Procedure....6356
Expected Outcome....6356
Follow-On Procedure....6356
Starter Control Circuit Test....6357
Overview....6357
Spacial Tools....6357
Equipment Condition....6357
Test Setup....6357
Test Procedure....6357
Expected Outcome....6358
Follow-On Procedure....6358
Inspections....6359
Ring Gear Inspection....6359
Overview....6359
Special Tools....6359
Equipment Condition....6359
Inspection Procedure....6359
Expected Outcome....6360
Follow-On Procedure....6361
Electrical System Inspection....6362
Overview....6362
Special Tools....6362
Equipment Condition....6362
Inspection Procedure....6362
Expected Outcome....6363
Follow-On Procedure....6363
5. Accessories....6364
Air Dryer and Heated Drain Valve....6364
Overview....6364
Diagnostics....6364
Air Horn....6366
Overview....6366
Operational Checkout Procedure....6367
Air Horn Test....6368
Air Solenoid....6369
Overview....6369
Operational Checkout Procedure....6379
Air Solenoid Diagnosis....6380
Auxiliary Power Source....6381
Overview....6381
Diagnostics....6381
Axle Load Monitor....6383
Overview....6383
User Programmable Parameters....6383
Diagnostic Trouble Codes (DTC)....6385
Diagnostics....6387
Body Controller Signals....6389
Body Controller Functions....6390
To activate the axle load monitor feature, the following conditions must be true:....6390
C.B. Power Radio....6391
Overview....6391
Diagnostics....6391
Cigar Lighter and Power Feed ....6393
Overview....6393
Diagnostics....6393
Cruise Control....6396
Overview....6396
Operational Checkout Procedure....6398
Cruise Control Switch Tests....6399
Customer Installed Lift Gate Power Source....6401
Overview....6401
User Programmable Parameters....6401
Diagnostics....6403
Differential Lock, Air Controlled....6404
Overview....6404
User Programmable Parameters....6405
Diagnostics....6407
Electric Horn....6410
Overview....6410
Operational Checkout Procedure....6411
Electric Horn Test....6412
Fifth Wheel Slide, Air Controlled....6413
Overview....6413
User Programmable Parameters....6413
Diagnostics....6414
Fuel Transfer Pump....6416
Overview....6416
User Programmable Parameters....6416
Diagnostics....6419
Heated Mirrors....6423
Overview....6423
Feature Codes....6424
Diagnostic Trouble Codes....6426
Diagnostics....6427
Heated Seats....6429
Overview....6429
Diagnostics....6429
Load Shedding....6430
Overview....6430
Latching Relay Diagnostics....6430
Power Divider Lock, Air Controlled....6432
Overview....6432
User Programmable Parameters....6432
Diagnostics....6434
Power Take Off (PTO)....6435
Overview....6435
Operational Checkout Procedure....6460
PTO Test....6462
Power Windows and Locks....6463
Overview....6463
Operational Checkout Procedure....6466
Power Windows....6467
Overview....6467
Operational Checkout Procedure....6469
Power Window Test....6470
Power Door Locks....6471
Overview....6471
Operational Checkout Procedure....6473
Power Door Lock Tests....6474
Power Mirrors....6475
Overview....6475
Diagnostics....6476
Radio and Speakers....6479
Overview....6479
Diagnostics....6479
Remote Power Module....6481
Overview....6481
RPM Addressing....6481
Operational Checkout Procedure....6486
RPM Diagnostics....6487
Roof Auxiliary and Air Shield Light....6488
Overview....6488
Roof Auxiliary Load....6489
Overview....6489
Operational Checkout Procedure....6489
Roof Auxiliary Load Test....6490
Lighted Air Shield....6491
Overview....6491
Lighted Air Shield Preliminary Check....6491
Lighted Air Shield Test....6492
Seat Belt and Seat Sensor....6493
Overview....6493
Feature Codes....6493
User programmable parameters....6493
Diagnostics....6494
Self Contained Air Seat....6495
Overview....6495
Diagnostics....6495
Suspension Dump....6496
Overview....6496
User Programmable Parameters....6496
Diagnostics....6499
Theft Deterrent System....6501
Overview....6501
Operational Checkout Procedure....6503
Theft Deterrent System Not Responding....6504
Fault Overview....6504
Fault Facts....6504
Possible Causes....6504
Two-speed Axle Switch....6507
Overview....6507
Diagnostics....6507
Two-way Radio....6508
Overview....6508
Diagnostics....6508
Water In Fuel Monitor Test....6509
Overview....6509
Diagnostics....6509
Wheelchair Lift Interlock....6511
Overview....6511
Activate Wheelchair Lift Solenoid....6511
Activate Audible Alarm....6512
Diagnostic Trouble Codes....6514
Operational Checkout Procedure....6515
6. Aftertreatment....6518
Overview....6518
Operation....6518
Aftertreatment Definitions....6519
Soot Accumulation Level Indications....6519
Feature Related Text Messages in the Gauge Cluster....6521
Feature Codes....6521
Diagnostic Trouble Codes....6523
Body Controller Signals....6526
Body Controller Functions....6528
Parked Regeneration....6529
Inhibit Regeneration....6530
Parked Regeneration Switch Indicator....6531
Inhibit Regeneration Switch Indicator....6532
DPF Status Warning Lamp....6533
HEST Warning Lamp....6534
Audible Alarm....6535
Aftertreatment Troubleshooting....6536
Parked Regeneration Switch Test....6536
Parked Regeneration Switch Indicator Test....6537
Inhibit Regeneration Switch Test....6537
Inhibit Regeneration Switch Indicator Test....6538
DPF Status Warning Lamp Test....6538
HEST Warning Lamp Test....6538
Lamp Check....6538
Lost Communication and Warning Lamp Diagnostics....6539
7. Brakes and Traction Control System....6540
Bendix Air Brake System....6540
Anti-Lock Brake System (ABS)....6540
Overview....6540
Inputs....6543
Outputs....6544
Operational Checkout Procedure....6546
Overview....6546
ABS Module Loss of Communication....6547
Overview....6547
Fault Facts....6547
Tools Required....6547
Possible Causes....6547
Automatic Traction Control (ATC) System....6550
Overview....6550
Inputs....6552
Outputs....6552
Electronic Stability Control (ESC) System....6554
Overview....6554
Inputs....6556
Outputs....6557
Wabco Hydraulic Brake System....6560
SmartTrac Anti-Lock Brake System (ABS)....6560
Overview....6560
Operational Checkout Procedure....6568
Overview....6568
Low Brake Fluid Level Diagnostics....6571
Overview....6571
Associated Faults....6571
Fault Facts....6571
Special Tools....6571
Possible Causes....6571
ABS Diagnostics....6574
Overview....6574
Associated Faults....6575
Fault Facts....6575
Special Tools....6575
Possible Causes....6575
SPN 1044 FMI 3 Hydraulic Pump Motor – Above Normal....6582
Overview....6582
Associated Faults....6582
Fault Facts....6582
Special Tools....6582
Possible Causes....6582
SPN 1044 FMI 4 Hydraulic Pump Motor – Below Normal....6586
Overview....6586
Associated Faults....6586
Fault Facts....6586
Special Tools....6586
Possible Causes....6586
SPN 1044 FMI 5 Hydraulic Pump Motor – Open....6592
Overview....6592
Associated Faults....6592
Fault Facts....6592
Special Tools....6592
Possible Causes....6592
SPN 2584 FMI 3 Hydraulic Brake Pressure Warning State Circuit 1 – Above Normal....6596
Overview....6596
Associated Faults....6596
Fault Facts....6596
Special Tools....6596
Possible Causes....6596
SPN 2584 FMI 4 Hydraulic Brake Pressure Warning State Circuit 1 – Below Normal....6603
Overview....6603
Associated Faults....6603
Fault Facts....6603
Special Tools....6603
Possible Causes....6603
SPN 2584 FMI 5 Hydraulic Brake Pressure Warning State Circuit 1 – Open....6610
Overview....6610
Associated Faults....6610
Fault Facts....6610
Special Tools....6610
Possible Causes....6610
SPN 2931 FMI 1 Hydraulic Brake Fluid Level Switch — Below Normal....6616
Overview....6616
Associated Faults....6616
Fault Facts....6616
Possible Causes....6617
SPN 520941 FMI 5 Hydro-Max Control output of BC – Open....6618
Overview....6618
Associated Faults....6618
Fault Facts....6618
Special Tools....6618
Possible Causes....6618
SPN 520941 FMI 6 Hydro-Max Control output of BC – Shorted to Ground / Over Current....6629
Overview....6629
Associated Faults....6629
Fault Facts....6629
Special Tools....6629
Possible Causes....6629
Hydraulic Brake System Inspection....6633
Overview....6633
Special Tools....6633
Equipment Condition....6633
Test Setup....6633
Test Procedure....6634
Expected Outcome....6634
Automatic Traction Control System with SmartTrac....6635
Overview....6635
Full Power Anti-Lock Brake System (ABS)....6638
Overview....6638
Standard Features....6638
System Layout....6641
System Components....6642
Hydraulic Compact Unit (HCU)....6643
Electronic Control Unit (ECU)....6648
Wheel Speed Sensors....6649
Service Brakes (Normal Braking)....6651
Normal Operation (Brakes Applied)....6652
Normal Braking with Electronic Brakeforce Distribution....6653
Anti-lock Brake System (ABS)....6653
ABS Decrease Pressure Stage....6656
ABS Hold Stage....6658
ABS Increase Pressure Stage....6660
Warning Indicators....6660
Service Procedures....6661
Fault Detection....6662
TOOLBOX™ Software....6663
Diagnostic Trouble Codes....6663
Observing Signals with the EZ-Tech® Service Tool....6663
Definitions....6664
Tech Tips....6664
Troubleshooting Tables....6665
General Information Regarding the Driver Interface....6665
Troubleshooting Table (System Reaction)....6665
Multiple Failures Table....6666
Special System Conditions....6666
Repair Instructions....6666
ABS and ATC Wiring Inspection....6681
Overview....6681
Special Tools....6681
Equipment Conditions....6681
Inspection Procedure....6681
Follow-On Procedure....6681
Wheel Speed Sensor Output Voltage Test....6682
Overview....6682
Special Tools....6682
Equipment Conditions....6682
Test Setup....6682
Test Procedure....6682
Front Axle....6682
Rear Axle....6682
Follow-On Procedure....6683
Wheel Speed Sensor Resistance....6684
Overview....6684
Special Tools....6684
Equipment Conditions....6684
Test Setup....6684
Test Procedure....6684
Follow-On Procedure....6684
Automatic Traction Control System with Full Power Brakes....6685
Overview....6685
TRAC CTRL Indicator....6685
Traction Control Mud/Snow Switch....6686
ATC Inactive (ATC Circuit Operation with No ATC Event Occurring)....6688
ATC Active (ATC Circuit Operation while Experiencing an ATC Event)....6690
Warning Indicators....6690
Service Procedures....6692
Fault Detection....6693
TOOLBOX™ Software....6694
Diagnostic Trouble Codes....6694
Observing Signals with the EZ-Tech® Service Tool....6694
Definitions....6694
Tech Tips....6695
Parking Brake....6696
Overview....6696
Park Brake Indicator....6697
Park Brake Switch Diagnostics....6698
Overview....6698
Associated Faults....6698
Fault Facts....6698
Special Tools....6698
Possible Causes....6698
8. Collision Mitigation Systems....6702
Bendix® Wingman® Advanced™....6702
Overview....6702
Adaptive Cruise Control (ACC)....6705
Alerts....6705
Collision Mitigation Braking....6705
Tech Tips....6707
Operational Checkout Procedure....6708
Overview....6708
Special Tools....6708
Driver Interface Unit....6710
Electrical Test....6710
Overview....6710
Special Tools....6710
Equipment Conditions....6710
Test Setup....6710
Follow-On Procedure....6712
Removal....6713
Overview....6713
Special Tools....6713
Equipment Conditions....6713
Removal Procedure....6713
Follow-On Procedure....6713
Installation....6714
Overview....6714
Special Tools....6714
Torque Specifications....6714
Equipment Conditions....6714
Installation Procedure....6714
Follow-On Procedure....6714
Radar Sensor....6715
Electrical Test....6715
Overview....6715
Special Tools....6715
Equipment Conditions....6715
Test Setup....6715
Follow-On Procedure....6717
Removal....6718
Overview....6718
Special Tools....6718
Equipment Conditions....6718
Removal Procedure....6718
Follow-On Procedure....6719
Installation....6720
Overview....6720
Special Tools....6720
Torque Specifications....6720
Equipment Conditions....6720
Installation Procedure....6720
Follow-On Procedure....6721
Adjustment....6722
Overview....6722
Special Tools....6722
Equipment Conditions....6722
Lateral Adjustment Procedure....6722
Vertical Adjustment Procedure....6724
Follow-On Procedure....6726
Bendix® Wingman® Fusion™....6727
Overview....6727
The following features are included with Bendix Wingman Fusion:....6728
Adaptive Cruise Control (ACC)....6729
Alerts....6729
Collision Mitigation Braking....6729
SafetyDirect Capability....6730
Stationary Vehicle Braking (SVB)....6730
Tech Tips....6731
Operational Checkout Procedure....6732
Overview....6732
Special Tools....6732
Camera Bracket....6735
Removal....6735
Overview....6735
Special Tools....6735
Equipment Conditions....6735
Removal Procedure....6736
Follow-On Procedure....6736
Installation....6737
Overview....6737
Special Tools....6737
Equipment Conditions....6737
Installation Procedure....6738
Follow-On Procedure....6739
Camera Sensor....6740
Electrical Test....6740
Overview....6740
Special Tools....6740
Equipment Conditions....6740
Test Setup....6740
Follow-On Procedure....6742
Removal....6743
Overview....6743
Special Tools....6743
Equipment Conditions....6743
Removal Procedure....6743
Follow-On Procedure....6744
Installation....6745
Overview....6745
Special Tools....6745
Torque Specifications....6745
Equipment Conditions....6745
Installation Procedure....6745
Follow-On Procedure....6746
SafetyDirect® Module....6747
Electrical Test....6747
Overview....6747
Special Tools....6747
Equipment Conditions....6747
Test Setup....6747
Follow-On Procedure....6749
Removal....6750
Overview....6750
Special Tools....6750
Equipment Conditions....6750
Removal Procedure....6750
Follow-On Procedure....6750
Installation....6751
Overview....6751
Special Tools....6751
Torque Specifications....6751
Equipment Conditions....6751
Installation Procedure....6751
Follow-On Procedure....6751
9. Engine....6752
Cummins - DuraStar....6752
Overview....6752
Cummins - WorkStar....6754
Overview....6754
Cummins Diagnostics....6756
Table Of Contents....6756
Fault Code Diagnostics....6757
Fault Code List....6757
SPN 111 FMI 1 (Cummins FC 235) - Coolant Level - Data Valid But Below Normal Operating Range - Most Severe Level....6759
Fault Overview....6759
Associated Faults....6759
Fault Facts....6759
Conditions For Clearing The Fault Codes....6759
Possible Causes....6759
SPN 111 FMI 3 (Cummins FC 195) - Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source....6771
Fault Overview....6771
Associated Faults....6771
Fault Facts....6771
Conditions For Clearing The Fault Codes....6771
Possible Causes....6771
SPN 111 FMI 4 (Cummins FC 196) - Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source....6783
Fault Overview....6783
Associated Faults....6783
Fault Facts....6783
Conditions For Clearing The Fault Codes....6783
Possible Causes....6783
SPN 111 FMI 17 (Cummins FC 2448) - Coolant Level - Data Valid But Below Normal Operating Range - Least Severe Level....6795
Fault Overview....6795
Associated Faults....6795
Fault Facts....6795
Conditions For Clearing The Fault Codes....6795
Possible Causes....6795
SPN 111 FMI 18 (Cummins FC 197) - Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level....6807
Fault Overview....6807
Associated Faults....6807
Fault Facts....6807
Conditions For Clearing The Fault Codes....6807
Possible Causes....6807
SPN 1569 FMI 15 (Cummins FC 6255) - Engine Protection Torque Derate - Data Valid But Above Normal Operating Range - Least Severe Level....6819
Fault Overview....6819
Associated Faults....6819
Fault Facts....6819
Conditions For Clearing The Fault Codes....6819
Possible Causes....6819
SPN 1569 FMI 31 (Cummins FC 3714) - Engine Protection Torque Derate - Condition Exists....6820
Fault Overview....6820
Conditions For Clearing The Fault Codes....6820
Associated Faults....6820
Fault Facts....6820
Possible Causes....6820
SPN 1761 FMI 1 (Cummins FC 1673) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Most Severe Level....6821
Fault Overview....6821
Associated Faults....6821
Fault Facts....6821
Conditions For Clearing The Fault Codes....6821
Possible Causes....6821
SPN 1761 FMI 3 (Cummins FC 1669) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Above Normal or Shorted to High Source....6822
Fault Overview....6822
Associated Faults....6822
Fault Facts....6822
Conditions For Clearing The Fault Codes....6822
Possible Causes....6822
SPN 1761 FMI 4 (Cummins FC 1668) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Below Normal or Shorted to Low Source....6823
Fault Overview....6823
Associated Faults....6823
Fault Facts....6823
Conditions For Clearing The Fault Codes....6823
Possible Causes....6823
SPN 1761 FMI 9 (Cummins FC 4677) Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Abnormal Update Rate ....6824
Fault Overview....6824
Associated Faults....6824
Fault Facts....6824
Conditions For Clearing The Fault Codes....6824
Possible Cause....6824
SPN 1761 FMI 10 (Cummins FC 4769) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal Rate of Change....6829
Fault Overview....6829
Associated Faults....6829
Fault Facts....6829
Conditions For Clearing The Fault Codes....6829
Possible Causes....6829
SPN 1761 FMI 11 (Cummins FC 4739) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Root Cause Not Known....6832
Fault Overview....6832
Associated Faults....6832
Fault Facts....6832
Conditions For Clearing The Fault Codes....6832
Possible Causes....6832
SPN 1761 FMI 13 (Cummins FC 4732) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of Calibration....6833
Fault Overview....6833
Associated Faults....6833
Fault Facts....6833
Conditions For Clearing The Fault Codes....6833
Possible Causes....6833
SPN 1761 FMI 17 (Cummins FC 3497) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Least Severe Level....6835
Fault Overview....6835
Associated Faults....6835
Fault Facts....6835
Conditions For Clearing The Fault Codes....6835
Possible Causes....6835
SPN 1761 FMI 18 (Cummins FC 3498) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range -Moderately Severe Level ....6836
Fault Overview....6836
Associated Faults....6836
Fault Facts....6836
Conditions For Clearing The Fault Codes....6836
Possible Causes....6836
SPN 3031 FMI 2 (Cummins FC 1679) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic, Intermittent, or Incorrect....6837
Fault Overview....6837
Associated Faults....6837
Fault Facts....6837
Conditions For Clearing The Fault Codes....6837
Possible Causes....6837
SPN 3031 FMI 3 (Cummins FC 1678) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Above Normal or Shorted to High Source ....6839
Fault Overview....6839
Associated Faults....6839
Fault Facts....6839
Conditions For Clearing The Fault Codes....6839
Possible Causes....6839
SPN 3031 FMI 4 (Cummins FC 1677) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Below Normal or Shorted to Low Source....6841
Fault Overview....6841
Associated Faults....6841
Fault Facts....6841
Conditions For Clearing The Fault Codes....6841
Possible Causes....6841
SPN 3031 FMI 9 (Cummins FC 4572) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal Update Rate....6843
Fault Overview....6843
Associated Faults....6843
Fault Facts....6843
Conditions For Clearing The Fault Codes....6843
Possible Cause....6843
SPN 3031 FMI 11 (Cummins FC 4737) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause Not Known....6849
Fault Overview....6849
Associated Faults....6849
Fault Facts....6849
Conditions For Clearing The Fault Codes....6849
Possible Causes....6849
SPN 3031 FMI 13 (Cummins FC 4731) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out of Calibration....6850
Fault Overview....6850
Associated Faults....6850
Fault Facts....6850
Conditions For Clearing The Fault Codes....6850
Possible Causes....6850
SPN 3364 FMI 2 (Cummins FC 3878) - Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or Incorrect....6852
Fault Overview....6852
Associated Faults....6852
Fault Facts....6852
Conditions For Clearing The Fault Codes....6852
Possible Causes....6852
SPN 3364 FMI 3 (Cummins FC 1686) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Above Normal or Shorted to High Source....6853
Fault Overview....6853
Associated Faults....6853
Fault Facts....6853
Conditions For Clearing The Fault Codes....6853
Possible Cause....6853
SPN 3364 FMI 4 - (Cummins 1685) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Below Normal or Shorted to Low Source....6855
Fault Overview....6855
Associated Faults....6855
Fault Facts....6855
Conditions For Clearing The Fault Codes....6855
Possible Cause....6855
SPN 3364 FMI 9 (Cummins FC 3868) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate....6857
Fault Overview....6857
Associated Faults....6857
Fault Facts....6857
Conditions For Clearing The Fault Codes....6857
Possible Cause....6857
SPN 3364 FMI 10 (Cummins FC 4277) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate of Change ....6862
Fault Overview....6862
Associated Faults....6862
Fault Facts....6862
Conditions For Clearing The Fault Codes....6862
Possible Causes....6862
SPN 3364 FMI 11 (Cummins FC 1715) - Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known....6865
Fault Overview....6865
Associated Faults....6865
Fault Facts....6865
Conditions For Clearing The Fault Codes....6865
Possible Causes....6865
SPN 3364 FMI 13 (Cummins FC 1714) - Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration....6866
Fault Overview....6866
Associated Faults....6866
Fault Facts....6866
Conditions For Clearing The Fault Codes....6866
Possible Causes....6866
SPN 3364 FMI 15 (Cummins FC 4842) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal Operating Range - Least Severe Level....6868
Fault Overview....6868
Associated Faults....6868
Fault Facts....6868
Conditions For Clearing The Fault Codes....6868
Possible Causes....6868
SPN 3364 FMI 18 (Cummins FC 3867) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal Operating Range - Moderately Severe Level....6870
Fault Overview....6870
Associated Faults....6870
Fault Facts....6870
Conditions For Clearing The Fault Codes....6870
Possible Causes....6870
SPN 3521 FMI 11 (Cummins FC 4768) - Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known....6872
Fault Overview....6872
Associated Faults....6872
Fault Facts....6872
Conditions For Clearing The Fault Codes....6872
Possible Causes....6872
SPN 3521 FMI 16 (Cummins FC 6765) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above Normal Operating Range - Moderately Severe Level....6873
Fault Overview....6873
Associated Faults....6873
Fault Facts....6873
Conditions For Clearing The Fault Codes....6873
Possible Causes....6873
SPN 3521 FMI 18 (Cummins FC 6766) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below Normal Operating Range - Moderately Severe Level....6875
Fault Overview....6875
Associated Faults....6875
Fault Facts....6875
Conditions For Clearing The Fault Codes....6875
Possible Causes....6875
SPN 3521 FMI 31 (Cummins FC 4235) - Aftertreatment 1 Diesel Exhaust Fluid Property- Condition Exists....6877
Fault Overview....6877
Associated Faults....6877
Fault Facts....6877
Conditions For Clearing The Fault Codes....6877
Possible Causes....6877
SPN 4096 FMI 31 (Cummins FC 3547) - Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition Exists....6879
Fault Overview....6879
Associated Faults....6879
Fault Facts....6879
Conditions For Clearing The Fault Codes....6879
Possible Causes....6879
SPN 5246 FMI 0 (Cummins FC 3712) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Most Severe Level....6880
Fault Overview....6880
Associated Faults....6880
Fault Facts....6880
Conditions For Clearing The Fault Codes....6880
Possible Causes....6880
SPN 5246 FMI 15 (Cummins FC 4134) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Least Severe Level....6881
Fault Overview....6881
Associated Faults....6881
Fault Facts....6881
Conditions For Clearing The Fault Codes....6881
Possible Causes....6881
SPN 5246 FMI 16 (Cummins FC 6254) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Moderately Severe Level....6882
Fault Overview....6882
Associated Faults....6882
Fault Facts....6882
Conditions For Clearing The Fault Codes....6882
Possible Causes....6882
Tests and Inspections....6883
Overview....6883
DEF Head Unit Coolant Line Routing Inspection....6884
Overview....6884
Tools Required....6884
Equipment Condition....6884
Inspection Procedure....6884
Expected Outcome....6885
DEF Quality Test....6886
Overview....6886
Tools Required....6886
Equipment Condition....6886
Test Procedure....6886
Expected Outcome....6887
DEFTHV Coolant Flow Test....6888
Overview....6888
Tools Required....6888
Equipment Condition....6888
Test Setup....6888
Test Procedure....6888
Expected Outcome....6888
10. Engine Accessories....6889
Engine Cooling Fan Control....6889
Overview....6889
Operation....6889
Feature Codes....6890
Diagnostic Trouble Codes....6891
Operational Checkout....6892
Body Controller Signals....6893
Body Controller Functions....6895
Fan Control — General Information....6895
ON/OFF Fan Control....6895
Low Air Pressure Engine Fan Override (0595BBB)....6896
Variable Speed Fan Control (0595AYH)....6896
Exhaust Brake....6899
Overview....6899
Operation....6899
Feature Codes....6899
Diagnostic Trouble Codes....6899
Operational Checkout....6901
Exhaust Brake Switch Test....6902
Body Controller Signals....6903
Body Controller Functions....6903
To activate the exhaust brake feature, the following conditions must be true:....6903
If the conditions to activate the feature (above) are true, then the following will occur:....6903
Remote Engine Speed Control Module (RESCM)....6904
Overview....6904
Operation....6904
Feature Codes....6905
User Programmable Parameters....6905
Diagnostic Trouble Codes....6906
RESCM Preliminary Check....6911
Body Controller Signals....6912
Body Controller Functions....6914
Snow Valve (engine intake) (big bore engines)....6915
The snow valve (engine intake) feature turns a drum inside the air cleaner to divert engine air intake from outside of the vehicle to inside the engine compartment. This prevents heavy snow from clogging the air intake.....6915
Operation....6915
Feature Codes....6916
User Programmable Parameters....6916
Diagnostic Trouble Codes....6916
Snow Valve Operational Checkout....6917
Snow Valve Mechanical Checks....6918
Snow Valve Switch Test....6919
Snow Valve Module Checks....6920
Body Controller Signals....6922
Body Controller Functions....6922
To activate the feature, the following conditions must be true:....6922
If the conditions to activate the feature (above) are true, then the following will occur:....6922
If any of the following conditions occur, then the feature will be deactivated.....6923
If any of the conditions to deactivate the feature (above) are true, then the following will occur:....6923
Snow Valve (engine intake) (non big bore engines)....6924
Overview....6924
Operation....6924
Operational Checkout....6924
Snow Valve Mechanical Checks....6925
Snow Valve Module Checks....6925
Feature Codes....6926
11. Data Links....6927
J1708 Datalink....6927
J1708 Data Link (ATA)....6927
J1708 Switch Pack Data Link....6928
Overview....6928
Switch Pack Electrical Tests....6930
Overview....6930
Special Tools....6930
Equipment Condition....6930
Test Setup....6930
Test Procedure....6930
Follow On Procedure....6932
12. HVAC....6933
Overview....6933
Condenser....6934
A/C compressor....6934
HVAC controller....6935
Air Distribution (General)....6936
Air Distribution (Air Conditioning)....6938
NORM A/C / Instrument Panel Vent (A)....6939
MAX A/C (B)....6939
Bi-Level A/C (C)....6939
Heat and Ventilation Floor (D)....6939
Bi-Level Defrost / Heat (E)....6939
Defrost (F)....6939
A/C Refrigerant Flow....6940
Compression....6940
Condensation....6941
Expansion....6941
Evaporation....6941
General Operation of the HVAC Electrical System....6941
Operational Checkout Procedure....6942
Overview....6942
Symptoms....6944
A/C Blows Warm All the Time (Incorrect System Pressure)....6944
Overview....6944
Possible Causes....6944
Compressor Does Not Cycle....6948
Overview....6948
Possible Causes....6948
Operator Not Able to Control Air Flow Outlet....6951
Overview....6951
Diagnostics....6955
Diagnostic Trouble Code (DTC) List....6955
SPN 876 FMI 5 – Compressor Clutch Circuit ....6956
Fault Overview....6956
Associated Faults....6956
Fault Facts....6956
Possible Causes....6956
SPN 1552 FMI 2 – A/C Control Head Temperature Mix DM1....6957
Fault Overview....6957
Associated Faults....6957
Fault Facts....6957
Possible Causes....6957
Pin-Point Test SPN 1552 FMI 2....6958
Tools Required....6958
SPN 2609 FMI 16 – A/C High Pressure Protection....6959
Fault Overview....6959
Associated Faults....6959
Fault Facts....6959
Possible Causes....6959
SPN 3981 FMI 2 – A/C Control Head Mode Fault DM1....6962
Fault Overview....6962
Associated Faults....6962
Fault Facts....6962
Possible Causes....6962
Pin-Point Test SPN 3981 FMI 2....6963
Tools Required....6963
SPN 3984 FMI 2 – A/C Control Head Air Inlet DM1....6964
Fault Overview....6964
Associated Faults....6964
Fault Facts....6964
Possible Causes....6964
Pin-Point Test SPN 3984 FMI 2....6965
Tools Required....6965
SPN 3985 FMI 9 – A/C Control Head Circuit Failed To Communicate With Body Controller....6966
Fault Overview....6966
Associated Faults....6966
Fault Facts....6966
Possible Causes....6966
Pin-Point Test SPN 3985 FMI 9....6967
Tools Required....6967
SPN 520465 FMI 2 – A/C Control Head Multiple Motor Faults....6969
Fault Overview....6969
Associated Faults....6969
Fault Facts....6969
Possible Causes....6969
Pin-Point Test SPN 520465 FMI 2....6971
Tools Required....6971
Tests....6974
A/C Compressor Clutch Electrical Tests....6974
Overview....6974
Special Tools....6974
Equipment Condition....6974
Test Setup....6974
Test Procedure....6974
Expected Outcome....6977
Follow-On Procedure....6977
A/C Request Electrical Tests....6978
Overview....6978
Special Tools....6978
Equipment Condition....6978
Test Setup....6978
Test Procedure....6978
Expected Outcome....6979
Follow-On Procedure....6979
A/C System Functional Test....6980
Overview....6980
Special Tools....6980
Equipment Condition....6980
Test Setup....6980
Test Procedure....6980
Expected Outcome....6980
Follow-On Procedure....6980
A/C System Restriction Test....6981
Overview....6981
Special Tools....6981
Equipment Condition....6981
Test Setup....6981
Test Procedure....6981
Expected Outcome....6982
Blend Door Tests....6983
Overview....6983
Special Tools....6983
Equipment Condition....6983
Test Setup....6983
Test Procedure....6984
Expected Outcome....6987
Follow-On Procedure....6987
Blower Motor Electrical Tests....6988
Overview....6988
Special Tools....6988
Equipment Condition....6988
Test Setup....6988
Test Procedure....6988
Expected Outcome....6991
Follow-On Procedure....6991
Body Controller Power and GND Tests....6992
Overview....6992
Special Tools....6992
Equipment Condition....6992
Test Setup....6992
Test Procedure....6992
Expected Outcome....6993
Follow-On Procedure....6993
Charge Quantity Measurement Test....6994
Overview....6994
Special Tools....6994
Equipment Condition....6994
Test Setup....6994
Test Procedure....6994
Compressor Clutch Signal Check....6995
Overview....6995
Special Tools....6995
Equipment Condition....6995
Test Setup....6995
Test Procedure....6996
Expected Outcome....6998
Follow-On Procedure....6998
Control Head Electrical Tests....6999
Overview....6999
Special Tools....6999
Equipment Condition....6999
Test Setup....6999
Test Procedure....6999
Expected Outcome....7001
Follow On Procedure....7001
Freeze Probe Electrical Tests....7002
Overview....7002
Special Tools....7002
Equipment Condition....7002
Test Setup....7002
Test Procedure....7002
Expected Outcome....7004
Follow On Procedure....7004
Heater Core Seal Leak Test....7005
Overview....7005
Special Tools....7005
Equipment Condition....7005
Test Setup....7005
Test Procedure....7006
Expected Outcome....7007
Follow On Procedure....7007
HVAC Actuator Calibration Procedure....7008
Overview....7008
Special Tools....7008
Equipment Condition....7008
Test Setup....7008
Test Procedure....7008
Expected Outcome....7008
Leak Detection Test....7009
Overview....7009
Special Tools....7009
Equipment Conditions....7009
Refrigerant Present....7009
No Refrigerant Present....7010
No Refrigerant Present - High Pressure Nitrogen....7011
Follow-On Procedure....7013
Low-Pressure Switch Electrical Tests....7014
Overview....7014
Special Tools....7014
Equipment Condition....7014
Test Setup....7014
Test Procedure....7014
Expected Outcome....7016
Follow On Procedure....7016
Mode Door Tests....7017
Overview....7017
Special Tools....7017
Equipment Condition....7017
Test Setup....7017
Test Procedure....7018
Expected Outcome....7021
Follow On Procedure....7021
Pressure Transducer Electrical Tests....7022
Overview....7022
Special Tools....7022
Equipment Condition....7022
Three-wire Pressure Transducer Test Procedure....7022
Expected Outcome....7024
Pressure Transducer Functional Test....7025
Overview....7025
Special Tools....7025
Equipment Condition....7025
Test Setup....7025
Pressure Test Procedure....7025
Temperature Test Procedure....7025
Expected Outcome....7026
Recirculation Door Tests....7027
Overview....7027
Special Tools....7027
Equipment Condition....7027
Test Setup....7027
Test Procedure....7028
Expected Outcome....7031
Follow On Procedure....7031
Static Pressure Test....7032
Overview....7032
Special Tools....7032
Equipment Condition....7032
Test Setup....7032
Test Procedure....7032
Expected Outcome....7033
Follow On Procedure....7033
System Performance Test....7034
Overview....7034
Special Tools....7034
Equipment Condition....7034
Test Setup....7034
Test Procedure....7034
Expected Outcome....7035
Follow-On Procedure....7035
Inspections....7036
A/C System Internal Damage Inspection....7036
Overview....7036
Special Tools....7036
Equipment Condition....7036
Inspection Procedure....7036
Expected Outcome....7040
A/C System Inspection....7041
Overview....7041
Special Tools....7041
Equipment Condition....7041
Inspection Procedure....7042
Expected Outcome....7049
HVAC Module Inspection....7050
Overview....7050
Special Tools....7050
Equipment Condition....7050
Test Setup....7050
Inspection Procedure....7050
Expected Outcome....7052
13. Instrumentation and Gauges....7053
Overview....7053
Operational Checkout Procedure....7053
Overview....7053
Step-Based Diagnostics....7054
Audible Alarm....7056
One-time Five-short-beeps Alarm....7056
Repetitive One-short-beep Alarm....7056
One-time Ten-short-beeps Alarm ....7056
One-time Three-long-beeps Alarm....7057
Repetitive Short Duration Blips ....7057
EGC Programming....7057
Gauges....7058
Air 1 Gauge....7058
Overview....7058
Possible Causes....7059
Step Based Diagnostics....7059
Pin-Point Tests — Air 1 Gauge....7062
Tools Required....7063
Air 2 Gauge....7071
Overview....7071
Possible Causes....7072
Step Based Diagnostics....7072
Pin-Point Tests — Air 2 Gauge....7075
Tools Required....7076
Auxiliary Gauge Switch Pack....7083
Overview....7083
In-Gauge Warning Lamps....7083
Gauge Sweep....7083
Lost Communication....7084
Gauge Faults....7085
Diagnostic Trouble Codes....7086
Operational Checkout Procedure....7088
Eaton Hybrid Auxiliary Gauge Pack....7089
AGSP Power and Data Link Voltage Checks....7089
Gauge Troubleshooting Procedure....7089
Troubleshooting Specific Gauges....7091
Forward-Rear Axle Temperature Gauge Troubleshooting....7091
Rear-Rear Axle Temperature Gauge Troubleshooting....7093
Air Application Gauge Troubleshooting....7095
Ammeter Gauge Troubleshooting....7098
Compass Display....7099
Overview....7099
Diagnostic Trouble Codes....7100
DEF Level....7101
Overview....7101
Possible Causes....7101
Step Based Diagnostics....7101
Engine Coolant Temperature....7103
Overview....7103
Step Based Diagnostics....7103
Engine Oil Pressure....7104
Overview....7104
Step Based Diagnostics....7104
Engine Oil Temperature....7105
Overview....7105
Step Based Diagnostics....7105
Engine Speed (Tachometer)....7106
Overview....7106
Step Based Diagnostics....7106
Fuel Level....7107
Overview....7107
Possible Causes....7107
Step Based Diagnostics....7108
Outside Air Temperature....7113
Overview....7113
Step Based Diagnostics....7114
Transmission Temperature....7116
Overview....7116
Possible Causes....7116
Step-Based Diagnostics....7116
Pin-Point Tests....7120
Vehicle Speed (Speedometer)....7122
Overview....7122
Step Based Diagnostics....7122
Voltage....7123
Overview....7123
Possible Causes....7123
Step Based Diagnostics....7123
Special Tools....7123
14. Interior Lighting....7125
Dome and Courtesy Lights....7125
Overview....7125
Operational Checkout Procedure....7126
Dome and Courtesy Light Tests....7127
15. Exterior Lighting....7129
Back Up Lights....7129
Overview....7129
Operational Checkout Procedure....7130
Back Up Lights Test....7131
Brake Switch....7132
Overview....7132
Air Brake Switch....7133
Hydro-Max Hydraulic Brake Switch....7135
Full Power Hydraulic Brake Switch....7137
Operational Checkout Procedure....7140
Overview....7140
Special Tools....7140
Brake Switch Electrical & Circuit Test....7142
Overview....7142
Fault Facts....7142
Special Tools....7142
Possible Causes....7142
SPN 597 FMI 0 – Brake Switch Reading Above Normal Range....7148
Fault Overview....7148
Associated Faults....7148
Fault Facts....7148
Special Tools....7148
Possible Causes....7148
SPN 597 FMI 1 – Brake Switch Reading Below Normal Range....7152
Overview....7152
Associated Faults....7152
Fault Facts....7152
Special Tools....7152
Possible Causes....7152
SPN 597 FMI 2 – Brake Switch Inputs Do Not Match....7154
Fault Overview....7154
Associated Faults....7154
Fault Facts....7154
Special Tools....7154
Possible Causes....7154
SPN 597 FMI 3 – Voltage Above Normal or Short to High Source....7155
Fault Overview....7155
Associated Faults....7155
Fault Facts....7155
Special Tools....7155
Possible Causes....7155
SPN 3541 FMI 6 – Current Above Normal or Grounded Circuit....7157
Fault Overview....7157
Associated Faults....7157
Fault Facts....7157
Special Tools....7157
Possible Causes....7157
Fog Lights....7159
Overview....7159
Operational Checkout Procedure....7161
Overview....7161
Fog Light Input Diagnostics....7164
Fault Overview....7164
Fault Facts....7164
Possible Causes....7164
Fog Light Output - Not Illuminating....7166
Fault Overview....7166
Fault Facts....7166
Possible Causes....7166
Pin-Point Test - Fog Light Output - Not Illuminating....7171
Tools Required....7171
Fog Light Output Diagnostics - Illuminating When Not Requested....7175
Fault Overview....7175
Fault Facts....7175
Possible Causes....7175
Pin-Point Test -Fog Light Output - Illuminating When Not Requested....7178
Tools Required....7178
SPN 2388 FMI 5 - Left Fog Light Open Circuit....7180
Fault Overview....7180
Associated Faults....7180
Fault Facts....7180
Possible Causes....7180
Pin-Point Test - SPN 2388 FMI 5....7182
Tools Required....7182
SPN 2388 FMI 6 - Left Fog Light Short to GND....7184
Fault Overview....7184
Associated Faults....7184
Fault Facts....7184
Possible Causes....7184
Pin-Point Test - SPN 2388 FMI 6....7186
Tools Required....7186
SPN 4008 FMI 5 - Right Fog Light Open Circuit....7188
Fault Overview....7188
Associated Faults....7188
Fault Facts....7188
Possible Causes....7188
Pin-Point Test - SPN 4008 FMI 5....7190
Tools Required....7190
SPN 4008 FMI 6 - Right Fog Light Short to GND....7192
Fault Overview....7192
Associated Faults....7192
Fault Facts....7192
Possible Causes....7192
Pin-Point Test - SPN 4008 FMI 6....7194
Tools Required....7194
Headlights and Daytime Running Lights....7196
Overview....7196
Operational Checkout Procedure....7198
Overview....7198
Low Beam Input Diagnostics....7203
Fault Overview....7203
Fault Facts....7203
Possible Causes....7203
Low Beam Output Diagnostics - Not illuminating....7205
Fault Overview....7205
Fault Facts....7205
Possible Causes....7205
Pin-Point Test - Low Beam Head Lamp Output - Not Illuminating....7210
Tools Required....7210
Low Beam Output Diagnostics - Illuminating When Not Requested....7214
Fault Overview....7214
Fault Facts....7214
Possible Causes....7214
Pin-Point Test - Low Beam Head Lamp Output - Illuminating When Not Requested....7217
Tools Required....7217
SPN 2653 FMI 5 - Left Low Beam Open Circuit....7219
Fault Overview....7219
Associated Faults....7219
Fault Facts....7219
Possible Causes....7219
Pin-Point Test - SPN 2653 FMI 5....7221
Tools Required....7221
Pin-Point Test - SPN 2653 FMI 5....7222
SPN 2653 FMI 6 - Left Low Beam Short to GND....7223
Fault Overview....7223
Associated Faults....7223
Fault Facts....7223
Possible Causes....7223
Pin-Point Test - SPN 2653 FMI 6....7225
Tools Required....7225
SPN 2655 FMI 5 - Right Low Beam Open Circuit....7226
Fault Overview....7226
Associated Faults....7226
Fault Facts....7226
Possible Causes....7226
Pin-Point Test - SPN 2655 FMI 5....7228
Tools Required....7228
SPN 2655 FMI 6 - Right Low Beam Short to GND....7229
Fault Overview....7229
Associated Faults....7229
Fault Facts....7229
Possible Causes....7229
Pin-Point Test - SPN 2655 FMI 6....7231
Tools Required....7231
High Beam Input Diagnostics....7232
Fault Overview....7232
Fault Facts....7232
Possible Causes....7232
Pin-Point Test - High Beam Lamps Input....7235
Tools Required....7235
High Beam Output Diagnostics - Not Illuminating....7238
Fault Overview....7238
Fault Facts....7238
Possible Causes....7238
Pin-Point Test - High Beam Head Lamp Output - Not Illuminating....7243
Tools Required....7243
High Beam Output Diagnostics - Illuminating When Not Requested....7247
Fault Overview....7247
Fault Facts....7247
Possible Causes....7247
Pin-Point Test - High Beam Head Lamp Output - Illuminating When Not Requested....7250
Tools Required....7250
SPN 4011 FMI 5 - Left High Beam Open Circuit....7252
Fault Overview....7252
Associated Faults....7252
Fault Facts....7252
Possible Causes....7252
Pin-Point Test - SPN 4011 FMI 5....7254
Tools Required....7254
SPN 4011 FMI 6 - Left High Beam Short to Ground....7255
Fault Overview....7255
Associated Faults....7255
Fault Facts....7255
Possible Causes....7255
Pin-Point Test - SPN 4011 FMI 6....7257
Tools Required....7257
SPN 4012 FMI 5 - Right High beam Open Circuit....7258
Fault Overview....7258
Associated Faults....7258
Fault Facts....7258
Possible Causes....7258
Pin-Point Test - SPN 4012 FMI 5....7260
Tools Required....7260
SPN 4012 FMI 6 - Right High Beam Short to Ground....7261
Fault Overview....7261
Associated Faults....7261
Fault Facts....7261
Possible Causes....7261
Pin-Point Test - SPN 4012 FMI 6....7263
Tools Required....7263
Park and Marker Lights....7264
Overview....7264
Operational Checkout Procedure....7266
Overview....7266
Park Light Input Diagnostics....7270
Fault Overview....7270
Fault Facts....7270
Possible Causes....7270
Park Light Output - Not Illuminating....7272
Fault Overview....7272
Fault Facts....7272
Possible Causes....7272
Pin-Point Test - Park Light Output - Not Illuminating....7275
Tools Required....7275
Park Light Output Diagnostics - Illuminating When Not Requested....7277
Fault Overview....7277
Fault Facts....7277
Possible Causes....7277
Pin-Point Test - Park Light Output - Illuminating When Not Requested....7279
Tools Required....7279
SPN 2378 FMI 5 - Park Light UnderCurrent....7281
Fault Overview....7281
Associated Faults....7281
Fault Facts....7281
Possible Causes....7281
Pin-Point Test - SPN 2378 FMI 5....7283
Tools Required....7283
SPN 2378 FMI 6 - Park Light OverCurrent....7285
Fault Overview....7285
Associated Faults....7285
Fault Facts....7285
Possible Causes....7285
Pin-Point Test - SPN 2378 FMI 6....7287
Tools Required....7287
SPN 4024 FMI 2 - Marker Light Interrupt Switch Failure....7289
Fault Overview....7289
Associated Faults....7289
Fault Facts....7289
Possible Causes....7289
Snow Plow Lights....7291
Snow Plow Light System Overview....7291
Operational Checkout Procedure....7293
Overview....7293
Snow Plow Light Input Diagnostics....7296
Fault Overview....7296
Fault Facts....7296
Possible Causes....7296
Snow Plow Light Output - Not Illuminating....7298
Fault Overview....7298
Fault Facts....7298
Possible Causes....7298
Pin-Point Test - Snow Plow Light Output - Not Illuminating....7302
Tools Required....7302
Snow Plow Low Beam Gen 4 Output - Not illuminating....7303
Fault Overview....7303
Fault Facts....7303
Possible Causes....7303
Pin-Point Test - Snow Plow Low Beam Gen 4 Output - Not illuminating....7306
Tools Required....7306
Snow Plow High Beam Gen 4 Output - Not illuminating....7307
Fault Overview....7307
Fault Facts....7307
Possible Causes....7307
Pin-Point Test - Snow Plow High Beam Gen 4 Output - Not illuminating....7310
Tools Required....7310
Stop, Turn, and Hazard Lights....7311
Overview....7311
Operational Checkout Procedure....7312
Overview....7312
Turn Signal, Hazard, and Front Turn Lamp Diagnostics....7320
Overview....7320
Hazard Input Diagnostics....7322
Feature Code Overview....7322
Fault Facts....7322
Possible Causes....7322
Pin-Point Test - Hazard Input Diagnostics....7325
Tools Required....7325
Turn Signal Input Diagnostics....7331
Feature Code Overview....7331
Fault Facts....7331
Possible Causes....7331
Pin-Point Test - Turn Signal Input Diagnostics....7334
Tools Required....7334
Front Turn Lamp Not Illuminating....7340
Feature Code Overview....7340
Fault Facts....7340
Possible Causes....7340
Pin-Point Test- Front Turn Lamp Output Not Illuminating....7344
Tools Required....7344
Front Turn Lamps Illuminating When Not Requested....7348
Feature Code Overview....7348
Fault Facts....7348
Possible Causes....7348
Pin-Point Test - Front Turn Lamps Illuminating When Not Requested....7350
Tools Required....7350
SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7352
Fault Overview....7352
Associated Faults....7352
Fault Facts....7352
Possible Causes....7352
Pin-Point Test SPN 2368 FMI 5....7354
Tools Required....7354
SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7356
Fault Overview....7356
Associated Faults....7356
Fault Facts....7356
Possible Causes....7356
Pin-Point Test SPN 2368 FMI 6....7358
Tools Required....7358
SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7360
Fault Overview....7360
Associated Faults....7360
Fault Facts....7360
Possible Causes....7360
Pin-Point Test SPN 2370 FMI 5....7362
Tools Required....7362
SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7364
Fault Overview....7364
Associated Faults....7364
Fault Facts....7364
Possible Causes....7364
Pin-Point Test SPN 2370 FMI 6....7366
Tools Required....7366
Combined Stop and Turn Lamps Diagnostics....7368
Overview....7368
Combined Stop and Turn Lamps - Rear Turn Lamp Not Illuminating....7370
Feature Code Overview....7370
Fault Facts....7370
Possible Causes....7370
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7374
Tools Required....7374
Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7378
Feature Code Overview....7378
Fault Facts....7378
Possible Causes....7378
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7380
Tools Required....7380
SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7382
Fault Overview....7382
Associated Fault....7382
Fault Facts....7382
Possible Causes....7382
Pin-Point Test SPN 2372 FMI 5....7384
Tools Required....7384
SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7386
Fault Overview....7386
Associated Faults....7386
Fault Facts....7386
Possible Causes....7386
Pin-Point Test SPN 2372 FMI 6....7388
Tools Required....7388
SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7390
Fault Overview....7390
Associated Faults....7390
Fault Facts....7390
Possible Causes....7390
Pin-Point Test SPN 2374 FMI 5....7392
Tools Required....7392
SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7394
Fault Overview....7394
Associated Faults....7394
Fault Facts....7394
Possible Causes....7394
Pin-Point Test SPN 2374 FMI 6....7396
Tools Required....7396
Separate Stop and Turn Lamps Diagnostics....7398
Overview....7398
Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7399
Feature Code Overview....7399
Fault Facts....7399
Possible Causes....7399
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7403
Tools Required....7403
Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7407
Feature Code Overview....7407
Fault Facts....7407
Possible Causes....7407
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7409
Tools Required....7409
Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....7411
Feature Code Overview....7411
Fault Facts....7411
Possible Causes....7411
Pin-Point Test - Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....7414
Tools Required....7414
Separate Stop and Turn Lamps- Stop Lamps Illuminating When Not Requested....7418
Feature Code Overview....7418
Fault Facts....7418
Possible Causes....7418
Pin-Point Test - Separate Stop and Turn Lamps- Rear Stop Lamps Illuminating When Not Requested....7420
Tools Required....7420
Trailer Lighting....7422
Trailer Lighting Overview....7422
Operational Checkout Procedure....7424
Overview....7424
Pin-Point Test - Trailer Lights Operational Checkout Procedure....7426
Tools Required....7426
Trailer Marker Lights - Not Illuminating....7430
Fault Overview....7430
Fault Facts....7430
Possible Causes....7430
Pin-Point Test - Trailer Marker Light Output - Not Illuminating....7433
Tools Required....7433
Trailer Tail Lights - Not Illuminating....7439
Fault Overview....7439
Fault Facts....7439
Possible Causes....7439
Pin-Point Test - Trailer Tail Light Output - Not Illuminating....7442
Tools Required....7442
Trailer Left Turn Lights - Not Illuminating....7448
Fault Overview....7448
Fault Facts....7448
Possible Causes....7448
Pin-Point Test - Trailer Left Turn Output - Not Illuminating....7451
Tools Required....7451
Trailer Right Turn Lights - Not Illuminating....7457
Fault Overview....7457
Fault Facts....7457
Possible Causes....7457
Pin-Point Test - Trailer Right Turn Output - Not Illuminating....7460
Tools Required....7460
Trailer Brake Lights - Not Illuminating....7466
Fault Overview....7466
Fault Facts....7466
Possible Causes....7466
Pin-Point Test - Trailer Brake Light Output - Not Illuminating....7469
Tools Required....7469
Trailer Auxiliary Power Circuit....7475
Overview....7475
Operational Checkout Procedure....7476
Trailer Auxiliary Power Test....7477
Electric Trailer Brakes....7478
Overview....7478
Operational Checkout Procedure....7479
Electric Trailer Brake Test....7480
Work Lights....7482
Overview....7482
Operation....7482
Operational Checkout Procedure....7484
Work Light Test....7485
16. Transmission....7486
Operation....7486
Available Body Controller Configurations....7488
User Programmable Parameters....7491
Diagnostic Trouble Codes....7492
Operational Checkout — All Transmissions....7494
Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....7499
LCT Column Shifter Interlock Checks....7500
TCM Power, Ground and Data Link Circuit Checks....7501
Shift Selector Power and Ground Circuit Checks....7502
Body Controller Signals....7503
Body Controller Functions....7504
Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....7504
PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....7504
Auto Neutral....7505
Auto Neutral Overview....7505
Overview....7505
Operational Checkout Procedure....7506
Overview....7506
Auto Neutral with Gen 2 Body Controller....7507
Overview....7507
Diagnostic Trouble Codes....7508
Activate Auto Neutral....7510
Error Operation....7511
Operational Checkout Procedure....7512
Auto Neutral Does Not Engage....7513
Auto Neutral Does Not Disengage....7514
Auto Neutral Warning Lamp Inoperative....7515
Auto Neutral with Gen 4 Body Controller....7517
Overview....7517
Auto Neutral Not Working Gen 4 Body Controller....7518
Fault Overview....7518
Fault Facts....7518
Possible Causes....7518
Power Take OFF Programming with Eaton® Procision™ Transmission....7521
Overview....7521
Programming Procedure....7522
Symptom(s)....7522
Customer Observations or Concerns....7522
Special Tools....7522
Diagnostic Steps....7523
17. Windshield Wiper System....7528
Windshield Wiper Diagnostics....7528
Overview....7528
Wiper Operation....7528
Park Operation....7528
Washer Operation....7528
Operational Checkout Procedure....7533
Overview....7533
Windshield Wiper Input 0 Not Working....7539
Fault Overview....7539
Fault Fact....7539
Possible Causes....7539
Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working....7542
Tools Required....7542
Windshield Wiper Input 1 Not Working....7546
Feature Overview....7546
Fault Fact....7546
Possible Causes....7546
Pin-Point Test - Windshield Wiper Input 1 Not Working....7548
Tools Required....7548
Windshield Wiper Input 2 Not Working....7552
Feature Overview....7552
Fault Fact....7552
Possible Causes....7552
Pin-Point Test - Windshield Wiper Input 2 Not Working....7555
Tools Required....7555
Windshield Wiper Low Speed Not Functioning....7559
Feature Code Overview....7559
Fault Facts....7559
Possible Causes....7559
Pin-Point Test - Windshield Wiper Low Speed Not Functioning....7564
Tools Required....7564
Windshield Wiper High Speed Not Functioning....7571
Feature Code Overview....7571
Fault Facts....7571
Possible Causes....7571
Pin-Point Test - Windshield Wiper High Speed Not Functioning....7576
Tools Required....7576
SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit....7584
Fault Overview....7584
Associated Faults....7584
Fault Facts....7584
Possible Causes....7584
Pin-Point Test - SPN 2636 FMI 5....7586
Tools Required....7586
SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current....7588
Fault Overview....7588
Associated Faults....7588
Fault Facts....7588
Possible Causes....7588
Pin-Point Test - SPN 2636 FMI 6....7589
Tools Required....7589
SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or High Resistance....7591
Fault Overview....7591
Associated Faults....7591
Fault Facts....7591
Possible Causes....7591
Pin-Point Test - SPN 2637 FMI 5....7593
Tools Required....7593
SPN 2637 FMI 6 - Wiper High / Low Relay Over Current....7595
Fault Overview....7595
Associated Faults....7595
Fault Facts....7595
Possible Causes....7595
Pin-Point Test - SPN 2637 FMI 6....7597
Tools Required....7597
SPN 4057 FMI 5 - Wiper Motor Under Current....7599
Fault Overview....7599
Associated Faults....7599
Fault Facts....7599
Possible Causes....7599
Pin-Point Test - SPN 4057 FMI 5....7603
Tools Required....7603
SPN 4057 FMI 6 - Wiper Motor Over Current....7609
Fault Overview....7609
Associated Faults....7609
Fault Facts....7609
Possible Causes....7609
Pin-Point Test - SPN 4057 FMI 6....7613
Tools Required....7613
Windshield Washer Pump is Not Working with Windshield Wipers....7617
Feature Overview....7617
Fault Fact....7617
Possible Causes....7617
Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....7620
Tools Required....7620
Windshield Wiper Not Working with Washer Pump....7625
Feature Overview....7625
Fault Fact....7625
Possible Causes....7625
Pin-Point Test - Windshield Wiper Not Working with Washer Pump....7627
Tools Required....7627
Windshield Wiper and Washer Pump Not Working....7629
Feature Overview....7629
Fault Fact....7629
Possible Causes....7629
Pin-Point Test - Windshield Wiper and Washer Pump Not Working....7632
Tools Required....7632
Windshield Washer Pump....7634
Windshield Washer Pump is Not Working with Windshield Wipers....7634
Feature Overview....7634
Fault Fact....7634
Possible Causes....7634
Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....7638
Tools Required....7638
Windshield Wiper Not Working with Washer Pump....7643
Feature Overview....7643
Fault Fact....7643
Possible Causes....7643
Pin-Point Test - Windshield Wiper Not Working with Washer Pump....7645
Tools Required....7645
Windshield Wiper and Washer Pump Not Working....7647
Feature Overview....7647
Fault Fact....7647
Possible Causes....7647
Pin-Point Test - Windshield Wiper and Washer Pump Not Working....7650
Tools Required....7650
Front End....7653
1. Hood, Grille, Fenders, and Bumper — 4100, 4200, 4300, 4400....7655
Description....7655
Bumper....7655
Hood....7656
Splash Panels....7656
Mud Guards....7657
Grille....7657
Air Intakes....7658
Fenders....7659
Fender Extensions....7659
Hood Seal....7660
Remove and Install....7662
4100 / 4200 / 4300 / 4400 Series Bumper....7662
Remove....7662
Install....7662
4100 / 4200 / 4300 / 4400 Series Hood....7663
Remove....7663
Install....7667
Splash Panels....7669
Remove....7669
Passenger Side....7670
Driver Side....7670
Install....7671
Mud Guards....7672
Remove....7672
Install....7672
Grille....7673
Remove....7673
Install....7674
Air Intakes....7675
Remove....7675
Install....7675
Fenders....7676
Overview....7676
Fender Lower Section — Remove....7677
Valance — Remove....7677
Fender Valance — Install....7677
Headlights — Remove....7679
Headlights — Install....7680
Clearance Lights — Remove....7681
Clearance Lights — Install....7681
Upper Hood Latch — Remove....7682
Upper Hood Latch — Install....7682
Fender Extensions....7683
Fender Extension — Remove....7683
Fender Extension — Install....7685
Hood Latch Lower Assembly — Remove....7686
Lower Hood Latch — Install....7687
Hood Seal....7688
Remove....7688
Install....7689
Adjustments....7690
Hood Adjustment and Alignment....7690
Hood Stop Adjustment....7691
Headlight Adjustment....7692
Headlamp Replacement....7693
Torque....7695
Fifth Wheels and Misc.....7697
Clutch....7701
1. Clutch Control Linkage — 2000, 4000, 7000, and 8000 Series....7703
Maintenance....7704
Lubrication....7704
Inspection....7704
Adjustment....7705
Push Type Clutches....7706
Overview....7706
Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....7706
Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....7707
Pull Type Clutches....7708
Overview....7708
Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....7708
Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....7709
Replacement....7710
Clutch Pedal Shaft Bushing....7710
Relay Shaft Bushing....7712
Troubleshooting....7714
Specifications....7715
Torque....7716
Engines....7717
1. Air Cleaner....7719
Air Cleaner - DuraStar....7719
Overview....7719
Air Cleaner - WorkStar....7720
Overview....7720
2. Block Heater....7721
Block Heater - DuraStar....7721
Overview....7721
Block Heater Socket - DuraStar....7721
Overview....7721
Block Heater - WorkStar....7722
Overview....7722
3. Engine Features....7723
Throttle Hand Control - DuraStar....7723
Overview....7723
Throttle Hand Control - WorkStar....7724
Overview....7724
4. Radiator / Cooling System....7725
DESCRIPTION....7725
Surge Tank (If Equipped)....7726
Deaeration Tank....7726
Fan Shroud....7727
Fan Drive....7727
A / C Condensor....7727
Radiator / Charge Air Cooler Assembly....7727
Cross-Member....7727
Low Temperature Radiator (LTR)....7727
Low Temperature Radiator (LTR) Thermostat....7727
Fuel Cooler Control Assembly....7727
Transmission Oil Cooler....7727
Removal and Installation....7728
Coolant Drain, Pressure Test, and Fill Procedures....7729
Overview....7729
Coolant Drain Procedure (Recommended)....7731
Pressure Test Procedure (Recommended)....7734
Coolant Fill Procedure (Recommended)....7737
Coolant Gravity Drain Procedure (Optional)....7740
Coolant Gravity Fill Procedure (optional) (MaxxForce® 7 and DT Engine)....7741
Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....7746
Splash Panel....7750
Removal....7750
Installation....7750
Surge Tank (if equipped)....7751
Surge Tank (with Cummins® ISB6.7 Engine) – Removal....7751
Surge Tank (with Cummins® ISB6.7 Engine) – Installation....7752
Deaeration Tank....7753
Deaeration Tank (Radiators with Single Mega Bracket) - Removal....7753
Deaeration Tank (Radiators with Single Mega Bracket) - Installation....7755
Deaeration Tank (Radiators with Dual Mega Bracket) – Removal....7756
Deaeration Tank (Radiators with Dual Mega Bracket) – Installation....7757
Engine Coolant Level (ECL) Sensor....7758
Removal....7758
Overview....7758
Special Tools....7758
Equipment Conditions....7759
Procedure....7760
Follow-On Procedure....7760
Installation....7761
Overview....7761
Special Tools....7761
Torque Specification....7762
Equipment Conditions....7762
Procedure....7763
Follow-On Procedure....7763
A / C Condenser....7764
Overview....7764
A / C Condenser (ISB6.7) Engine – Removal....7765
A / C Condenser – Installation....7767
Fan Belts....7768
Fan Belt with A / C (Cummins® ISB6.7 Engine) - Removal ....7768
Fan Belt with A / C (Cummins® ISB6.7 Engine) – Installation ....7769
Fan and Fan Drive Assembly....7770
Overview....7770
Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On....7771
Removal....7771
Install....7772
Fan and 12TTB Fan Drive (Borg-Warner 790) Viscous Type, Screw On....7773
Removal....7773
Install....7774
12THJ and 12THT Horton DA (optional)....7775
Removal....7775
Install....7776
12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7....7777
Removal....7777
Install....7778
12THJ Fan Drive Horton (DA) with ISB6.7....7779
Removal....7779
Install....7780
12THT Horton (DMA) Serviceable Fan Drive....7781
Remove....7781
Install....7787
12THT Pulley Bearing....7789
Removal....7789
Install....7789
12THT Fan Drive Friction Liner....7790
Removal....7790
Install....7795
12THT Clutch Pack Seal Face....7796
Removal....7796
Install....7796
12THT Air Cartridge....7797
Removal....7797
Install....7799
12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type....7802
Removal....7802
Install....7805
12TTJ Fan Drive Horton VS217 Electronic Viscous Fan....7806
Removal....7806
Install....7812
Fan Shroud....7813
Overview....7813
Fan Shroud (MaxxForce® DT and 9 Engines) - Removal....7813
Fan Shroud (MaxxForce® DT and 9 Engines) - Installation....7816
Fan Shroud (Cummins® ISB6.7 Engine) - Removal....7817
Fan Shroud (Cummins® ISB6.7 Engine) - Installation....7817
Coolant System Hoses....7818
Overview....7818
Heat Shrink Clamp ....7819
Removal....7819
Install....7820
Deaeration Tank Hose (Single Mega Bracket) MaxxForce® 7 Engine....7823
Removal....7823
Install....7824
Deaeration Tank Hose (Single Mega Bucket) MaxxForce® DT Engine without Interstage Charge Air Cooler (ISCAC) ....7825
Removal....7825
Install....7827
Deaeration Tank Hose (Dual Mega Bracket) MaxxForce® DT or 9 Engine with Interstage Charge Air Cooler....7829
Removal....7829
Install....7835
Deaeration Tank Hose (Dual Mega Bracket) N9® with Interstage Charge Air Cooler and SCR....7837
Removal....7837
Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine....7844
Removal....7844
Install....7846
Fuel Cooler Valve (FCV) Hoses MaxxForce® 7 Engine....7848
Removal....7848
Install....7852
Radiator Hoses DT Engine....7853
Removal....7853
Install....7854
Radiator Hoses ISB6.7 One Piece....7856
Removal....7856
Install....7858
Radiator Hoses MaxxForce® 7 Engine....7859
Removal....7859
Install....7860
Coolant Package....7862
Overview....7862
Coolant Package – Removal....7862
Coolant Package – Installation....7869
Radiator Core / CAC Assembly....7871
Overview....7871
Radiator Core / CAC Assembly - Removal....7871
Radiator Core / CAC Assembly - Installation....7873
Fuel Cooler Control Radiator Assembly....7875
Fuel Cooler Radiator Assembly - Removal....7875
Fuel Cooler Radiator Assembly - Installation....7876
Fuel Cooler Control Valve (FCCV)....7877
Fuel Coolant Control Valve - Removal....7877
Fuel Cooler Control Valve - Installation....7878
Low Temperature Radiator (LTR)....7879
Low Temperature Radiator – Removal....7879
Low Temperature Radiator – Installation....7880
Low Temperature Radiator (LTR) Thermostat....7881
Low Temperature Radiator (LTR) Thermostat – Removal....7881
Low Temperature Radiator (LTR) Thermostat – Installation....7882
Low Temperature Radiator Hoses....7883
Low Temperature Radiator Hoses – Removal....7883
Low Temperature Radiator (LTR) Thermostat Hose – Installation....7887
Removal and Installation — Cummins....7888
Radiator and Component Removal....7888
Cross-Member....7888
Engine Coolant Level (ECL) Sensor....7890
Overview....7890
Special Tools....7891
Equipment Conditions....7891
Procedure....7893
Follow-On Procedure....7893
Surge Tank....7894
Charge Air Cooler Pipes....7896
Cooling System Radiator Hose....7898
Radiator....7901
Radiator Shroud and Frame....7902
Charge Air Cooler....7905
Radiator Core....7905
Radiator and Component Installation....7906
Radiator Core....7906
Radiator Hose....7906
Charge Air Cooler Pipes....7909
Surge Tank....7909
Engine Coolant Level (ECL) Sensor....7910
Overview....7910
Special Tools....7911
Torque Specification....7911
Equipment Conditions....7911
Procedure....7912
Follow-On Procedure....7912
Front Cross-Member....7913
Cooling Package Cleaning Procedures....7914
Overview....7914
Cleaning Cooling Package (MaxxForce® DT, 9, and 10 Engines)....7916
Cleaning Cooling Package (Navistar® 11 and 13 Engines)....7917
Inspection Procedures....7919
Deaeration Tank and Cap Inspection Procedures....7919
Deaeration Tank....7919
Deaeration Tank Cap Vacuum Relief Check....7921
Fan Drive Pulley and Pulley Groove Inspection Procedures....7922
Pulley Crack Inspection....7922
Pulley Nick Inspection....7923
12TTB Fan Drive (Borg-Warner 790) Viscous Type Inspection Procedures....7924
Fan Drive Movement....7924
12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....7925
Fan Drive Movement....7925
12TTJ Fan Drive Horton VS217 Inspection Procedures....7926
Fan Drive Movement....7926
12THT Horton Drivemaster Advantage Fan Drive Inspection Procedures....7928
Fan Drive Movement....7928
Clutch Pack Face Seal....7930
Cartridge Assembly Seal and Spring....7931
Friction Liner Measurement....7932
Fan Drive Bearing Measurement and Inspection....7933
12TTD Borg – Warner 842B Visctronics Inspection Procedure....7934
Fan Drive Movement....7934
Fuel Cooler Valve (FCV) Inspection Procedure....7935
Fuel Cooler Valve (FCV) Filter Screen – Removal....7935
Fuel Cooler Valve (FCV) Filter Screen – Installation....7937
12THT and 12THJ Horton DriveMaster Advantage (DMA) Fan Drive System Diagnostics....7938
12THT and 12THJ Horton DriveMaster Advantage (DMA) System: Operational Checkout Procedure....7938
Overview....7938
Operational Checks – Start Fan Drive Diagnostics Here....7939
Visual Air Leak Check....7939
Symptom 1: Fan Always ON....7941
Symptom 2: Fan Always Off....7960
Symptom 3: Fan Cycles Too Frequently....7968
Symptom 4: Excessive Noise From Fan Drive....7970
12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics....7973
12TTD Borg-Warner 842B Visctronic Fan Drive: Operational Checkout Procedure....7973
Overview....7973
Tools Required....7973
Operational Checks – Start Fan Drive Diagnostics Here....7973
Symptom 1: Fan Always ON....7975
Symptom 2: Fan Always OFF....7982
Symptom 3: Cycles Too Frequently....7999
Symptom 4: Excessive Noise From Fan Drive....8002
12TTJ Horton Drivemaster VS217 Fan Drive Assembly System Diagnostics....8005
12TTJ Horton Drivemaster VS217 Fan Drive Assembly: Operational Checkout Procedure....8005
Overview....8005
Tools Required....8005
Operational Checks – Start Fan Drive Diagnostics Here....8005
Symptom 1: Fan Always ON....8007
Symptom 2: Fan Always OFF....8014
Symptom 3: Fan Drive Cycles Too Frequently....8036
Symptom 4: Excessive Noise From Fan Drive....8037
12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....8039
12TSY Borg-Warner SA85 Fan Drive Assembly: Operational Checkout Procdure....8039
Overview....8039
Tools Required....8039
12TTB Borg-Warner Series 790 Viscous Fan Drive Assembly System Diagnostics....8041
12TTB Borg-Warner 790 Fan Drive Assembly: Operational Checkout Procedure....8041
Overview....8041
Tools Required....8041
Radiator Shutters....8043
Overview....8043
Operation....8045
Overview....8045
Air Shutter Controls....8046
Hydraulic Shutter Controls....8046
Shutters on Vehicles with Air Conditioning....8046
Shutters on Vehicles with ON / OFF Fan Drive Clutch....8047
Shutters on Vehicles with Viscous Fan Drive....8049
Maintenance....8050
Troubleshooting....8051
Overview....8051
Troubleshooting Chart....8051
Replace....8051
Overview....8051
3000 / 4000 Series Vehicles....8051
Shutter-to-Radiator....8051
Shutter-to-Charge Air Cooler....8051
8000 Series Vehicles....8053
Overview....8053
8100....8053
8200 / 8300....8055
Specifications....8057
Transmissions....8059
1. 6 Speed Transmissions International Model ES52–7A and ESO65–7A 6–Plus....8065
General Information....8065
How to Shift the Transmission — Synchronizer Information....8065
Description....8065
Upshifting....8065
Downshifting....8066
Towing....8066
Troubleshooting....8067
Important Procedure....8067
Check Function Prior to Disassembly....8067
Inspect Thoroughly During Disassembly....8067
Repair or Replace Worn Part....8067
Noisy Operation....8067
Noise in Neutral....8069
Noise in Gear....8069
Back-Up Lights Do Not Operate....8069
Oil Leaks....8069
Walking or Jumping Out of Gear....8070
Hard Shifting....8071
Sticking in Gear....8071
Bearing Failures....8071
Dirt....8072
Fatigue....8072
Corrosion....8072
Shaft Fits....8072
Installation and Removal of Bearings....8072
Interchangeability....8072
Clutch Troubleshooting....8073
Disassembly....8074
General....8074
Overview....8074
Cleanliness....8074
Bearings....8074
Front Bearing Retainer and Seal....8074
End Yokes and Flanges....8074
Power Take Offs....8075
Shift Tower....8075
Rear Case....8077
Main Case....8091
Mainshaft Disassembly....8103
Countershaft Disassembly and Reassembly....8110
Clean and Inspection....8112
Reassembly....8114
Mainshaft....8114
Main Case....8119
Rear Case....8124
Shift Tower....8135
Shift Knob Installation....8136
Lubrication....8137
Recommended Lubricants....8137
Oil Changes....8137
Refill....8137
Overfilling....8137
Specifications....8139
Torque....8140
2. 6 Speed Transmissions Eaton Series FS-5106 and FS-6206....8141
Identification....8141
Maintenance....8142
Precautions....8144
Disassembly....8144
Inspection....8144
Reassembly....8146
Remove....8147
Gear Shift Lever Assembly....8147
Shifter Housing....8148
Yoke....8149
Clutch Housing....8151
Input Shaft....8153
Mainshaft....8156
Countershaft and Reverse Idler....8159
Disassemble....8164
Gear Shift Lever Assembly....8164
Shifter Housing....8168
Mainshaft....8174
Countershaft and Reverse Idler....8191
Reassemble....8198
Gear Shift Lever Assembly....8198
Shifter Housing....8201
Countershaft and Reverse Idler....8207
Mainshaft....8213
Install....8235
Countershaft and Reverse Idler....8235
Mainshaft....8242
Clutch Housing....8251
Yoke....8252
Shifter Housing Assembly....8253
Gear Shift Lever Housing....8255
Lubrication....8256
General....8256
Proper Oil Level....8256
Draining Oil....8256
Refilling....8256
Operating Temperatures....8257
Specifications....8258
Torque....8259
3. 5 Speed Transmissions Spicer ES43–5 and ES53–5....8262
General Safety Precautions....8262
Operation....8263
How to Shift the Transmission....8263
Synchronizer Information....8263
Upshifting....8263
Downshifting....8264
Disassembly....8265
General....8265
Inspect Thoroughly During Disassembly....8265
Rebuild Facilities....8265
Cleanliness....8265
Bearings....8265
Shift Tower....8265
Clutch Housing....8267
Case and Shift Forks....8268
Mainshaft....8285
Clean and Inspect....8293
Clean....8293
Inspect....8293
Clutch Gears....8293
Gears....8293
Thrust Washers....8293
Snap Rings....8293
Mainshaft....8293
Bearings....8293
Housings....8294
Reassembly....8295
General....8295
End Yokes and Flanges....8295
Power Take-Offs....8295
Mainshaft....8295
Case....8301
Shift Tower....8318
Shift Knob Installation....8319
Lubrication....8321
Recommended Lubricants....8321
Oil Changes....8321
Refill....8321
Overfilling....8321
Troubleshooting....8322
Troubleshooting Procedure....8322
Noisy Operation....8322
Troubleshooting Chart....8323
Bearings....8326
Dirt....8326
Fatigue....8326
Corrosion....8327
Shaft Fits....8327
Installation and Removal of Bearings....8327
Interchangeability....8327
Clutch Troubleshooting....8327
Specifications....8328
Gear Ratios....8328
Gimbal Tower Shift Pattern....8328
Torque....8329
Special Tools....8331
4. 7 Speed Transmissions Spicer PS110–7, PS145–7....8332
General Safety Precautions....8332
Operation....8333
How to Shift Spicer PS110–7A, PS145–7A, and PS110–7B Transmissions....8333
Overview....8333
Starting....8333
Upshifting....8333
Downshifting....8334
Replacement Parts....8334
Maintenance....8335
Tool Reference....8335
Road Test....8335
Check Remote Control....8335
Disassemble....8336
General....8336
Inspect Thoroughly During Assembly....8336
Rebuild Facilities....8336
Cleanliness....8336
Bearings....8336
Power Take-Offs....8336
Shift Tower....8337
Remote Control....8339
Shifter Housing....8340
Case and Gears....8345
Mainshaft....8359
Input Shaft....8366
Clean and Inspect....8367
Clean....8367
Inspect....8367
Overview....8367
Clutch Gears....8367
Gears....8367
Thrust Washers....8367
Snap Rings....8367
Mainshaft....8368
Bearings....8368
Housings....8368
Reassemble....8369
General....8369
End Yokes and Flanges....8369
Power Take-Offs....8369
Input Shaft....8369
Countershaft....8372
Mainshaft....8374
Case and Gears....8380
Shifter Housing....8392
Remote Control....8394
Shift Tower....8394
Lubrication....8395
Recommended Lubricants....8395
Oil Changes....8395
Refill....8395
Overfilling....8395
Troubleshooting....8396
Noise....8396
Overview....8396
Growling, Humming, and Grinding....8396
Hissing, Thumping, and Bumping....8396
Gear Whine....8397
Metallic Rattles....8397
Troubleshooting Chart....8397
Bearings....8400
Dirt....8400
Fatigue....8400
Corrosion....8400
Shaft Fits....8401
Installation and Removal....8401
Interchangeability....8401
Clutch....8401
Specifications....8402
Gear Ratios....8403
Shift Pattern....8403
Torque....8404
Special Tools....8406
5. Meritor Transfer Cases MTC–4208, MTC–4210 and MTC–4213....8407
Description....8407
Transfer Case Model Nomenclature....8418
Operation....8419
Front Axle Declutch....8419
Full Torque Power Take-Off (PTO)....8419
Removal....8420
Disassembly....8423
Front and Rear Output Yokes....8423
Front Input Shaft, Input Bearing Cage and Pump Assembly....8423
Front Input Shaft, Input Shaft Bearing Cage and Oil Pump....8430
Idle Gear Shaft....8432
Optional PTO Assembly on MTC–4208 and MTC–4208 Transfer Cases....8433
Prepare Parts for Assembly....8434
Ground and Polished Parts....8434
Parts with a Rough Finish....8434
Transfer Case Assemblies....8435
To prevent damage to property, never use a metallic scraper and / or wire brush when cleaning aluminum components and / or sealing surfaces. Metallic scrapers and wire brushes are made of materials harder than aluminum that can scratch, gouge, scrape, or....8435
Dry Cleaned Parts....8435
Prevent Corrosion....8435
Oil Seals and O-Rings....8435
Inspect Parts....8436
Overview....8436
General....8436
Helical Gears....8439
Shafts....8441
PTO Components....8442
High and Low Shifting Components....8442
Oil and Lubrication System....8442
Transfer Case Halves....8443
Preparing Case and Cover Seal Replacement....8443
To prevent damage to property, never use a metallic scraper and / or wire brush when cleaning aluminum components and / or sealing surfaces. Metallic scrapers and wire brushes are made of materials harder than aluminum that can scratch, gouge, scrape, or....8443
Assembly....8444
General....8444
MTC–4213 Rear Output Shaft End Play Adjustment....8447
MTC–4208 and MTC-4210 Rear output Shaft End Play Adjustment....8449
Idler Shaft Bearing End Play Adjustment....8450
Front Output Shaft End Play Adustment....8451
Shim Assembly....8452
High and Low Shifter Assembly....8452
Front Axle Shifter Assembly....8454
Front Input Shaft, Input Shaft Bearing Cage and Oil Pump Assembly....8455
Input Bearing Cage and Oil Pump Assembly Installation, Bearing End Play Adjustment and Transfer Case Final Assembly....8457
Transfer Case Shifting Check....8459
Adjust Oil Level....8460
Transfer Case Assembly Test....8460
Power Take-Off (PTO)....8461
Remove Transfer Case Rear Access Cover....8461
Install Yoke Onto PTO....8462
Install Optional Indicator Switch....8462
Install PTO Onto Transfer Case....8463
Test PTO Installation....8463
Overview....8463
PTO Without an Optional Indicator Switch....8464
PTO With an Optional Indicator Switch....8464
Test Transfer Case with PTO Assembly Installed....8465
PTO MDP-10–AF-100....8467
PTO Assembly....8470
Installation....8474
General....8474
Check and Adjust Oil....8474
Diagnostics....8476
Lubrication and Maintenance....8482
Lubrication....8482
Overview....8482
Lubricant Temperatures....8482
Multi-Viscosity Oils....8482
Do Not Install API GL-5 Oils....8482
Petroleum-Base and Synthentic-Base Oils....8483
Operating Information....8483
Magnets and Magnetic Drain Plugs....8483
Breather....8483
Seals....8484
Temperature Indicator....8484
Check and Adjust Oil Level....8484
Drain and Replace Oil....8485
Torque....8487
Rear Axle and Suspension....8489
1. IROS....8491
Description....8491
Height Control Valve....8493
Operation....8495
Service Checls (Valve on Truck)....8496
Ride Height Adjustment Procedure....8497
Overview....8497
Special Tools....8497
Specifications....8497
Equipment Conditions....8497
Procedure....8497
Follow-On Procedure....8500
Travel exceeds specification:....8500
Travel is less than specification:....8501
Rod Cutting Instructions....8502
Final Assembly Instructions....8502
Air Lines....8504
Suspension Dump Feature....8505
Operation....8506
Main Support Member....8508
Main Support Member Removal....8508
Main Support Member Install....8509
Shock Absorbers....8511
Torque Rods....8511
Remove and Install....8511
Suspension Air Springs Removal....8512
Suspension Air Spring Install....8514
Shock Absorbers....8515
Removal Suspension System Shock Absorbers....8515
Install Shock Absorber....8517
Main Support Members....8518
Remove....8518
Install....8518
Torque Rods....8520
Remove....8520
Install....8520
Main Support Member Bushings....8521
U-Bolts and U-Bolt Nuts Installation....8523
Installing U-Bolts and U-Bolt Nuts....8523
Overview....8523
Special Tools....8523
Torque Specifications....8523
Equipment Condition....8523
Procedure....8524
Follow-On Procedure....8525
Checking U-Bolt Nut Torque and U-Bolt Nut Tightening....8526
Torque....8527
Fuel System....8529
1. DEF Tank....8531
DEF Tank - DuraStar....8531
Overview....8531
DEF....8531
DEF Tank....8531
DEF Supply Module....8532
DEF Tank Pickup Assembly....8532
DEF Lines....8532
DEF Coolant Lines....8532
DEF Tank Heater Valve....8532
DEF Line Heater....8532
DEF Tank - WorkStar....8532
Overview....8532
DEF....8533
DEF Tank....8533
DEF Supply Module....8533
DEF Tank Pickup Assembly....8533
DEF Lines....8533
DEF Coolant Lines....8533
DEF Tank Heater Valve....8534
DEF Line Heater....8534
2. Dual Draw Dual Return Fuel Tanks....8534
Overview....8534
Removal....8535
Installation....8539
3. Fuel/Water....8540
Fuel Heater - WorkStar....8540
Overview....8540
Fuel / Water Separator - DuraStar....8541
Overview....8541
Fuel / Water Separator - WorkStar....8543
Davco....8543
Overview....8543
Racor....8545
Overview....8545
Cummins....8546
Overview....8546
Fuel Cooler - DuraStar....8547
Overview....8547
Fuel Cooler - WorkStar....8547
Overview....8547
Cab....8549
1. HVAC....8551
HVAC System Repair....8551
A/C Condenser....8551
Blend Door Actuator....8552
Removal....8552
Installation....8553
Blend Door Gear Train....8554
Removal....8554
Installation....8557
Blower Assembly....8558
Removal....8558
Installation....8559
Blower Scroll Housing....8560
Removal....8560
Installation....8561
Compressor....8562
Removal....8562
Installation....8563
Evaporator....8564
Removal....8564
Installation....8565
Filter-Drier....8566
Removal....8566
Installation....8568
Freeze Probe....8569
Removal....8569
Installation....8570
Fresh Air Module....8571
Removal....8571
Installation....8573
Heater Core....8574
Removal....8574
Installation....8576
Heater Hoses / Lines....8577
HVAC Air Filter....8578
Removal....8578
Installation....8579
HVAC Control Panel Assembly....8580
Removal....8580
Installation....8581
Interior Module....8582
Removal....8582
Installation....8588
Interior Module Trim Cover....8590
Removal....8590
Installation....8591
Linear Power Module (LPM)....8592
Removal....8592
Installation....8594
Low Pressure Switch....8595
Removal....8595
Installation....8596
Mode Door Actuator....8597
Removal....8597
Installation....8598
Mode Door Gear Train....8599
Removal....8599
Installation....8602
Pressure Transducer....8603
Removal....8603
Installation....8604
Recirculation Door Actuator....8605
Removal....8605
Installation....8606
Recirculation Door Gear Train....8607
Removal....8607
Installation....8609
Recirculation Filters....8610
Removal....8610
Installation....8612
Recirculation, Mode, and Blend Doors....8613
Refrigerant Line....8614
Removal....8614
Installation....8616
Separating Blower Scroll Housing....8617
Removal....8617
Installation....8619
Separating Front HVAC Module....8620
Removal....8620
Installation....8624
Thermostatic Expansion Valve (TXV)....8625
Removal....8625
Installation....8626
Service Procedures....8627
Charge A/C System (Charge Mode)....8627
Discharge A/C System (Recycle Mode)....8629
Evacuate A/C System (Vacuum Mode)....8631
Checking Compressor Oil Level....8633
Overview....8633
Special Tools....8633
Equipment Conditions....8633
Procedure....8633
Follow-On Procedure....8635
Oil Fill Guidelines....8636
Overview....8636
Special Tools....8636
Equipment Conditions....8636
Procedure....8638
Oil separation during refrigerant recovery....8638
Component replacement....8638
Oil loss due to refrigerant leak....8638
Compressor replacement due to internal compressor failure....8638
Compressor replacement due to clutch failure....8638
Follow-On Procedure....8638
Refrigerant Identification....8639
Overview....8639
Special Tools....8639
Equipment Conditions....8639
Procedure....8639
Follow-On Procedure....8639
Flush and Purge A/C System....8640
Evaporator....8640
Overview....8640
Special Tools....8640
Equipment Conditions....8640
Evaporator Flush and Purge Procedure....8643
Follow-On Procedure....8645
Supply and Return Lines....8646
Overview....8646
Special Tools....8646
Equipment Conditions....8646
Supply and Return Line Flush and Purge Procedure....8646
Follow-On Procedure....8648
Condenser....8649
Overview....8649
Special Tools....8649
Equipment Conditions....8649
Condenser Flush and Purge Procedure....8650
Follow-On Procedure....8653
Front Wheels....8655
Rear Wheels....8659
tables....5787
Service Procedures....5787
Adjusted Chamber Stroke Chart....5795
Troubleshooting Chart....5813
Torque Chart....5815
Troubleshooting Chart....5821
Torque Chart....5823
Length of Slack Adjuster/Size of Chamber Table....5831
Maximum Stroke Available Chart....5836
Service Procedures....5861
Torque Specifications....5871
Torque Specifications....5888
Torque Specifications....5898
Torque Specifications....5909
Torque....5926
Service Procedures....5929
Torque Specifications....5935
Torque Specifications....5987
Torque Specifications....5994
Torque Specifications....6002
Torque Specifications....6006
Torque Specifications....6015
Torque Specifications....6022
Torque Specifications....6028
Torque Specifications....6037
Torque Specifications....6061
Torque Specifications....6070
Torque Specifications....6079
Torque Chart....6110
Drag Link Nut Torque Chart....6137
Dual Steering Gear Drag Link Nut Torque Chart....6140
Master Gear Drag Link Nut Torque Chart....6140
Drag Link Torque Chart....6151
Specifications....6194
M-Series Torque Chart....6194
All Steering Applications Torque Chart....6195
Special Tools....6195
Service Information....6199
Service Information....6199
Service Information....6199
Procedures....6230
DuraStar....6255
WorkStar....6256
Torque Specifications....6257
Torque Specifications....6262
Approximate CAN DC Voltage Measurements (Key ON)....6274
Approximate CAN Resistance Measurements (Batteries Disconnected)....6274
Feature Codes....6278
Remote Start Stop....6278
Feature Code....6289
Diagnostic Trouble Codes....6290
Remote Start/Stop Preliminary Check....6291
Diagnostic Section....6294
Diagnostics....6300
500K Input Diagnostic Section....6319
Diagnostic Section....6324
Battery Type....6334
Description....6334
Battery Chemistry....6334
Description....6334
Battery Type....6339
Description....6339
Battery Chemistry....6340
Description....6340
Individual Battery Test RESULTS....6342
Recommended Action....6342
Starting System RESULTS....6343
Recommended Action....6343
RESULTS....6347
Recommended Action....6347
Operational Checkout....6364
Heated Drain Valve Test....6364
Air Dryer Test....6365
Feature Codes....6366
Diagnostic Trouble Codes....6366
Air Horns Preliminary Checks....6367
Feature Code....6369
Diagnostic Trouble Codes....6370
Air Solenoid Preliminary Check....6379
Operational Checkout....6381
Aux Power Source Tests....6382
Operational Checkout....6387
Axle Pressure Transducer Voltage Checks....6388
C.B. Radio Power Source Preliminary Check....6391
C.B. Radio Power Connector Tests....6392
Cigar Lighter and Power Feed Preliminary Check....6393
Cigar Lighter Tests....6394
Cigar Lighter Power Source Tests....6394
Two Post Power Source Tests....6395
Feature Codes....6396
Diagnostic Trouble Codes....6397
Cruise Control Preliminary Check....6398
Steering Wheel Mounted Cruise Control Command Switch Test (0595AYJ)....6399
Steering Wheel Mounted Cruise Control Command Switch Test (0595AAP)....6400
Diagnostic Trouble Codes....6402
Operational Checkout....6403
Lift Gate Test....6403
Diagnostic Trouble Codes....6406
Operational Checkout....6407
(0595ACT) Differential Lock Test....6408
(0595ACU) Differential Lock Test....6409
Feature Codes....6410
Diagnostic Trouble Codes....6410
Electric Horn Preliminary Check....6411
Diagnostic Trouble Codes....6414
Operational Checkout....6414
Fifth Wheel Slide Test....6415
Diagnostic Trouble Codes....6418
Operational Checkout....6419
Fuel Transfer Pump Won’t Run Test....6420
Fuel Transfer Pump Continuously Runs Test....6422
Operational Checkout....6427
Heated Mirrors Test....6427
Left Heated Mirror Test....6428
Right Heated Mirror Test....6428
Operational Checkout....6429
Heated Seat Test....6429
Feature Code....6430
Diagnostic Trouble Codes....6431
Diagnostic Trouble Codes....6433
Power Divider Lock Preliminary Check....6434
Power Divider Lock Test....6434
Additional Signals Used for PTO Operation....6438
Feature Description....6439
Fault Codes....6450
PTO Hour Meter/ PTO Indicator Checks....6462
Feature Codes....6463
Diagnostic Trouble Codes....6464
Power Locks Preliminary Check....6466
Power Windows Preliminary Check....6469
One Power Window Inop Test....6470
All Power Windows Inop Test....6470
Power Locks Preliminary Check....6473
One Door Lock Inop Test....6474
All Door Locks Inop Test....6474
Power Mirror Preliminary Check....6476
Power Mirror Tests....6477
Radio Preliminary Check....6479
Radio Test....6480
Fault Codes....6482
RPM Checks....6487
Feature Codes....6488
Lighted Air Shield DTC....6488
Roof Auxiliary Load Preliminary Check....6489
IP Mounted Roof Auxiliary Load Switch Test....6490
Operational Checkout....6494
0595BAG Seat Belt Test....6494
Operational Checkout....6495
Self Contained Air Seat Test....6495
Diagnostic Trouble Codes....6498
Operational Checkout....6499
Suspension Dump Test....6500
Feature Codes....6501
Theft Deterrent Diagnostics....6502
Diagnostic Trouble Codes....6507
Operational Checkout....6507
Two-Speed Switch Test....6507
Two-Way Radio Circuit Tests....6508
Feature Codes....6509
Diagnostic Trouble Codes....6509
Operational Checkout....6509
Water Probe Test....6510
Additional Signals Used for Wheelchair Lift Interlock Operation....6513
Wheelchair Lift Interlock Checks....6516
Parked Regeneration (Particulate_Trap_Regeneration_Force_Switch = 1)....6536
Inhibit Regeneration (Particulate_Trap_Regeneration_Inhibit_Switch = 1)....6537
DuraStar....6540
WorkStar....6540
Service Information....6544
DuraStar....6550
WorkStar....6550
Service Information....6553
DuraStar....6554
WorkStar....6554
Service Information....6558
Warning Indicators....6660
Sensor Check Pins ....6684
Warning Indicators....6691
Test Procedure....6710
Test Procedure....6715
Specifications....6722
Specifications....6737
Test Procedure....6740
Test Procedure....6747
Exhaust Brake Switch Test....6902
RESCM Checks....6912
Switch Pack Preliminary Check....6928
Switch Pack Test....6929
System Pressure Test Chart....6982
R-134a Static Temperature / Pressure Table....7033
System Performance Test Specifications....7035
Air gauge feature codes....7058
Air 1 gauge fault codes....7059
Check for short to GND in Primary Air Pressure signal circuit....7064
Check for short to GND in Primary Air Pressure signal circuit B40....7065
Check for VREF and GND at Primary Air Pressure Transducer....7066
Check for Open or high resistance in Primary Air Pressure signal circuit....7067
Check for Open or high resistance in Primary Air Pressure signal circuit A40....7068
Check for Open or high resistance in Primary Air Pressure signal circuit B40....7069
Body Controller output test....7070
Air gauge feature codes....7071
Air 2 gauge fault codes....7072
Check for short to GND in Secondary Air Pressure signal circuit....7077
Check for short to GND in Secondary Air Pressure signal circuit B40A....7078
Check for VREF and GND at Secondary Air Pressure Transducer....7079
Check for Open or high resistance in Secondary Air Pressure signal circuit....7080
Check for Open or high resistance in Secondary Air Pressure signal circuit A40A....7081
Check for Open or high resistance in Secondary Air Pressure signal circuit B40A....7082
Body Controller output test....7082
Gauge Table....7084
Gauge Response to Faults....7085
Axle Temperature Sensor Voltage Checks....7093
Rear- Rear Axle Temperature Sensor Voltage Checks....7095
Air Pressure Transducer Voltage Checks....7098
Feature Codes....7099
Compass Module Voltage Checks....7100
DEF level feature codes....7101
DEF level fault codes....7101
Coolant temperature feature codes....7103
Coolant temperature fault codes....7103
Oil pressure feature codes....7104
Oil pressure fault codes....7104
Oil temperature feature codes....7105
Oil temperature fault codes....7105
Engine speed feature codes....7106
Engine speed fault codes....7106
Fuel gauge feature codes....7107
Fuel gauge fault codes....7107
Fault codes....7113
Ambient Air Temperature Sensor Table....7114
Transmission temperature feature codes....7116
Transmission temperature fault codes....7116
Transmission oil temp sensor resistance specification....7120
Measure resistance of transmission oil temperature circuit at Connector 1702....7121
Measure resistance of transmission oil temperature sensor....7121
Vehicle speed feature codes....7122
Vehicle speed fault codes....7122
Feature Codes....7125
Dome and Courtesy Light Fault Codes....7125
Door Switch Short Circuit Tests....7127
Door Switch Open Circuit Tests....7127
Dome Light Short Circuit Test....7127
Dome Light Open Circuit Test....7128
Back Up Light Fault Codes....7129
Backup Light Relay Tests....7131
Backup Light Ball Switch Tests....7131
Brake Switch Diagnostics....7139
Brake Switch Fault Code Diagnostics....7139
Tech Tips....7139
Feature Codes....7160
Fog Light Diagnostics....7160
Fog Light Fault Code Diagnostics....7160
Feature Codes....7196
Low Beam Headlight Diagnostics....7197
High Beam Headlight Diagnostics....7197
Feature Codes....7264
Park / Marker Lights....7265
Feature Codes....7291
Snow Plow Light Diagnostics....7292
Diagnostic Section....7311
Software Feature Codes....7311
Turn Signal Input and Front Turn Lamp Diagnostics....7321
Combined Stop and Turn Lamps....7368
Separate Stop and Turn Lamps....7398
Feature Codes....7422
Trailer Lights Diagnostics....7423
Feature Codes....7475
Diagnostic Trouble Codes....7475
Trailer Auxiliary Power Circuit Preliminary Checks....7476
Feature Code....7478
Diagnostic Trouble Codes....7478
Electric Trailer Brake Preliminary Check....7479
Feature Codes....7483
Dome and Courtesy Light Fault Codes....7483
Work Light System Preliminary Checks....7484
Work Light Switch Test....7485
Work Light Open Circuit Test....7485
Work Light Short Circuit Test....7485
Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....7499
LCT Column Shifter Interlock Checks....7500
TCM Power, Ground and Data Link Circuit Checks....7501
Shift Selector Power and Ground Circuit Checks....7502
Diagnostic Section....7505
Software Feature Codes....7505
Diagnostic Trouble Codes (DTC)....7522
Feature Codes....7530
Windshield Wiper Diagnostics....7531
Washer Pump Diagnostics....7532
Windshield Wiper Input Switch....7532
Torque Chart....7695
Troubleshooting Table....7714
Specifications....7715
Torque Chart....7716
Troubleshooting Chart....8051
Torque Chart....8057
Lubrication Table....8137
Specifications Table....8139
Torque Chart....8140
Specifications Table....8258
Torque Chart....8259
Troubleshooting Chart....8323
Specifications....8328
Gear Ratio Table....8328
Torque Chart....8329
Troubleshooting Chart....8397
Specifications....8402
Gear Ratios Table....8403
Torque Chart....8404
Example of Shim Selection....8452
Possible Combinations that meet required shim stack:....8452
Kit 2540....8461
PTO Switch Option....8462
PTO Yoke Options and Dimensions....8466
PTO MDP-10–AF-100 Components....8469
Transfer Case Oil Change Intervals....8485
Transfer Case Oil Specifications (NOTES 1, 2, 3)....8486
Transfer Case Oil Capacities....8486
Dry Weight....8486
Torque Chart....8488
Torque Chart....8528
Torque Specifications....8633
Oil Capacity by Component....8636
0000871480 - 2010-2017 DuraStar and WorkStar Technician Manual (Service and Diagnostics), Revision 4....8664
toc....8666
Table of Contents....8666
Safety Terminology....8669
Safety Instructions....8669
Work Area....8669
Safety Equipment....8669
Protective Measures....8669
Vehicle....8669
Engine....8670
Fire Prevention....8670
Batteries....8670
Compressed Air....8670
Tools....8670
Fluids Under Pressure....8671
Fuel....8671
Removal of Tools, Parts, and Equipment....8671
Frame....8672
Front Axle....8676
Front Suspension....8680
Brakes....8684
1. Air Brakes....8688
Bendix ABS Air Brakes....8688
4–Channel with Electronic Stability and Automatic Traction Control....8688
Overview....8688
6–Channel with Electronic Stability and Automatic Traction Control....8692
Overview....8692
Anti-Lock Brake System (ABS) Module Removal....8695
Special Tools....8695
Torque Specifications....8695
Equipment Conditions....8695
Removal Procedure....8695
Follow-On Procedure....8695
Anti-Lock Brake System (ABS) Module Installation....8696
Special Tools....8696
Torque Specifications....8696
Equipment Conditions....8696
Installation Procedure....8696
Follow-On Procedure....8696
Modulator Valve M-40 Removal....8697
Modulator Valve M-40 Installation....8698
Steering Angle Sensor Removal....8699
Special Tools....8699
Torque Specifications....8699
Equipment Conditions....8699
Removal Procedure....8699
Follow-On Procedure....8701
Steering Angle Sensor Installation....8702
Special Tools....8702
Torque Specifications....8702
Equipment Conditions....8702
Installation Procedure....8702
Follow-On Procedure....8704
Wheel Speed Sensor WS-24 Removal....8705
Wheel Speed Sensor WS-24 Installation....8706
Yaw Rate Sensor Removal....8707
Yaw Rate Sensor Installation....8708
2. Automatic Slack Adjusters: Rockwell....8709
General....8709
Clevis Types....8711
Quick Connect Clevis....8711
One Piece Clevis....8712
Thread Sizes....8712
Operation....8713
Maintenance....8714
Minor Inspections and Lubrication....8714
Major Inspections....8714
Troubleshooting....8716
Remove....8718
Disassemble....8720
Clean and Inspect....8726
Clean....8726
Overview....8726
Metal Parts with Polished Surfaces....8726
Parts Not Made of Metal....8726
Inspect....8727
Corrosion Protection....8727
Assemble....8728
Install....8736
Preparations for Installation....8736
Installation of the Slack Adjuster....8739
Adjust Chamber Stroke (Preferred)....8741
Brake Adjustment....8743
Follow-On Procedures....8746
Lubrication....8747
Anti-Seize Compound....8747
Torque....8748
3. Bosch Park Brake: Lever Actuated or Air Power....8750
Brake Shoe Adjustment....8750
Drum Off....8750
Drum On....8752
Inspection....8753
Park Brake Cable Adjustment (Lever Actuated)....8754
Park Brake: Power Brake....8756
Manually Releasing Power Park Brake....8756
Rod Stroke Sensor: Remove ....8757
Rod Stroke Sensor: Install....8759
Spring Chamber Assembly: Remove....8760
Spring Chamber Assembly: Install....8762
Special Tools....8764
4. SmartTrac™ Brakes and Traction Control System....8765
Hydraulic Brake System....8765
Overview....8765
Brake Bleed Procedure....8768
Overview....8768
Special Tools....8768
Equipment Conditions....8768
Procedure....8768
Follow-On Procedure....8769
Manual Brake Bleeding....8770
Overview....8770
Special Tools....8770
Equipment Conditions....8770
Procedure....8771
Follow-On Procedure....8773
Traction Control....8774
Overview....8774
Parking Brake....8776
Overview....8776
Parking Brake Cable....8777
Overview....8777
5. Full Power Hydraulic ABS Brake System for Models Built Starting 03 May 2007....8778
Safety Precautions....8778
General Warnings / Cautions for Servicing the Full Power Brake System....8778
Asbestos and Non-Asbestos Fibers....8782
Asbestos Fibers Warning....8782
Hazard Summary....8782
Recommended Work Practices....8782
Regulatory Guidance....8783
Non-Asbestos Fibers Warning....8784
Hazard Summary....8784
Recommended Work Practices....8784
Regulatory Guidance....8785
Overview....8786
Standard Features....8786
Optional Features....8786
Service Brakes (Normal Braking)....8786
Normal Braking with Electronic Brakeforce Distribution....8787
Anti-lock Braking System (ABS)....8787
Automatic Traction Control (ATC) System (Optional)....8788
Overview....8788
TRAC CTRL Indicator....8788
Traction Control Mud/Snow Switch....8789
Warning Indicators....8790
System Layout....8793
System Components....8795
Overview....8795
Master Cylinder and Reservoir....8796
Hydraulic Compact Unit (HCU)....8797
Electronic Control Unit (ECU)....8802
Foundation Brakes (Rotors and Calipers)....8803
Wheel Speed Sensors....8804
Body Controller....8805
Driveline Parking Brake Drum....8805
Traction Control (Mud and Snow) Switch (with Optional ATC)....8806
Electronic Gauge Cluster (EGC)....8808
Brake Pressure Indicator....8808
Brake Fluid Indicator....8808
ABS Indicator....8808
TRAC CTRL Indicator....8809
Brake Indicator....8809
Operation....8810
Warning Indicators....8812
Normal Breaking Operation....8815
Overview....8815
Normal Operation (Brakes Not Applied)....8815
Normal Operation (Brakes Applied)....8817
Anti-lock (ABS) Braking Mode....8818
Overview....8818
ABS Decrease Pressure Stage....8819
ABS Hold Stage....8820
ABS Increase Pressure Stage....8821
Automatic Traction Control (ATC) Mode (Vehicles with Optional ATC)....8822
Overview....8822
ATC Inactive (ATC Circuit Operation with No ATC Event Occurring)....8823
ATC Active (ATC Circuit Operation while Experiencing an ATC Event)....8825
System Maintenance....8827
Service Procedures....8828
Equipment Conditions....8828
Pressure Bleeding the Full Power Breaks System....8829
Overview....8829
Tools Required....8829
Master Cylinder (MC) Bleeding Procedure....8830
Brake Caliper Bleeding Procedure....8834
Overview....8834
Test Setup....8834
Test Procedure....8834
Wheel Speed Sensor Adjustment....8837
Sensor Adjustment....8837
Diagnostics and Troubleshooting....8838
Diagnosis....8838
Overview....8838
Fault Detection....8839
TOOLBOX™ Software....8839
Diagnostic Trouble Codes....8839
Observing Signals with the EZ-Tech® Service Tool....8840
Definitions....8840
Troubleshooting....8840
Introduction....8840
Troubleshooting Tables....8840
General Information Regarding the Driver Interface....8840
Troubleshooting Table (System Reaction)....8841
Multiple Failures Table....8841
Special System Conditions....8841
Repair Instructions....8841
Warning Indicators....8856
General Electrical System....8856
ABS and ATC Wiring....8858
Wheel Speed Sensor Output Voltage Test....8858
Front Axle....8858
Rear Axle....8859
Wheel Speed Sensor Resistance....8859
Remove and Install....8861
Master Cylinder (MC)....8865
Overview....8865
Remove....8866
Install....8870
Brake Light Switch (Mounted on MC)....8872
Overview....8872
Remove....8872
Install....8872
Master Cylinder Reservoir....8873
Overview....8873
Remove....8873
Equipment Conditions....8873
Remove Procedure....8873
Install....8875
Follow-On Procedures....8876
Fluid Level Switch (Mounted on MC Reservoir)....8877
Overview....8877
Remove....8877
Equipment Conditions....8877
Remove Procedure....8877
Install....8877
Follow-On Procedure....8877
Low Pressure Hose....8878
Overview....8878
Remove....8878
Equipment Conditions....8878
Remove Procedure....8878
Install....8881
Electronic Control Unit (ECU)....8883
Overview....8883
Remove....8884
Install....8886
Accumulator....8888
Overview....8888
Remove....8888
Install....8890
Accumulator Disposal Procedure....8892
Hydraulic Compact Unit (HCU)....8894
Overview....8894
Remove....8895
Install....8898
HCU Reservoir....8901
Overview....8901
Remove....8901
Install....8902
Relay Valve Assembly....8903
Overview....8903
Remove....8903
Install....8906
HCU Pumps....8908
Overview....8908
Secondary HCU Pump Removal and Installation....8908
Primary HCU Pump Removal and Installation....8912
Brake Lines (General)....8913
Overview....8913
Remove....8913
Install....8914
Wheel Speed Sensor....8916
Overview....8916
Sensor Lube Specification....8917
Remove....8917
Install....8918
Specifications....8919
Torque....8919
Full Power Brake System Specifications....8922
Tire Size Range....8922
Special Tools....8923
Essential Tools....8923
Overview....8923
Brake Bleeding Adapter (ZTSE4678)....8923
Regulator / Filter (ZTSE4757)....8923
Electronic Service Tool (EST), EZ-TECH® ....8924
TOOLBOX Diagnostic Software....8924
Common Tools....8924
Steering....8926
1. Steering Wheel and Steering Column Assembly....8928
Description....8928
Steering Wheel....8928
Clock Spring....8928
Steering Column....8929
Remove and Install Procedures....8930
Equipment Conditions....8930
Steering Wheel....8931
Overview....8931
Removal....8932
Installation....8934
Clock Spring....8936
Removal....8936
Installation....8939
Steering Column....8941
Overview....8941
Removal....8941
Installation....8942
Checks and Adjustments....8944
Steering Wheel....8944
Check....8944
Adjust....8944
Torque....8945
2. Power Steering Gear: Sheppard M-Series....8946
Identification....8946
Operation....8949
OIL FLOW THROUGH THE GEAR....8950
Steering System Diagnostics....8952
Diagnostic Overview....8952
Define the Concern....8952
Perform Visual Inspection....8952
Inspect Mechanical Components....8952
Hydraulic Diagnosis....8952
Oil Flow and Pressure Recommendations....8955
Common Complaints....8955
Troubleshooting....8958
Symptoms Table....8958
Re-phasing Column....8961
Troubleshooting Checklist....8962
Preventative Maintenance....8963
Fluid and Filter Change....8963
Input Shaft Seal Replacement — Disassembly....8965
Input Shaft Seal Replacement — Assembly....8969
Bleeding....8972
Single Gear System....8972
Dual Steering Gears....8974
Set Relief Plungers....8977
Pitman Arm....8978
Remove....8978
Install....8980
Steering Gear Disassembly....8987
Sub-assembly Repair....9002
M-SERIES - OPTIONAL INTEGRAL RELIEF VALVE....9002
Clean....9004
Inspect....9005
Parts Discolored (Blue)....9005
Broken Housing....9005
Housing or Piston Scoring....9005
Sector Shaft Roller (Bearing Wear)....9005
Actuating Shaft....9006
Thrust Bearings....9006
Actuating Shaft Thread Wear....9006
Piston Rings Cut, Pinched, Sheered or Worn....9006
Reassemble....9007
Dual Steering System....9023
Description....9023
Operation....9023
Integral Slave Gear....9026
Adjustments....9028
Final....9028
Axle Stop....9028
Specifications....9029
Torque....9029
Special Tools....9030
Glossary of Terms and Definitions....9030
3. Power Steering Gear with Hydro-Max® Brake System....9033
Overview....9033
Cummins ISB with TRW....9034
Cummins ISB with Sheppard....9034
N9 with TRW....9034
Power Steering Fluid Flow Test....9035
Overview....9035
Special Tools....9035
Equipment Conditions....9035
Procedure....9036
Follow-On Procedure....9037
Drivelines....9038
Exhaust....9042
Electrical / Software....9046
1. How to Use Diamond Logic® Builder (DLB)....9060
Interface Device Selection....9060
Connecting Diamond Logic® Builder Software....9062
Activating Diagnostic mode....9063
Making a Session with Diamond Logic® Builder....9064
2. 12 Volt Electrical System....9065
Battery Box....9065
Overview....9065
Battery Disconnect....9068
Special Tools....9068
Torque Specifications....9068
Equipment Conditions....9068
Disconnect Procedure....9069
Follow-On Procedure....9069
Battery Reconnect....9070
Special Tools....9070
Torque Specifications....9070
Equipment Conditions....9070
Reconnect Procedure....9071
Follow-On Procedure....9071
Battery Disconnect Switch....9072
Overview....9072
Brake Switch....9073
Overview....9073
SPN 597 FMI 0 – Brake Switch reading above normal range....9076
Overview....9076
Associated Faults....9076
Fault Facts....9076
Tools Required....9076
Possible Causes....9076
SPN 597 FMI 1 – Brake Switch reading below normal range....9079
Overview....9079
Associated Faults....9079
Fault Facts....9079
Possible Causes....9079
CAN Systems....9081
Overview....9081
Faults....9081
Short....9081
Terminating Resistor Failure....9081
Backbone Open....9081
Node Open....9082
Tests....9083
Module Communication Test....9083
Overview....9083
Tools Required....9083
Equipment Condition....9083
Test Setup....9083
Test Procedure....9084
Follow-On Procedure....9084
Remote Start / Stop....9085
Remote Start Stop Overview....9085
Remote Start / Stop with 500K....9087
Overview....9087
Operational Checkout Procedure....9088
Overview....9088
Remote Start / Stop Not Operating with 500K....9089
Fault Overview....9089
Fault Facts....9089
Possible Causes....9089
Pin-Point Test - Remote Start / Stop Not Operating with 500K....9096
Tools Required....9096
Remote Start / Stop with 250K....9097
Overview....9097
Operational Checkout Procedure....9099
Troubleshooting....9100
Operational Checkout Procedure....9100
Electrical System Operational Checkout Procedure....9100
Starting System....9102
System Overview....9102
Battery Pack....9102
Starter....9102
Control....9102
No Click No Crank....9103
Overview....9103
Possible Causes....9103
Click No Crank....9105
Overview....9105
Possible Causes....9105
Low Cranking Speed....9106
Overview....9106
Possible Causes....9106
250K Input Diagnostics....9107
Overview....9107
Navistar Starter Input Diagnostics....9108
Navistar Starter Input Pinpoint Tests....9111
Cummins Starter Input Diagnostics....9117
Cummins Starter Input Pinpoint Tests....9121
500K Input Diagnostics....9124
Overview....9124
Key Switch and Grid Control....9124
Crank Inhibit....9124
GridCtrl_CrankInhibit....9124
Crank_Inhibit_Reason....9124
Lower_Clutch_Signal....9125
Neutral_Status_TCM....9125
Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal)....9125
Hood_Switch....9125
500K Input Operational Checkout Procedure....9127
Overview....9127
Charging System....9131
System Overview....9131
Battery Pack....9131
Alternator....9131
Red Battery Warning Light....9132
Overview....9132
Possible Causes....9132
Repeated Jump Starts....9133
Overview....9133
Possible Causes....9133
Battery Gauge Reading High....9135
Overview....9135
Possible Causes....9135
Battery Gauge Reading Low / Fluctuating....9136
Overview....9136
Possible Causes....9136
Tests....9138
Battery Test....9138
Overview....9138
Tools Required....9138
Equipment Condition....9138
Test Setup....9138
Test Procedure....9138
Expected Outcome....9139
Follow-On Procedure....9140
Electrical System Test....9141
Overview....9141
Tools Required....9141
Equipment Condition....9141
Test Setup....9141
Test Procedure....9141
Starter System Test Procedure....9144
Charging System Test Procedure....9145
Expected Outcome....9146
Follow-On Procedure....9146
Cable Drop Test....9147
Overview....9147
Tools Required....9147
Equipment Condition....9147
Test Setup....9147
Test Procedure....9147
Expected Outcome....9148
Follow-On Procedure....9148
Parasitic Draw Test....9149
Overview....9149
Tools Required....9149
Equipment Condition....9149
Test Setup....9149
Test Procedure....9150
Expected Outcome....9152
Follow-On Procedure....9152
Manual Engine Bar Test....9153
Overview....9153
Tools Required....9153
Equipment Condition....9153
Test Setup....9153
Test Procedure....9153
Expected Outcome....9153
Follow-On Procedure....9153
Starter Control Circuit Test....9154
Overview....9154
Tools Required....9154
Equipment Condition....9154
Test Setup....9154
Test Procedure....9154
Expected Outcome....9154
Follow-On Procedure....9155
Inspections....9156
Ring Gear Inspection....9156
Overview....9156
Tools Required....9156
Equipment Condition....9156
Inspection Procedure....9156
Expected Outcome....9157
Follow-On Procedure....9157
Electrical System Inspection....9158
Overview....9158
Tools Required....9158
Equipment Condition....9158
Inspection Procedure....9158
Expected Outcome....9158
Follow-On Procedure....9158
3. Accessories....9159
Air Dryer and Heated Drain Valve....9159
Overview....9159
Diagnostics....9159
Air Horn....9160
Overview....9160
Operational Checkout Procedure....9162
Air Horn Test....9163
Air Solenoid....9163
Overview....9163
Operational Checkout Procedure....9174
Air Solenoid Diagnosis....9175
Auxiliary Power Source....9175
Overview....9175
Diagnostics....9176
Axle Load Monitor....9177
Overview....9177
User Programmable Parameters....9178
Diagnostic Trouble Codes (DTC)....9180
Diagnostics....9182
Body Controller Signals....9184
Body Controller Functions....9185
To activate the axle load monitor feature, the following conditions must be true:....9185
C.B. Power Radio....9186
Overview....9186
Diagnostics....9186
Cigar Lighter and Power Feed ....9187
Overview....9187
Diagnostics....9188
Cruise Control....9190
Overview....9190
Operational Checkout Procedure....9193
Cruise Control Switch Tests....9195
Customer Installed Lift Gate Power Source....9196
Overview....9196
User Programmable Parameters....9197
Diagnostics....9199
Differential Lock, Air Controlled....9199
Overview....9199
User Programmable Parameters....9201
Diagnostics....9204
Electric Horn....9206
Overview....9206
Operational Checkout Procedure....9208
Electric Horn Test....9209
Fifth Wheel Slide, Air Controlled....9209
Overview....9209
User Programmable Parameters....9210
Diagnostics....9211
Fuel Transfer Pump....9212
Overview....9212
User Programmable Parameters....9212
Diagnostics....9215
Heated Mirrors....9218
Overview....9218
Feature Codes....9220
Diagnostic Trouble Codes....9222
Diagnostics....9223
Heated Seats....9225
Overview....9225
Diagnostics....9226
Load Shedding....9227
Overview....9227
Latching Relay Diagnostics....9227
Power Divider Lock, Air Controlled....9228
Overview....9228
User Programmable Parameters....9229
Diagnostics....9231
Power Take Off (PTO)....9232
Overview....9232
Operational Checkout Procedure....9257
PTO Test....9259
Power Windows and Locks....9263
Overview....9263
Operational Checkout Procedure....9267
Power Windows....9268
Power Window Overview....9268
Operational Checkout Procedure....9270
Power Window Test....9271
Power Door Locks....9272
Power Door Lock Overview....9272
Operational Checkout Procedure....9274
Power Door Lock Tests....9275
Power Mirrors....9279
Overview....9279
Diagnostics....9280
Radio and Speakers....9284
Overview....9284
Diagnostics....9284
Remote Power Module....9285
Overview....9285
RPM Addressing....9286
Operational Checkout Procedure....9290
RPM Diagnostics....9291
Roof Auxiliary and Air Shield Light....9293
Overview....9293
Roof Auxiliary Load....9294
Overview....9294
Operational Checkout Procedure....9294
Roof Auxiliary Load Test....9295
Lighted Air Shield....9296
Overview....9296
Lighted Air Shield Preliminary Check....9296
Lighted Air Shield Test....9297
Seat Belt and Seat Sensor....9298
Overview....9298
Feature Codes....9298
User programmable parameters....9298
Diagnostics....9299
Self Contained Air Seat....9300
Overview....9300
Diagnostics....9300
Suspension Dump....9304
Overview....9304
User Programmable Parameters....9304
Diagnostics....9307
Theft Deterrent System....9308
Overview....9308
Operational Checkout Procedure....9310
Theft Deterrent System Not Responding....9311
Fault Overview....9311
Fault Facts....9311
Possible Causes....9311
Two-speed Axle Switch....9313
Overview....9313
Diagnostics....9314
Two-way Radio....9314
Overview....9314
Diagnostics....9315
Water In Fuel Monitor Test....9316
Overview....9316
Diagnostics....9317
Wheelchair Lift Interlock....9317
Overview....9317
Activate Wheelchair Lift Solenoid....9318
Activate Audible Alarm....9318
Diagnostic Trouble Codes....9320
Operational Checkout Procedure....9321
4. Aftertreatment....9324
Overview....9324
Operation....9324
Aftertreatment Definitions....9325
Soot Accumulation Level Indications....9325
Feature Related Text Messages in the Gauge Cluster....9327
Feature Codes....9327
Diagnostic Trouble Codes....9329
Body Controller Signals....9332
Body Controller Functions....9334
Parked Regeneration....9335
Inhibit Regeneration....9336
Parked Regeneration Switch Indicator....9337
Inhibit Regeneration Switch Indicator....9338
DPF Status Warning Lamp....9339
HEST Warning Lamp....9340
Audible Alarm....9341
Aftertreatment Troubleshooting....9342
Parked Regeneration Switch Test....9342
Parked Regeneration Switch Indicator Test....9343
Inhibit Regeneration Switch Test....9343
Inhibit Regeneration Switch Indicator Test....9344
DPF Status Warning Lamp Test....9344
HEST Warning Lamp Test....9344
Lamp Check....9344
Lost Communication and Warning Lamp Diagnostics....9345
5. Brakes and Traction Control System....9346
Bendix Air Brake System....9346
Anti-Lock Brake System (ABS)....9346
Overview....9346
Inputs....9349
Outputs....9350
Operational Checkout Procedure....9352
Overview....9352
Symptom 1: ABS Module Loss of Communication....9353
Overview....9353
Fault Facts....9353
Tools Required....9353
Possible Causes....9353
Automatic Traction Control System....9356
Overview....9356
Inputs....9358
Outputs....9358
Electronic Stability Control (ESC) System....9360
Overview....9360
Inputs....9361
Outputs....9362
Parking Brake....9364
Overview....9364
Park Brake Indicator....9365
Park Brake Switch Diagnostics....9366
Overview....9366
Associated Faults....9366
Fault Facts....9366
Special Tools....9366
Possible Causes....9366
SmartTrac™ Hydraulic Brake System....9370
Overview....9370
Operational Checkout Procedure....9376
Overview....9376
Low Brake Fluid Level Diagnostics....9379
Overview....9379
Associated Faults....9379
Fault Facts....9379
Special Tools....9379
Possible Causes....9379
ABS Diagnostics....9382
Overview....9382
Associated Faults....9383
Fault Facts....9383
Special Tools....9383
Possible Causes....9383
SPN 1044 FMI 3 Hydraulic Pump Motor – Above Normal....9390
Overview....9390
Associated Faults....9390
Fault Facts....9390
Special Tools....9390
Possible Causes....9390
SPN 1044 FMI 4 Hydraulic Pump Motor – Below Normal....9394
Overview....9394
Associated Faults....9394
Fault Facts....9394
Special Tools....9394
Possible Causes....9394
SPN 1044 FMI 5 Hydraulic Pump Motor – Open....9400
Overview....9400
Associated Faults....9400
Fault Facts....9400
Special Tools....9400
Possible Causes....9400
SPN 2584 FMI 3 Hydraulic Brake Pressure Warning State Circuit 1 – Above Normal....9404
Overview....9404
Associated Faults....9404
Fault Facts....9404
Special Tools....9404
Possible Causes....9404
SPN 2584 FMI 4 Hydraulic Brake Pressure Warning State Circuit 1 – Below Normal....9410
Overview....9410
Associated Faults....9410
Fault Facts....9410
Special Tools....9410
Possible Causes....9410
SPN 2584 FMI 5 Hydraulic Brake Pressure Warning State Circuit 1 – Open....9416
Overview....9416
Associated Faults....9416
Fault Facts....9416
Special Tools....9416
Possible Causes....9416
SPN 520941 FMI 5 Hydro-Max Control output of BC – Open....9422
Overview....9422
Associated Faults....9422
Fault Facts....9422
Special Tools....9422
Possible Causes....9422
SPN 520941 FMI 6 Hydro-Max Control output of BC – Shorted to Ground / Over Current....9431
Overview....9431
Associated Faults....9431
Fault Facts....9431
Special Tools....9431
Possible Causes....9431
Tests and Inspections....9435
Hydraulic Brake System Inspection....9435
Overview....9435
Special Tools....9435
Equipment Condition....9435
Test Setup....9436
Test Procedure....9436
Expected Outcome....9436
Traction Control System....9437
Overview....9437
6. Collision Avoidance Systems....9440
Collision Mitigation System....9440
Bendix® Wingman® Advanced™....9440
Overview....9440
Adaptive Cruise Control (ACC)....9443
Alerts....9443
Collision Mitigation Braking....9443
Tech Tips....9445
Operational Checkout Procedure....9446
Overview....9446
Symptom 1: Radar Sensor Loss of Communication....9448
Overview....9448
Fault Facts....9448
Tools Required....9448
Possible Causes....9448
Radar Sensor Removal....9451
Special Tools....9451
Torque Specifications....9451
Equipment Conditions....9451
Removal Procedure....9451
Follow-On Procedure....9452
Radar Sensor Installation....9453
Special Tools....9453
Torque Specifications....9453
Equipment Conditions....9453
Installation Procedure....9453
Follow-On Procedure....9454
Radar Sensor Adjustment....9455
Special Tools....9455
Equipment Conditions....9455
Lateral Adjustment Procedure....9456
Vertical Adjustment Procedure....9458
Follow-On Procedure....9460
Bendix® Wingman® Fusion™....9461
Overview....9461
Adaptive Cruise Control (ACC)....9463
Alerts....9463
Collision Mitigation Braking....9464
SafetyDirect Capability....9464
Stationary Vehicle Braking (SVB)....9464
Tech Tips....9466
Operational Checkout Procedure....9467
Overview....9467
Symptom 2: Camera Sensor Loss of Communication....9470
Overview....9470
Fault Facts....9470
Tools Required....9470
Possible Causes....9470
Symptom 3: SafetyDirect® Module Loss of Communication....9473
Overview....9473
Fault Facts....9473
Tools Required....9473
Possible Causes....9473
Camera Removal....9476
Special Tools....9476
Torque Specifications....9476
Equipment Conditions....9476
Removal Procedure....9476
Follow-On Procedure....9477
Camera Installation....9478
Special Tools....9478
Torque Specifications....9478
Equipment Conditions....9478
Installation Procedure....9478
Follow-On Procedure....9479
SafetyDirect® Module Removal....9480
Special Tools....9480
Torque Specifications....9480
Equipment Conditions....9480
Removal Procedure....9480
Follow-On Procedure....9480
SafetyDirect® Module Installation....9481
Special Tools....9481
Torque Specifications....9481
Equipment Conditions....9481
Installation Procedure....9481
Follow-On Procedure....9481
7. Engine Accessories....9482
Engine Cooling Fan Control....9482
Overview....9482
Operation....9482
Feature Codes....9483
Diagnostic Trouble Codes....9484
Operational Checkout....9485
Body Controller Signals....9486
Body Controller Functions....9488
Fan Control — General Information....9488
ON/OFF Fan Control....9488
Low Air Pressure Engine Fan Override (0595BBB)....9489
Variable Speed Fan Control (0595AYH)....9489
Exhaust Brake....9492
Overview....9492
Operation....9492
Feature Codes....9492
Diagnostic Trouble Codes....9492
Operational Checkout....9494
Exhaust Brake Switch Test....9495
Body Controller Signals....9496
Body Controller Functions....9496
To activate the exhaust brake feature, the following conditions must be true:....9496
If the conditions to activate the feature (above) are true, then the following will occur:....9496
Remote Engine Speed Control Module (RESCM)....9497
Overview....9497
Operation....9497
Feature Codes....9498
User Programmable Parameters....9498
Diagnostic Trouble Codes....9499
RESCM Preliminary Check....9504
Body Controller Signals....9505
Body Controller Functions....9508
Snow Valve (engine intake) (big bore engines)....9509
Overview....9509
Operation....9509
Feature Codes....9510
User Programmable Parameters....9510
Diagnostic Trouble Codes....9510
Snow Valve Operational Checkout....9511
Snow Valve Mechanical Checks....9512
Snow Valve Switch Test....9513
Snow Valve Module Checks....9514
Body Controller Signals....9516
Body Controller Functions....9516
To activate the feature, the following conditions must be true:....9516
If the conditions to activate the feature (above) are true, then the following will occur:....9516
If any of the following conditions occur, then the feature will be deactivated.....9517
If any of the conditions to deactivate the feature (above) are true, then the following will occur:....9517
Snow Valve (engine intake) (non big bore engines)....9518
Overview....9518
Operation....9518
Operational Checkout....9518
Snow Valve Mechanical Checks....9519
Snow Valve Module Checks....9519
Feature Codes....9520
8. Data Link System....9521
Overview....9521
J1708 Datalink....9521
J1708 Data Link (ATA)....9521
J1708 Switch Pack Data Link....9522
Overview....9522
9. HVAC System....9524
Overview....9524
Air Distribution (General)....9526
Air Distribution (Air Conditioning)....9528
Air Distribution (Heat and Ventilation)....9529
Air Distribution (Defrost)....9529
A/C Refrigerant Flow....9530
General Operation of the HVAC Electrical System....9532
Operational Checkout Procedure....9533
1.0 – Front HVAC System Operational Checkout Procedure....9533
Symptoms....9535
1.1 – A/C Blows Warm All the Time (Incorrect System Pressure)....9535
Overview....9535
Possible Causes....9535
1.2 – Heater Does Not Blow Warm....9539
1.3 – Compressor Does Not Cycle....9540
Overview....9540
Possible Causes....9540
1.4 – Operator Not Able to Control Air Flow Outlet....9543
Overview....9543
Special Tools....9547
A/C System Flush Tool 19-000-01....9547
Servicing System RHS980C-NAV....9548
RHS980C-NAV TEMPERATURE PROBES....9549
REFRIGERANT IDENTIFIER ....9549
Air Conditioning Oil and Dye Injection Equipment 12401-NAV....9550
D-400A AND D440A-NAV REFRIGERANT LEAK DETECTORS....9551
TOOLS OBTAINED LOCALLY....9552
Fault Codes....9554
SPN 876 FMI 5 – Compressor Clutch Circuit ....9554
Fault Overview....9554
Associated Faults....9554
Fault Facts....9554
Possible Causes....9554
SPN 1079 FMI 1 – 5 Volt Sensor Supply Below Normal....9555
SPN 1552 FMI 2 – A/C Control Head Temperature Mix DM1....9556
Fault Overview....9556
Associated Faults....9556
Fault Facts....9556
Possible Causes....9556
Pin-Point Test SPN 1552 FMI 2....9557
Tools Required....9557
SPN 2609 FMI 16 – A/C High Pressure Protection....9558
Fault Overview....9558
Associated Faults....9558
Fault Facts....9558
Possible Causes....9558
SPN 3981 FMI 2 – A/C Control Head Mode Fault DM1....9561
Fault Overview....9561
Associated Faults....9561
Fault Facts....9561
Possible Causes....9561
Pin-Point Test SPN 3981 FMI 2....9562
Tools Required....9562
SPN 3984 FMI 2 – A/C Control Head Air Inlet DM1....9563
Fault Overview....9563
Associated Faults....9563
Fault Facts....9563
Possible Causes....9563
Pin-Point Test SPN 3984 FMI 2....9564
Tools Required....9564
SPN 3985 FMI 9 – A/C Control Head Circuit Failed To Communicate With Body Controller....9565
Fault Overview....9565
Associated Faults....9565
Fault Facts....9565
Possible Causes....9565
Pin-Point Test SPN 3985 FMI 9....9566
Tools Required....9566
SPN 520465 FMI 2 – A/C Control Head Multiple Motor Faults....9568
Fault Overview....9568
Associated Faults....9568
Fault Facts....9568
Possible Causes....9568
Pin-Point Test SPN 520465 FMI 2....9570
Tools Required....9570
Tests and Inspections....9573
A/C Compressor Clutch Electrical Tests....9573
Overview....9573
Tools Required....9573
Equipment Condition....9573
Test Setup....9573
Test Procedure....9573
Expected Outcome....9576
Follow-On Procedure....9576
A/C Request Electrical Tests....9577
Overview....9577
Tools Required....9577
Equipment Condition....9577
Test Setup....9577
Test Procedure....9577
Expected Outcome....9578
Follow-On Procedure....9578
A/C System Functional Test....9579
Overview....9579
Tools Required....9579
Equipment Condition....9579
Test Setup....9579
Test Procedure....9579
Expected Outcome....9579
Follow-On Procedure....9579
A/C System Inspection....9580
Overview....9580
Tools Required....9580
Equipment Condition....9580
Inspection Procedure....9581
Expected Outcome....9588
A/C System Internal Damage Inspection....9589
Overview....9589
Tools Required....9589
Equipment Condition....9589
Inspection Procedure....9589
Expected Outcome....9592
A/C System Restriction Test....9593
Overview....9593
Tools Required....9593
Equipment Condition....9593
Test Setup....9593
Test Procedure....9593
Expected Outcome....9594
Blend Door Tests....9595
Overview....9595
Tools Required....9595
Equipment Condition....9595
Test Setup....9595
Test Procedure....9596
Expected Outcome....9599
Follow-On Procedure....9599
Blower Motor Electrical Tests....9600
Overview....9600
Tools Required....9600
Equipment Condition....9600
Test Setup....9600
Test Procedure....9600
Expected Outcome....9603
Follow-On Procedure....9603
Body Controller Power and GND Tests....9605
Overview....9605
Tools Required....9605
Equipment Condition....9605
Test Setup....9605
Test Procedure....9605
Expected Outcome....9606
Follow-On Procedure....9606
Charge Quantity Measurement Test....9607
Overview....9607
Tools Required....9607
Equipment Condition....9607
Test Setup....9607
Test Procedure....9607
Expected Outcome....9607
Compressor Clutch Signal Check....9608
Overview....9608
Tools Required....9608
Equipment Condition....9608
Test Setup....9608
Test Procedure....9609
Expected Outcome....9611
Follow-On Procedure....9611
Control Head Electrical Tests....9612
Overview....9612
Tools Required....9612
Equipment Condition....9612
Test Setup....9612
Test Procedure....9612
Expected Outcome....9614
Follow On Procedure....9614
Freeze Probe Electrical Tests....9615
Overview....9615
Tools Required....9615
Equipment Condition....9615
Test Setup....9615
Test Procedure....9615
Expected Outcome....9617
Follow On Procedure....9617
Heater Core Seal Leak Test....9618
Overview....9618
Tools Required....9618
Equipment Condition....9618
Test Setup....9618
Test Procedure....9619
Expected Outcome....9620
Follow On Procedure....9620
HVAC Actuator Calibration Procedure....9621
Overview....9621
Tools Required....9621
Equipment Condition....9621
Test Setup....9621
Test Procedure....9621
Expected Outcome....9621
HVAC Module Inspection....9622
Overview....9622
Tools Required....9622
Equipment Condition....9622
Test Setup....9622
Inspection Procedure....9622
Expected Outcome....9624
Leak Detection Test....9625
Overview....9625
Tools Required....9625
Equipment Condition....9625
Test Procedure Refrigerant Present....9625
Test Procedure No Refrigerant Present....9626
Test Procedure No Refrigerant Present - High Pressure Nitrogen....9627
Expected Outcome....9628
Low-Pressure Switch Electrical Tests....9629
Overview....9629
Tools Required....9629
Equipment Condition....9629
Test Setup....9629
Test Procedure....9629
Expected Outcome....9631
Follow On Procedure....9631
Mode Door Tests....9632
Overview....9632
Tools Required....9632
Equipment Condition....9632
Test Setup....9632
Test Procedure....9633
Expected Outcome....9636
Follow On Procedure....9636
Pressure Transducer Electrical Tests....9637
Overview....9637
Tools Required....9637
Equipment Condition....9637
Three-wire Pressure Transducer Test Procedure....9637
Expected Outcome....9639
Pressure Transducer Functional Test....9640
Overview....9640
Tools Required....9640
Equipment Condition....9640
Test Setup....9640
Pressure Test Procedure....9640
Temperature Test Procedure....9640
Expected Outcome....9641
Recirculation Door Tests....9642
Overview....9642
Tools Required....9642
Equipment Condition....9642
Test Setup....9642
Test Procedure....9643
Expected Outcome....9646
Follow On Procedure....9646
Static Pressure Test....9647
Overview....9647
Tools Required....9647
Equipment Condition....9647
Test Setup....9647
Test Procedure....9647
Expected Outcome....9648
Follow On Procedure....9648
System Performance Test....9649
Overview....9649
Tools Required....9649
Equipment Condition....9649
Test Setup....9649
Test Procedure....9649
Expected Outcome....9650
Follow-On Procedure....9650
Switch Pack Electrical Tests....9651
Overview....9651
Tools Required....9651
Equipment Condition....9651
Test Setup....9651
Test Procedure....9651
Expected Outcome....9654
Follow On Procedure....9654
Flush and Purge HVAC System....9656
Flush HVAC System....9656
Overview....9656
Tools Required....9658
Equipment Conditions....9661
Flush Procedure....9662
Refrigerant Line Flush....9669
Purge HVAC System....9670
Overview....9670
Purge Procedure....9671
Service Procedures....9672
Charging the System (Charge Mode)....9672
Checking Compressor Oil Level....9673
Discharging the System (Recycle Mode)....9676
Evacuating the System (Vacuum Mode)....9678
Oil Fill....9680
Oil Fill Guidelines....9680
Oil Separation During Refrigerant Recovery....9682
Excessive Oil Loss Due to Refrigerant Leaks....9682
Refrigerant Identification....9685
Overview....9685
Tools Required....9685
Procedure....9685
Remove and Install Procedures....9686
A / C Condenser – Removal....9686
Analog Controls – Installation....9687
Blend Door Actuator – Removal....9688
Blend Door Actuator – Installation....9689
Blend Door Gear Train – Removal....9690
Blend Door Gear Train – Installation....9693
Blower Assembly – Removal....9694
Blower Assembly – Installation....9695
Blower Scroll Housing – Removal....9696
Blower Scroll Housing – Installation....9697
Compressor / Clutch – Removal....9698
Digital Controls – Installation....9699
Evaporator – Removal....9700
Evaporator – Installation....9701
Filter-Drier – Removal....9702
Filter-Drier – Installation....9704
Front HVAC Module – Removal....9705
Freeze Probe – Removal....9711
Freeze Probe – Installation....9712
Fresh Air Module – Removal....9713
Fresh Air Module – Installation....9715
Heater Core – Removal....9716
Heater Core – Installation....9718
Heater Hoses / Lines....9719
HVAC Air Filter – Removal....9720
HVAC Air Filter – Installation....9721
HVAC Control Panel Assembly – Removal....9722
HVAC Control Panel Assembly – Installation....9723
Interior Module – Installation....9724
Interior Module Trim Cover – Removal....9726
Interior Module Trim Cover – Installation....9727
Linear Power Module (LPM) – Removal....9728
Linear Power Module (LPM) – Installation....9730
Low Pressure Switch – Removal....9731
Low Pressure Switch – Installation....9732
Mode Door Actuator – Removal....9733
Mode Door Actuator – Installation....9734
Mode Door Gear Train – Removal....9735
Mode Door Gear Train – Installation....9738
Pressure Transducer – Removal....9739
Pressure Transducer – Installation....9740
Recirculation Door Actuator – Removal....9741
Recirculation Door Actuator – Installation....9742
Recirculation Door Gear Train – Removal....9743
Recirculation Door Gear Train – Installation....9745
Recirculation Filters – Removal....9746
Recirculation Filters – Installation....9748
Recirculation, Mode, and Blend Doors – Removal....9749
Refrigerant Line – Removal....9750
Refrigerant Line – Installation....9752
Separating Blower Scroll Housing – Removal....9753
Separating Front HVAC Module – Removal....9755
Splitting / Separating Blower Scroll Housing – Installation....9758
Splitting / Separating Interior Module – Installation....9759
Thermostatic Expansion Valve (TXV) – Removal....9760
Thermostatic Expansion Valve (TXV) – Installation....9761
10. Instrumentation and Gauges....9762
Overview....9762
Operational Checkout Procedure....9762
Overview....9762
Step-Based Diagnostics....9763
Audible Alarm....9765
One-time Five-short-beeps Alarm....9765
Repetitive One-short-beep Alarm....9765
One-time Ten-short-beeps Alarm ....9765
One-time Three-long-beeps Alarm....9766
Repetitive Short Duration Blips ....9766
EGC Programming....9766
Gauges....9767
Air 1 Gauge....9767
Overview....9767
Possible Causes....9768
Step Based Diagnostics....9768
Pin-Point Tests — Air 1 Gauge....9771
Tools Required....9772
Air 2 Gauge....9780
Overview....9780
Possible Causes....9781
Step Based Diagnostics....9781
Pin-Point Tests — Air 2 Gauge....9784
Tools Required....9785
Auxiliary Gauge Switch Pack....9792
Overview....9792
In-Gauge Warning Lamps....9792
Gauge Sweep....9792
Lost Communication....9793
Gauge Faults....9794
Diagnostic Trouble Codes....9795
Operational Checkout Procedure....9797
Eaton Hybrid Auxiliary Gauge Pack....9798
AGSP Power and Data Link Voltage Checks....9798
Gauge Troubleshooting Procedure....9799
Troubleshooting Specific Gauges....9800
Forward-Rear Axle Temperature Gauge Troubleshooting....9800
Rear-Rear Axle Temperature Gauge Troubleshooting....9802
Air Application Gauge Troubleshooting....9806
Ammeter Gauge Troubleshooting....9808
Compass Display....9808
Overview....9808
Diagnostic Trouble Codes....9809
DEF Level....9811
Overview....9811
Possible Causes....9811
Step Based Diagnostics....9811
Engine Coolant Temperature....9813
Overview....9813
Step Based Diagnostics....9813
Engine Oil Pressure....9814
Overview....9814
Step Based Diagnostics....9814
Engine Oil Temperature....9815
Overview....9815
Step Based Diagnostics....9815
Engine Speed (Tachometer)....9816
Overview....9816
Step Based Diagnostics....9816
Fuel Level....9817
Overview....9817
Possible Causes....9817
Step Based Diagnostics....9818
Outside Air Temperature....9823
Overview....9823
Step Based Diagnostics....9824
Transmission Temperature....9826
Overview....9826
Possible Causes....9826
Step-Based Diagnostics....9826
Pin-Point Tests....9830
Vehicle Speed (Speedometer)....9832
Overview....9832
Step Based Diagnostics....9832
Voltage....9833
Overview....9833
Possible Causes....9833
Step Based Diagnostics....9833
Special Tools....9833
11. Interior Lighting....9835
Dome and Courtesy Lights....9835
Overview....9835
Operational Checkout Procedure....9836
Dome and Courtesy Light Tests....9837
12. Exterior Lighting....9839
Back Up Lights....9839
Overview....9839
Operational Checkout Procedure....9840
Back Up Lights Test....9841
Brake Switch ....9843
Operational Checkout Procedure....9844
Air Brakes - Feature Code 4091 / 4092 ....9848
Overview....9848
Brake Switch is Not Working....9851
Feature Code Overview....9851
Fault Facts....9851
Possible Causes....9851
Pin-Point Test - Feature Code 4091 / 4092....9854
Tools Required....9854
SPN 597 FMI 0 - Brake Switch Input short to PWR with Air Brakes 4091 / 4092....9857
Fault Overview....9857
Associated Faults....9857
Fault Facts....9857
Possible Causes....9857
Pin-Point Test - SPN 597 FMI 0 with Air Brakes (4091 / 4092)....9859
Tools Required....9859
SPN 597 FMI 1 - Brake Switch Reading Below Normal Range with Air Brakes 4091 / 4092....9863
Fault Overview....9863
Associated Faults....9863
Fault Facts....9863
Possible Causes....9863
SPN 597 FMI 2 - Analog Brake Switch signal does not agree with Digital brake switch signal....9865
Fault Overview....9865
Associated Faults....9865
Fault Facts....9865
Possible Causes....9865
Full Power Hydraulic Brakes - Feature Code 4085....9867
Overview....9867
Brake Switch Not Working....9870
Overview....9870
Fault Facts....9870
Possible Causes....9870
Pin-Point Test - Full Power Hydraulic Brakes (4085)....9873
Tools Required....9873
SPN 597 FMI 0 - Brake Switch Input short to PWR with Full Power Hydraulic Brakes (4085)....9878
Fault Overview....9878
Associated Faults....9878
Fault Facts....9878
Possible Causes....9878
Pin-Point Test - SPN 597 FMI 0 Full Power Hydraulic Brakes 4085....9880
Tools Required....9880
SPN 597 FMI 1 - Brake Switch Reading Below Normal Range with Hydraulic Brakes 4085....9881
Fault Overview....9881
Associated Faults....9881
Fault Facts....9881
Possible Causes....9881
SPN 597 FMI 2 - Analog Brake Switch signal does not agree with Digital brake switch signal....9883
Fault Overview....9883
Associated Faults....9883
Fault Facts....9883
Possible Causes....9883
SPN 597 FMI 3 - Voltage above Normal or Short to High Source with Full Power Hydraulic Brakes 4085....9885
Fault Overview....9885
Associated Faults....9885
Fault Facts....9885
Possible Causes....9885
Pin-Point Test - SPN 597 FMI 3 with Full Power Hydraulic Brakes (4085)....9887
Tools Required....9887
SPN 3541 FMI 6- Current above normal or Grounded Circuit with Full Power Hydraulic Brakes 4085....9889
Fault Overview....9889
Associated Faults....9889
Fault Facts....9889
Possible Causes....9889
Pin-Point Test - SPN 3541 FMI 6 with Full Power Hydraulic Brakes (4085)....9891
Tools Required....9891
Fog Lights....9893
Overview....9893
Operational Checkout Procedure....9895
Overview....9895
Fog Light Input Diagnostics....9898
Fault Overview....9898
Fault Facts....9898
Possible Causes....9898
Fog Light Output - Not Illuminating....9900
Fault Overview....9900
Fault Facts....9900
Possible Causes....9900
Pin-Point Test - Fog Light Output - Not Illuminating....9905
Tools Required....9905
Fog Light Output Diagnostics - Illuminating When Not Requested....9909
Fault Overview....9909
Fault Facts....9909
Possible Causes....9909
Pin-Point Test -Fog Light Output - Illuminating When Not Requested....9912
Tools Required....9912
SPN 2388 FMI 5 - Left Fog Light Open Circuit....9914
Fault Overview....9914
Associated Faults....9914
Fault Facts....9914
Possible Causes....9914
Pin-Point Test - SPN 2388 FMI 5....9916
Tools Required....9916
SPN 2388 FMI 6 - Left Fog Light Short to GND....9918
Fault Overview....9918
Associated Faults....9918
Fault Facts....9918
Possible Causes....9918
Pin-Point Test - SPN 2388 FMI 6....9920
Tools Required....9920
SPN 4008 FMI 5 - Right Fog Light Open Circuit....9922
Fault Overview....9922
Associated Faults....9922
Fault Facts....9922
Possible Causes....9922
Pin-Point Test - SPN 4008 FMI 5....9924
Tools Required....9924
SPN 4008 FMI 6 - Right Fog Light Short to GND....9926
Fault Overview....9926
Associated Faults....9926
Fault Facts....9926
Possible Causes....9926
Pin-Point Test - SPN 4008 FMI 6....9928
Tools Required....9928
Headlights and Daytime Running Lights....9930
Overview....9930
Operational Checkout Procedure....9933
Overview....9933
Low Beam Input Diagnostics....9938
Fault Overview....9938
Fault Facts....9938
Possible Causes....9938
Low Beam Output Diagnostics - Not illuminating....9940
Fault Overview....9940
Fault Facts....9940
Possible Causes....9940
Pin-Point Test - Low Beam Head Lamp Output - Not Illuminating....9945
Tools Required....9945
Low Beam Output Diagnostics - Illuminating When Not Requested....9949
Fault Overview....9949
Fault Facts....9949
Possible Causes....9949
Pin-Point Test - Low Beam Head Lamp Output - Illuminating When Not Requested....9952
Tools Required....9952
SPN 2653 FMI 5 - Left Low Beam Open Circuit....9954
Fault Overview....9954
Associated Faults....9954
Fault Facts....9954
Possible Causes....9954
Pin-Point Test - SPN 2653 FMI 5....9956
Tools Required....9956
Pin-Point Test - SPN 2653 FMI 5....9957
SPN 2653 FMI 6 - Left Low Beam Short to GND....9958
Fault Overview....9958
Associated Faults....9958
Fault Facts....9958
Possible Causes....9958
Pin-Point Test - SPN 2653 FMI 6....9960
Tools Required....9960
SPN 2655 FMI 5 - Right Low Beam Open Circuit....9961
Fault Overview....9961
Associated Faults....9961
Fault Facts....9961
Possible Causes....9961
Pin-Point Test - SPN 2655 FMI 5....9963
Tools Required....9963
SPN 2655 FMI 6 - Right Low Beam Short to GND....9964
Fault Overview....9964
Associated Faults....9964
Fault Facts....9964
Possible Causes....9964
Pin-Point Test - SPN 2655 FMI 6....9966
Tools Required....9966
High Beam Input Diagnostics....9967
Fault Overview....9967
Fault Facts....9967
Possible Causes....9967
Pin-Point Test - High Beam Lamps Input....9970
Tools Required....9970
High Beam Output Diagnostics - Not Illuminating....9973
Fault Overview....9973
Fault Facts....9973
Possible Causes....9973
Pin-Point Test - High Beam Head Lamp Output - Not Illuminating....9978
Tools Required....9978
High Beam Output Diagnostics - Illuminating When Not Requested....9982
Fault Overview....9982
Fault Facts....9982
Possible Causes....9982
Pin-Point Test - High Beam Head Lamp Output - Illuminating When Not Requested....9985
Tools Required....9985
SPN 4011 FMI 5 - Left High Beam Open Circuit....9987
Fault Overview....9987
Associated Faults....9987
Fault Facts....9987
Possible Causes....9987
Pin-Point Test - SPN 4011 FMI 5....9989
Tools Required....9989
SPN 4011 FMI 6 - Left High Beam Short to Ground....9990
Fault Overview....9990
Associated Faults....9990
Fault Facts....9990
Possible Causes....9990
Pin-Point Test - SPN 4011 FMI 6....9992
Tools Required....9992
SPN 4012 FMI 5 - Right High beam Open Circuit....9993
Fault Overview....9993
Associated Faults....9993
Fault Facts....9993
Possible Causes....9993
Pin-Point Test - SPN 4012 FMI 5....9995
Tools Required....9995
SPN 4012 FMI 6 - Right High Beam Short to Ground....9996
Fault Overview....9996
Associated Faults....9996
Fault Facts....9996
Possible Causes....9996
Pin-Point Test - SPN 4012 FMI 6....9998
Tools Required....9998
Park and Marker Lights....9999
Overview....9999
Operational Checkout Procedure....10001
Overview....10001
Park Light Input Diagnostics....10005
Fault Overview....10005
Fault Facts....10005
Possible Causes....10005
Park Light Output - Not Illuminating....10007
Fault Overview....10007
Fault Facts....10007
Possible Causes....10007
Pin-Point Test - Park Light Output - Not Illuminating....10010
Tools Required....10010
Park Light Output Diagnostics - Illuminating When Not Requested....10012
Fault Overview....10012
Fault Facts....10012
Possible Causes....10012
Pin-Point Test - Park Light Output - Illuminating When Not Requested....10014
Tools Required....10014
SPN 2378 FMI 5 - Park Light UnderCurrent....10016
Fault Overview....10016
Associated Faults....10016
Fault Facts....10016
Possible Causes....10016
Pin-Point Test - SPN 2378 FMI 5....10018
Tools Required....10018
SPN 2378 FMI 6 - Park Light OverCurrent....10020
Fault Overview....10020
Associated Faults....10020
Fault Facts....10020
Possible Causes....10020
Pin-Point Test - SPN 2378 FMI 6....10022
Tools Required....10022
SPN 40242 FMI 2 - Marker Light Interrupt Switch Failure....10024
Fault Overview....10024
Associated Faults....10024
Fault Facts....10024
Possible Causes....10024
Snow Plow Lights....10026
Snow Plow Light System Overview....10026
Operational Checkout Procedure....10028
Overview....10028
Snow Plow Light Input Diagnostics....10031
Fault Overview....10031
Fault Facts....10031
Possible Causes....10031
Snow Plow Light Output - Not Illuminating....10033
Fault Overview....10033
Fault Facts....10033
Possible Causes....10033
Pin-Point Test - Snow Plow Light Output - Not Illuminating....10037
Tools Required....10037
Snow Plow Low Beam Gen 4 Output - Not illuminating....10038
Fault Overview....10038
Fault Facts....10038
Possible Causes....10038
Pin-Point Test - Snow Plow Low Beam Gen 4 Output - Not illuminating....10041
Tools Required....10041
Snow Plow High Beam Gen 4 Output - Not illuminating....10042
Fault Overview....10042
Fault Facts....10042
Possible Causes....10042
Pin-Point Test - Snow Plow High Beam Gen 4 Output - Not illuminating....10045
Tools Required....10045
Stop, Turn, and Hazard Lights....10046
Overview....10046
Operational Checkout Procedure....10047
Overview....10047
Turn Signal, Hazard, and Front Turn Lamp Diagnostics....10055
Overview....10055
Hazard Input Diagnostics....10057
Feature Code Overview....10057
Fault Facts....10057
Possible Causes....10057
Pin-Point Test - Hazard Input Diagnostics....10060
Tools Required....10060
Turn Signal Input Diagnostics....10066
Feature Code Overview....10066
Fault Facts....10066
Possible Causes....10066
Pin-Point Test - Turn Signal Input Diagnostics....10069
Tools Required....10069
Front Turn Lamp Not Illuminating....10075
Feature Code Overview....10075
Fault Facts....10075
Possible Causes....10075
Pin-Point Test- Front Turn Lamp Output Not Illuminating....10079
Tools Required....10079
Front Turn Lamps Illuminating When Not Requested....10083
Feature Code Overview....10083
Fault Facts....10083
Possible Causes....10083
Pin-Point Test - Front Turn Lamps Illuminating When Not Requested....10085
Tools Required....10085
SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10087
Fault Overview....10087
Associated Faults....10087
Fault Facts....10087
Possible Causes....10087
Pin-Point Test SPN 2368 FMI 5....10089
Tools Required....10089
SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10091
Fault Overview....10091
Associated Faults....10091
Fault Facts....10091
Possible Causes....10091
Pin-Point Test SPN 2368 FMI 6....10093
Tools Required....10093
SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10095
Fault Overview....10095
Associated Faults....10095
Fault Facts....10095
Possible Causes....10095
Pin-Point Test SPN 2370 FMI 5....10097
Tools Required....10097
SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10099
Fault Overview....10099
Associated Faults....10099
Fault Facts....10099
Possible Causes....10099
Pin-Point Test SPN 2370 FMI 6....10101
Tools Required....10101
Combined Stop and Turn Lamps Diagnostics....10103
Overview....10103
Combined Stop and Turn Lamps - Rear Turn Lamp Not Illuminating....10105
Feature Code Overview....10105
Fault Facts....10105
Possible Causes....10105
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....10109
Tools Required....10109
Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10113
Feature Code Overview....10113
Fault Facts....10113
Possible Causes....10113
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10115
Tools Required....10115
SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10117
Fault Overview....10117
Associated Fault....10117
Fault Facts....10117
Possible Causes....10117
Pin-Point Test SPN 2372 FMI 5....10119
Tools Required....10119
SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10121
Fault Overview....10121
Associated Faults....10121
Fault Facts....10121
Possible Causes....10121
Pin-Point Test SPN 2372 FMI 6....10123
Tools Required....10123
SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....10125
Fault Overview....10125
Associated Faults....10125
Fault Facts....10125
Possible Causes....10125
Pin-Point Test SPN 2374 FMI 5....10127
Tools Required....10127
SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....10129
Fault Overview....10129
Associated Faults....10129
Fault Facts....10129
Possible Causes....10129
Pin-Point Test SPN 2374 FMI 6....10131
Tools Required....10131
Separate Stop and Turn Lamps Diagnostics....10133
Overview....10133
Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....10134
Feature Code Overview....10134
Fault Facts....10134
Possible Causes....10134
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....10138
Tools Required....10138
Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10142
Feature Code Overview....10142
Fault Facts....10142
Possible Causes....10142
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....10144
Tools Required....10144
Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....10146
Feature Code Overview....10146
Fault Facts....10146
Possible Causes....10146
Pin-Point Test - Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....10149
Tools Required....10149
Separate Stop and Turn Lamps- Stop Lamps Illuminating When Not Requested....10153
Feature Code Overview....10153
Fault Facts....10153
Possible Causes....10153
Pin-Point Test - Separate Stop and Turn Lamps- Rear Stop Lamps Illuminating When Not Requested....10155
Tools Required....10155
Trailer Lighting....10157
Trailer Lighting Overview....10157
Operational Checkout Procedure....10159
Overview....10159
Pin-Point Test - Trailer Lights Operational Checkout Procedure....10161
Tools Required....10161
Trailer Marker Lights - Not Illuminating....10165
Fault Overview....10165
Fault Facts....10165
Possible Causes....10165
Pin-Point Test - Trailer Marker Light Output - Not Illuminating....10168
Tools Required....10168
Trailer Tail Lights - Not Illuminating....10174
Fault Overview....10174
Fault Facts....10174
Possible Causes....10174
Pin-Point Test - Trailer Tail Light Output - Not Illuminating....10177
Tools Required....10177
Trailer Left Turn Lights - Not Illuminating....10183
Fault Overview....10183
Fault Facts....10183
Possible Causes....10183
Pin-Point Test - Trailer Left Turn Output - Not Illuminating....10186
Tools Required....10186
Trailer Right Turn Lights - Not Illuminating....10192
Fault Overview....10192
Fault Facts....10192
Possible Causes....10192
Pin-Point Test - Trailer Right Turn Output - Not Illuminating....10195
Tools Required....10195
Trailer Brake Lights - Not Illuminating....10201
Fault Overview....10201
Fault Facts....10201
Possible Causes....10201
Pin-Point Test - Trailer Brake Light Output - Not Illuminating....10204
Tools Required....10204
Trailer Auxiliary Power Circuit....10210
Overview....10210
Operational Checkout Procedure....10211
Trailer Auxiliary Power Test....10212
Electric Trailer Brakes....10213
Overview....10213
Operational Checkout Procedure....10214
Electric Trailer Brake Test....10215
Work Lights....10217
Overview....10217
Operation....10217
Operational Checkout Procedure....10219
Work Light Test....10220
13. Transmission....10222
Operation....10222
Available Body Controller Configurations....10224
User Programmable Parameters....10227
Diagnostic Trouble Codes....10228
Operational Checkout — All Transmissions....10230
Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....10235
LCT Column Shifter Interlock Checks....10236
TCM Power, Ground and Data Link Circuit Checks....10237
Shift Selector Power and Ground Circuit Checks....10238
Body Controller Signals....10239
Body Controller Functions....10241
Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....10241
PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....10241
Auto Neutral....10242
Auto Neutral Overview....10242
Overview....10242
Operational Checkout Procedure....10243
Overview....10243
Auto Neutral with Gen 2 Body Controller....10244
Overview....10244
Diagnostic Trouble Codes....10245
Activate Auto Neutral....10247
Error Operation....10248
Operational Checkout Procedure....10249
Auto Neutral Does Not Engage....10250
Auto Neutral Does Not Disengage....10251
Auto Neutral Warning Lamp Inoperative....10252
Auto Neutral with Gen 4 Body Controller....10254
Overview....10254
Auto Neutral Not Working Gen 4 Body Controller....10255
Fault Overview....10255
Fault Facts....10255
Possible Causes....10255
14. Windshield Wiper System....10258
Windshield Wiper Diagnostics....10258
Overview....10258
Wiper Operation....10258
Park Operation....10258
Washer Operation....10258
Operational Checkout Procedure....10263
Overview....10263
Windshield Wiper Input 0 Not Working....10269
Fault Overview....10269
Fault Fact....10269
Possible Causes....10269
Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working....10272
Tools Required....10272
Windshield Wiper Input 1 Not Working....10276
Feature Overview....10276
Fault Fact....10276
Possible Causes....10276
Pin-Point Test - Windshield Wiper Input 1 Not Working....10278
Tools Required....10278
Windshield Wiper Input 2 Not Working....10282
Feature Overview....10282
Fault Fact....10282
Possible Causes....10282
Pin-Point Test - Windshield Wiper Input 2 Not Working....10285
Tools Required....10285
Windshield Wiper Low Speed Not Functioning....10289
Feature Code Overview....10289
Fault Facts....10289
Possible Causes....10289
Pin-Point Test - Windshield Wiper Low Speed Not Functioning....10294
Tools Required....10294
Windshield Wiper High Speed Not Functioning....10301
Feature Code Overview....10301
Fault Facts....10301
Possible Causes....10301
Pin-Point Test - Windshield Wiper High Speed Not Functioning....10306
Tools Required....10306
SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit....10314
Fault Overview....10314
Associated Faults....10314
Fault Facts....10314
Possible Causes....10314
Pin-Point Test - SPN 2636 FMI 5....10316
Tools Required....10316
SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current....10318
Fault Overview....10318
Associated Faults....10318
Fault Facts....10318
Possible Causes....10318
Pin-Point Test - SPN 2636 FMI 6....10319
Tools Required....10319
SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or High Resistance....10321
Fault Overview....10321
Associated Faults....10321
Fault Facts....10321
Possible Causes....10321
Pin-Point Test - SPN 2637 FMI 5....10323
Tools Required....10323
SPN 2637 FMI 6 - Wiper High / Low Relay Over Current....10325
Fault Overview....10325
Associated Faults....10325
Fault Facts....10325
Possible Causes....10325
Pin-Point Test - SPN 2637 FMI 6....10327
Tools Required....10327
SPN 4057 FMI 5 - Wiper Motor Under Current....10329
Fault Overview....10329
Associated Faults....10329
Fault Facts....10329
Possible Causes....10329
Pin-Point Test - SPN 4057 FMI 5....10333
Tools Required....10333
SPN 4057 FMI 6 - Wiper Motor Over Current....10339
Fault Overview....10339
Associated Faults....10339
Fault Facts....10339
Possible Causes....10339
Pin-Point Test - SPN 4057 FMI 6....10343
Tools Required....10343
Windshield Washer Pump is Not Working with Windshield Wipers....10347
Feature Overview....10347
Fault Fact....10347
Possible Causes....10347
Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....10350
Tools Required....10350
Windshield Wiper Not Working with Washer Pump....10355
Feature Overview....10355
Fault Fact....10355
Possible Causes....10355
Pin-Point Test - Windshield Wiper Not Working with Washer Pump....10357
Tools Required....10357
Windshield Wiper and Washer Pump Not Working....10359
Feature Overview....10359
Fault Fact....10359
Possible Causes....10359
Pin-Point Test - Windshield Wiper and Washer Pump Not Working....10362
Tools Required....10362
Windshield Washer Pump....10364
Windshield Washer Pump is Not Working with Windshield Wipers....10364
Feature Overview....10364
Fault Fact....10364
Possible Causes....10364
Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....10368
Tools Required....10368
Windshield Wiper Not Working with Washer Pump....10373
Feature Overview....10373
Fault Fact....10373
Possible Causes....10373
Pin-Point Test - Windshield Wiper Not Working with Washer Pump....10375
Tools Required....10375
Windshield Wiper and Washer Pump Not Working....10377
Feature Overview....10377
Fault Fact....10377
Possible Causes....10377
Pin-Point Test - Windshield Wiper and Washer Pump Not Working....10380
Tools Required....10380
Front End....10384
1. Hood, Grille, Fenders, and Bumper — 4100, 4200, 4300, 4400....10386
Description....10386
Bumper....10386
Hood....10387
Splash Panels....10387
Mud Guards....10388
Grille....10388
Air Intakes....10389
Fenders....10390
Fender Extensions....10390
Hood Seal....10391
Remove and Install....10393
4100 / 4200 / 4300 / 4400 Series Bumper....10393
Remove....10393
Install....10393
4100 / 4200 / 4300 / 4400 Series Hood....10394
Remove....10394
Install....10398
Splash Panels....10400
Remove....10400
Passenger Side....10401
Driver Side....10401
Install....10402
Mud Guards....10403
Remove....10403
Install....10403
Grille....10404
Remove....10404
Install....10405
Air Intakes....10406
Remove....10406
Install....10406
Fenders....10407
Overview....10407
Fender Lower Section — Remove....10408
Valance — Remove....10408
Fender Valance — Install....10408
Headlights — Remove....10410
Headlights — Install....10411
Clearance Lights — Remove....10412
Clearance Lights — Install....10412
Upper Hood Latch — Remove....10413
Upper Hood Latch — Install....10413
Fender Extensions....10414
Fender Extension — Remove....10414
Fender Extension — Install....10416
Hood Latch Lower Assembly — Remove....10417
Lower Hood Latch — Install....10418
Hood Seal....10419
Remove....10419
Install....10420
Adjustments....10421
Hood Adjustment and Alignment....10421
Hood Stop Adjustment....10422
Headlight Adjustment....10423
Headlamp Replacement....10424
Torque....10426
Fifth Wheels and Misc.....10428
Clutch....10432
1. Clutch Control Linkage — 2000, 4000, 7000, and 8000 Series....10434
Maintenance....10435
Lubrication....10435
Inspection....10435
Adjustment....10436
Push Type Clutches....10437
Overview....10437
Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....10437
Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....10438
Pull Type Clutches....10439
Overview....10439
Vehicles with the Adjusting Yoke at the Front End of the Lower (Horizontal) Control Rod....10439
Vehicles with the Adjusting Yoke at the Rear End of the Lower (Horizontal) Control Rod....10440
Replacement....10441
Clutch Pedal Shaft Bushing....10441
Relay Shaft Bushing....10443
Troubleshooting....10445
Specifications....10446
Torque....10447
Engines....10448
1. Radiator / Cooling System....10450
DESCRIPTION....10450
Surge Tank (If Equipped)....10451
Deaeration Tank....10451
Fan Shroud....10451
Fan Drive....10451
A / C Condensor....10451
Radiator / Charge Air Cooler Assembly....10451
Cross-Member....10451
Low Temperature Radiator (LTR)....10451
Low Temperature Radiator (LTR) Thermostat....10451
Fuel Cooler Control Assembly....10452
Transmission Oil Cooler....10452
Removal and Installation....10453
Coolant Drain, Pressure Test, and Fill Procedures....10454
Overview....10454
Coolant Drain Procedure (Recommended)....10456
Pressure Test Procedure (Recommended)....10459
Coolant Fill Procedure (Recommended)....10462
Coolant Gravity Drain Procedure (Optional)....10465
Coolant Gravity Fill Procedure (optional) (MaxxForce® 7 and DT Engine)....10466
Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....10471
Splash Panel....10475
Removal....10475
Installation....10475
Surge Tank (if equipped)....10476
Surge Tank (with Cummins® ISB6.7 Engine) – Removal....10476
Surge Tank (with Cummins® ISB6.7 Engine) – Installation....10477
Deaeration Tank....10478
Deaeration Tank (Radiators with Single Mega Bracket) - Removal....10478
Deaeration Tank (Radiators with Single Mega Bracket) - Installation....10480
Deaeration Tank (Radiators with Dual Mega Bracket) – Removal....10481
Deaeration Tank (Radiators with Dual Mega Bracket) – Installation....10482
A / C Condenser....10483
Overview....10483
A / C Condenser (ISB6.7) Engine – Removal....10484
A / C Condenser – Installation....10486
Fan Belts....10487
Fan Belt with A / C (Cummins® ISB6.7 Engine) - Removal ....10487
Fan Belt with A / C (Cummins® ISB6.7 Engine) – Installation ....10488
Fan and Fan Drive Assembly....10489
Overview....10489
Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On....10490
Removal....10490
Install....10491
Fan and 12TTB Fan Drive (Borg-Warner 790) Viscous Type, Screw On....10492
Removal....10492
Install....10493
12THJ and 12THT Horton DA (optional)....10494
Removal....10494
Install....10495
12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7....10496
Removal....10496
Install....10497
12THJ Fan Drive Horton (DA) with ISB6.7....10498
Removal....10498
Install....10499
12THT Horton (DMA) Serviceable Fan Drive....10500
Remove....10500
Install....10506
12THT Pulley Bearing....10508
Removal....10508
Install....10508
12THT Fan Drive Friction Liner....10509
Removal....10509
Install....10514
12THT Clutch Pack Seal Face....10515
Removal....10515
Install....10515
12THT Air Cartridge....10516
Removal....10516
Install....10518
12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type....10521
Removal....10521
Install....10524
12TTJ Fan Drive Horton VS217 Electronic Viscous Fan....10525
Removal....10525
Install....10531
Fan Shroud....10532
Overview....10532
Fan Shroud (MaxxForce® DT and 9 Engines) - Removal....10532
Fan Shroud (MaxxForce® DT and 9 Engines) - Installation....10535
Fan Shroud (Cummins® ISB6.7 Engine) - Removal....10536
Fan Shroud (Cummins® ISB6.7 Engine) - Installation....10536
Coolant System Hoses....10537
Overview....10537
Heat Shrink Clamp ....10538
Removal....10538
Install....10539
Deaeration Tank Hose (Single Mega Bracket) MaxxForce® 7 Engine....10542
Removal....10542
Install....10543
Deaeration Tank Hose (Single Mega Bucket) MaxxForce® DT Engine without Interstage Charge Air Cooler (ISCAC) ....10544
Removal....10544
Install....10546
Deaeration Tank Hose (Dual Mega Bracket) MaxxForce® DT or 9 Engine with Interstage Charge Air Cooler....10548
Removal....10548
Install....10554
Deaeration Tank Hose (Dual Mega Bracket) N9® with Interstage Charge Air Cooler and SCR....10556
Removal....10556
Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine....10563
Removal....10563
Install....10565
Fuel Cooler Valve (FCV) Hoses MaxxForce® 7 Engine....10567
Removal....10567
Install....10571
Radiator Hoses DT Engine....10572
Removal....10572
Install....10573
Radiator Hoses ISB6.7 One Piece....10575
Removal....10575
Install....10577
Radiator Hoses MaxxForce® 7 Engine....10578
Removal....10578
Install....10579
Coolant Package....10581
Overview....10581
Coolant Package – Removal....10581
Coolant Package – Installation....10588
Radiator Core / CAC Assembly....10590
Overview....10590
Radiator Core / CAC Assembly - Removal....10590
Radiator Core / CAC Assembly - Installation....10592
Fuel Cooler Control Radiator Assembly....10594
Fuel Cooler Radiator Assembly - Removal....10594
Fuel Cooler Radiator Assembly - Installation....10595
Fuel Cooler Control Valve (FCCV)....10596
Fuel Coolant Control Valve - Removal....10596
Fuel Cooler Control Valve - Installation....10597
Low Temperature Radiator (LTR)....10598
Low Temperature Radiator – Removal....10598
Low Temperature Radiator – Installation....10599
Low Temperature Radiator (LTR) Thermostat....10600
Low Temperature Radiator (LTR) Thermostat – Removal....10600
Low Temperature Radiator (LTR) Thermostat – Installation....10601
Low Temperature Radiator Hoses....10602
Low Temperature Radiator Hoses – Removal....10602
Low Temperature Radiator (LTR) Thermostat Hose – Installation....10606
Removal and Installation — Cummins....10607
Radiator and Component Removal....10607
Cross-Member....10607
Surge Tank....10609
Charge Air Cooler Pipes....10612
Cooling System Radiator Hose....10613
Radiator....10616
Radiator Shroud and Frame....10618
Charge Air Cooler....10619
Radiator Core....10619
Radiator and Component Installation....10619
Radiator Core....10619
Radiator Hose....10620
Charge Air Cooler Pipes....10622
Surge Tank....10623
Front Cross-Member....10623
Cooling Package Cleaning Procedures....10625
Overview....10625
Cleaning Cooling Package (MaxxForce® DT, 9, and 10 Engines)....10627
Cleaning Cooling Package (Navistar® 11 and 13 Engines)....10628
Inspection Procedures....10630
Deaeration Tank and Cap Inspection Procedures....10630
Deaeration Tank....10630
Deaeration Tank Cap Vacuum Relief Check....10632
Fan Drive Pulley and Pulley Groove Inspection Procedures....10633
Pulley Crack Inspection....10633
Pulley Nick Inspection....10634
12TTB Fan Drive (Borg-Warner 790) Viscous Type Inspection Procedures....10635
Fan Drive Movement....10635
12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....10636
Fan Drive Movement....10636
12TTJ Fan Drive Horton VS217 Inspection Procedures....10637
Fan Drive Movement....10637
12THT Horton Drivemaster Advantage Fan Drive Inspection Procedures....10639
Fan Drive Movement....10639
Clutch Pack Face Seal....10641
Cartridge Assembly Seal and Spring....10642
Friction Liner Measurement....10643
Fan Drive Bearing Measurement and Inspection....10644
12TTD Borg – Warner 842B Visctronics Inspection Procedure....10645
Fan Drive Movement....10645
Fuel Cooler Valve (FCV) Inspection Procedure....10646
Fuel Cooler Valve (FCV) Filter Screen – Removal....10646
Fuel Cooler Valve (FCV) Filter Screen – Installation....10648
12THT and 12THJ Horton DriveMaster Advantage (DMA) Fan Drive System Diagnostics....10649
12THT and 12THJ Horton DriveMaster Advantage (DMA) System: Operational Checkout Procedure....10649
Overview....10649
Operational Checks – Start Fan Drive Diagnostics Here....10650
Visual Air Leak Check....10650
Symptom 1: Fan Always ON....10652
Symptom 2: Fan Always Off....10671
Symptom 3: Fan Cycles Too Frequently....10679
Symptom 4: Excessive Noise From Fan Drive....10681
12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics....10684
12TTD Borg-Warner 842B Visctronic Fan Drive: Operational Checkout Procedure....10684
Overview....10684
Tools Required....10684
Operational Checks – Start Fan Drive Diagnostics Here....10684
Symptom 1: Fan Always ON....10686
Symptom 2: Fan Always OFF....10694
Symptom 3: Cycles Too Frequently....10712
Symptom 4: Excessive Noise From Fan Drive....10715
12TTJ Horton Drivemaster VS217 Fan Drive Assembly System Diagnostics....10718
12TTJ Horton Drivemaster VS217 Fan Drive Assembly: Operational Checkout Procedure....10718
Overview....10718
Tools Required....10718
Operational Checks – Start Fan Drive Diagnostics Here....10718
Symptom 1: Fan Always ON....10720
Symptom 2: Fan Always OFF....10727
Symptom 3: Fan Drive Cycles Too Frequently....10750
Symptom 4: Excessive Noise From Fan Drive....10751
12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....10754
12TSY Borg-Warner SA85 Fan Drive Assembly: Operational Checkout Procdure....10754
Overview....10754
Tools Required....10754
12TTB Borg-Warner Series 790 Viscous Fan Drive Assembly System Diagnostics....10756
12TTB Borg-Warner 790 Fan Drive Assembly: Operational Checkout Procedure....10756
Overview....10756
Tools Required....10756
Radiator Shutters....10758
Overview....10758
Operation....10760
Overview....10760
Air Shutter Controls....10761
Hydraulic Shutter Controls....10761
Shutters on Vehicles with Air Conditioning....10761
Shutters on Vehicles with ON / OFF Fan Drive Clutch....10762
Shutters on Vehicles with Viscous Fan Drive....10764
Maintenance....10765
Troubleshooting....10766
Overview....10766
Troubleshooting Chart....10766
Replace....10766
Overview....10766
3000 / 4000 Series Vehicles....10766
Shutter-to-Radiator....10766
Shutter-to-Charge Air Cooler....10766
8000 Series Vehicles....10768
Overview....10768
8100....10768
8200 / 8300....10770
Specifications....10772
Transmissions....10774
1. 6 Speed Transmissions International Model ES52–7A and ESO65–7A 6–Plus....10780
General Information....10780
How to Shift the Transmission — Synchronizer Information....10780
Description....10780
Upshifting....10780
Downshifting....10781
Towing....10781
Troubleshooting....10782
Important Procedure....10782
Check Function Prior to Disassembly....10782
Inspect Thoroughly During Disassembly....10782
Repair or Replace Worn Part....10782
Noisy Operation....10782
Noise in Neutral....10784
Noise in Gear....10784
Back-Up Lights Do Not Operate....10784
Oil Leaks....10784
Walking or Jumping Out of Gear....10785
Hard Shifting....10786
Sticking in Gear....10786
Bearing Failures....10786
Dirt....10787
Fatigue....10787
Corrosion....10787
Shaft Fits....10787
Installation and Removal of Bearings....10787
Interchangeability....10787
Clutch Troubleshooting....10788
Disassembly....10789
General....10789
Overview....10789
Cleanliness....10789
Bearings....10789
Front Bearing Retainer and Seal....10789
End Yokes and Flanges....10789
Power Take Offs....10790
Shift Tower....10790
Rear Case....10792
Main Case....10806
Mainshaft Disassembly....10818
Countershaft Disassembly and Reassembly....10825
Clean and Inspection....10827
Reassembly....10829
Mainshaft....10829
Main Case....10834
Rear Case....10839
Shift Tower....10850
Shift Knob Installation....10851
Lubrication....10852
Recommended Lubricants....10852
Oil Changes....10852
Refill....10852
Overfilling....10852
Specifications....10854
Torque....10855
2. 6 Speed Transmissions Eaton Series FS-5106 and FS-6206....10856
Identification....10856
Maintenance....10857
Precautions....10859
Disassembly....10859
Inspection....10859
Reassembly....10861
Remove....10862
Gear Shift Lever Assembly....10862
Shifter Housing....10863
Yoke....10864
Clutch Housing....10866
Input Shaft....10868
Mainshaft....10871
Countershaft and Reverse Idler....10874
Disassemble....10879
Gear Shift Lever Assembly....10879
Shifter Housing....10883
Mainshaft....10889
Countershaft and Reverse Idler....10906
Reassemble....10913
Gear Shift Lever Assembly....10913
Shifter Housing....10916
Countershaft and Reverse Idler....10922
Mainshaft....10928
Install....10950
Countershaft and Reverse Idler....10950
Mainshaft....10957
Clutch Housing....10966
Yoke....10967
Shifter Housing Assembly....10968
Gear Shift Lever Housing....10970
Lubrication....10971
General....10971
Proper Oil Level....10971
Draining Oil....10971
Refilling....10971
Operating Temperatures....10972
Specifications....10973
Torque....10974
3. 5 Speed Transmissions Spicer ES43–5 and ES53–5....10977
General Safety Precautions....10977
Operation....10978
How to Shift the Transmission....10978
Synchronizer Information....10978
Upshifting....10978
Downshifting....10979
Disassembly....10980
General....10980
Inspect Thoroughly During Disassembly....10980
Rebuild Facilities....10980
Cleanliness....10980
Bearings....10980
Shift Tower....10980
Clutch Housing....10982
Case and Shift Forks....10983
Mainshaft....11000
Clean and Inspect....11008
Clean....11008
Inspect....11008
Clutch Gears....11008
Gears....11008
Thrust Washers....11008
Snap Rings....11008
Mainshaft....11008
Bearings....11008
Housings....11009
Reassembly....11010
General....11010
End Yokes and Flanges....11010
Power Take-Offs....11010
Mainshaft....11010
Case....11016
Shift Tower....11033
Shift Knob Installation....11034
Lubrication....11036
Recommended Lubricants....11036
Oil Changes....11036
Refill....11036
Overfilling....11036
Troubleshooting....11037
Troubleshooting Procedure....11037
Noisy Operation....11037
Troubleshooting Chart....11038
Bearings....11041
Dirt....11041
Fatigue....11041
Corrosion....11042
Shaft Fits....11042
Installation and Removal of Bearings....11042
Interchangeability....11042
Clutch Troubleshooting....11042
Specifications....11043
Gear Ratios....11043
Gimbal Tower Shift Pattern....11043
Torque....11044
Special Tools....11046
4. 7 Speed Transmissions Spicer PS110–7, PS145–7....11047
General Safety Precautions....11047
Operation....11048
How to Shift Spicer PS110–7A, PS145–7A, and PS110–7B Transmissions....11048
Overview....11048
Starting....11048
Upshifting....11048
Downshifting....11049
Replacement Parts....11049
Maintenance....11050
Tool Reference....11050
Road Test....11050
Check Remote Control....11050
Disassemble....11051
General....11051
Inspect Thoroughly During Assembly....11051
Rebuild Facilities....11051
Cleanliness....11051
Bearings....11051
Power Take-Offs....11051
Shift Tower....11052
Remote Control....11054
Shifter Housing....11055
Case and Gears....11060
Mainshaft....11074
Input Shaft....11081
Clean and Inspect....11082
Clean....11082
Inspect....11082
Overview....11082
Clutch Gears....11082
Gears....11082
Thrust Washers....11082
Snap Rings....11082
Mainshaft....11083
Bearings....11083
Housings....11083
Reassemble....11084
General....11084
End Yokes and Flanges....11084
Power Take-Offs....11084
Input Shaft....11084
Countershaft....11087
Mainshaft....11089
Case and Gears....11095
Shifter Housing....11107
Remote Control....11109
Shift Tower....11109
Lubrication....11110
Recommended Lubricants....11110
Oil Changes....11110
Refill....11110
Overfilling....11110
Troubleshooting....11111
Noise....11111
Overview....11111
Growling, Humming, and Grinding....11111
Hissing, Thumping, and Bumping....11111
Gear Whine....11112
Metallic Rattles....11112
Troubleshooting Chart....11112
Bearings....11115
Dirt....11115
Fatigue....11115
Corrosion....11115
Shaft Fits....11116
Installation and Removal....11116
Interchangeability....11116
Clutch....11116
Specifications....11117
Gear Ratios....11118
Shift Pattern....11118
Torque....11119
Special Tools....11121
5. Meritor Transfer Cases MTC–4208, MTC–4210 and MTC–4213....11122
Description....11122
Transfer Case Model Nomenclature....11133
Operation....11134
Front Axle Declutch....11134
Full Torque Power Take-Off (PTO)....11134
Removal....11135
Disassembly....11138
Front and Rear Output Yokes....11138
Front Input Shaft, Input Bearing Cage and Pump Assembly....11138
Front Input Shaft, Input Shaft Bearing Cage and Oil Pump....11145
Idle Gear Shaft....11147
Optional PTO Assembly on MTC–4208 and MTC–4208 Transfer Cases....11148
Prepare Parts for Assembly....11149
Ground and Polished Parts....11149
Parts with a Rough Finish....11149
Transfer Case Assemblies....11150
Dry Cleaned Parts....11150
Prevent Corrosion....11150
Oil Seals and O-Rings....11150
Inspect Parts....11151
Overview....11151
General....11151
Helical Gears....11154
Shafts....11156
PTO Components....11157
High and Low Shifting Components....11157
Oil and Lubrication System....11157
Transfer Case Halves....11158
Preparing Case and Cover Seal Replacement....11158
Assembly....11159
General....11159
MTC–4213 Rear Output Shaft End Play Adjustment....11162
MTC–4208 and MTC-4210 Rear output Shaft End Play Adjustment....11164
Idler Shaft Bearing End Play Adjustment....11165
Front Output Shaft End Play Adustment....11166
Shim Assembly....11167
High and Low Shifter Assembly....11168
Front Axle Shifter Assembly....11169
Front Input Shaft, Input Shaft Bearing Cage and Oil Pump Assembly....11170
Input Bearing Cage and Oil Pump Assembly Installation, Bearing End Play Adjustment and Transfer Case Final Assembly....11172
Transfer Case Shifting Check....11174
Adjust Oil Level....11175
Transfer Case Assembly Test....11175
Power Take-Off (PTO)....11176
Remove Transfer Case Rear Access Cover....11176
Install Yoke Onto PTO....11177
Install Optional Indicator Switch....11177
Install PTO Onto Transfer Case....11178
Test PTO Installation....11178
Overview....11178
PTO Without an Optional Indicator Switch....11179
PTO With an Optional Indicator Switch....11179
Test Transfer Case with PTO Assembly Installed....11180
PTO MDP-10–AF-100....11182
PTO Assembly....11185
Installation....11189
General....11189
Check and Adjust Oil....11189
Diagnostics....11191
Lubrication and Maintenance....11197
Lubrication....11197
Overview....11197
Lubricant Temperatures....11197
Multi-Viscosity Oils....11197
Do Not Install API GL-5 Oils....11197
Petroleum-Base and Synthentic-Base Oils....11198
Operating Information....11198
Magnets and Magnetic Drain Plugs....11198
Breather....11198
Seals....11199
Temperature Indicator....11199
Check and Adjust Oil Level....11199
Drain and Replace Oil....11200
Torque....11202
Rear Axle and Suspension....11204
1. IROS....11206
Description....11206
Height Control Valve....11208
Operation....11210
Service Checls (Valve on Truck)....11211
Ride Height Adjustment....11212
Rod Cutting Instructions....11213
Final Assembly Instructions....11213
Air Lines....11215
Suspension Dump Feature....11216
Operation....11217
Main Support Member....11219
Main Support Member Removal....11219
Main Support Member Install....11220
Shock Absorbers....11222
Torque Rods....11222
Remove and Install....11222
Suspension Air Springs Removal....11223
Suspension Air Spring Install....11225
Shock Absorbers....11226
Removal Suspension System Shock Absorbers....11226
Install Shock Absorber....11228
Main Support Members....11229
Remove....11229
Install....11229
Torque Rods....11231
Remove....11231
Install....11231
Main Support Member Bushings....11232
U-Bolts and U-Bolt Nuts Installation....11234
Installing U-Bolts and U-Bolt Nuts....11234
Checking U-Bolt Nut Torque and U-Bolt Nut Tightening....11235
Ride Height Dimensions....11236
Procedure for checking/setting ride height on the international ride optimized suspension (iros)....11236
1. If the axle travel exceeds specifications, ....11237
2. If the axle travel is less than specifications,....11238
Torque....11241
Fuel System....11244
1. Dual Draw Dual Return Fuel Tanks....11246
Overview....11246
Removal....11247
Installation....11251
Cab....11254
Front Wheels....11258
Rear Wheels....11262
tables....8716
Troubleshooting Chart....8716
Length of Slack Adjuster/Size of Chamber Table....8736
Maximum Stroke Available Chart....8741
Adjusted Chamber Stroke Chart....8742
Torque Chart....8748
Torque....8766
Warning Indicators....8790
Warning Indicators....8812
Sensor Check Pins ....8860
Torque Chart....8919
Special Service Tools....8923
Torque Chart....8945
Drag Link Nut Torque Chart....8972
Dual Steering Gear Drag Link Nut Torque Chart....8975
Master Gear Drag Link Nut Torque Chart....8975
Drag Link Torque Chart....8986
Specifications....9029
M-Series Torque Chart....9029
All Steering Applications Torque Chart....9030
Special Tools....9030
Service Information....9034
Service Information....9034
Service Information....9034
DuraStar....9065
WorkStar....9066
Torque Specifications....9067
Approximate CAN DC Voltage Measurements (Key ON)....9082
Approximate CAN Resistance Measurements (Batteries Disconnected)....9082
Feature Codes....9086
Remote Start Stop....9086
Feature Code....9097
Diagnostic Trouble Codes....9098
Remote Start/Stop Preliminary Check....9099
Diagnostic Section....9100
Diagnostic Section....9102
Diagnostics....9107
500K Input Diagnostic Section....9126
Diagnostic Section....9131
Operational Checkout....9159
Heated Drain Valve Test....9159
Air Dryer Test....9160
Feature Codes....9160
Diagnostic Trouble Codes....9161
Air Horns Preliminary Checks....9162
Feature Code....9164
Diagnostic Trouble Codes....9165
Air Solenoid Preliminary Check....9174
Operational Checkout....9176
Aux Power Source Tests....9177
Operational Checkout....9182
Axle Pressure Transducer Voltage Checks....9183
C.B. Radio Power Source Preliminary Check....9186
C.B. Radio Power Connector Tests....9187
Cigar Lighter and Power Feed Preliminary Check....9188
Cigar Lighter Tests....9189
Cigar Lighter Power Source Tests....9189
Two Post Power Source Tests....9190
Feature Codes....9191
Diagnostic Trouble Codes....9192
Cruise Control Preliminary Check....9193
Steering Wheel Mounted Cruise Control Command Switch Test (0595AYJ)....9195
Steering Wheel Mounted Cruise Control Command Switch Test (0595AAP)....9196
Diagnostic Trouble Codes....9198
Operational Checkout....9199
Lift Gate Test....9199
Diagnostic Trouble Codes....9203
Operational Checkout....9204
(0595ACT) Differential Lock Test....9205
(0595ACU) Differential Lock Test....9206
Feature Codes....9207
Diagnostic Trouble Codes....9207
Electric Horn Preliminary Check....9208
Diagnostic Trouble Codes....9211
Operational Checkout....9211
Fifth Wheel Slide Test....9212
Diagnostic Trouble Codes....9214
Operational Checkout....9215
Fuel Transfer Pump Won’t Run Test....9216
Fuel Transfer Pump Continuously Runs Test....9218
Operational Checkout....9223
Heated Mirrors Test....9224
Left Heated Mirror Test....9224
Right Heated Mirror Test....9225
Operational Checkout....9226
Heated Seat Test....9226
Feature Code....9227
Diagnostic Trouble Codes....9228
Diagnostic Trouble Codes....9230
Power Divider Lock Preliminary Check....9231
Power Divider Lock Test....9231
Additional Signals Used for PTO Operation....9235
Feature Description....9236
Fault Codes....9247
PTO Hour Meter/ PTO Indicator Checks....9259
Feature Codes....9263
Diagnostic Trouble Codes....9265
Power Locks Preliminary Check....9267
Power Windows Preliminary Check....9270
One Power Window Inop Test....9271
All Power Windows Inop Test....9271
Power Locks Preliminary Check....9274
One Door Lock Inop Test....9275
All Door Locks Inop Test....9275
Power Mirror Preliminary Check....9280
Power Mirror Tests....9281
Radio Preliminary Check....9284
Radio Test....9285
Fault Codes....9286
RPM Checks....9291
Feature Codes....9293
Lighted Air Shield DTC....9293
Roof Auxiliary Load Preliminary Check....9294
IP Mounted Roof Auxiliary Load Switch Test....9295
Operational Checkout....9299
0595BAG Seat Belt Test....9300
Operational Checkout....9300
Self Contained Air Seat Test....9301
Diagnostic Trouble Codes....9306
Operational Checkout....9307
Suspension Dump Test....9308
Feature Codes....9309
Theft Deterrent Diagnostics....9309
Diagnostic Trouble Codes....9313
Operational Checkout....9314
Two-Speed Switch Test....9314
Two-Way Radio Circuit Tests....9315
Feature Codes....9316
Diagnostic Trouble Codes....9316
Operational Checkout....9317
Water Probe Test....9317
Additional Signals Used for Wheelchair Lift Interlock Operation....9319
Wheelchair Lift Interlock Checks....9322
Parked Regeneration (Particulate_Trap_Regeneration_Force_Switch = 1)....9342
Inhibit Regeneration (Particulate_Trap_Regeneration_Inhibit_Switch = 1)....9343
DuraStar....9346
WorkStar....9346
Service Information....9350
DuraStar....9356
WorkStar....9356
Service Information....9358
DuraStar....9360
WorkStar....9360
Service Information....9363
Service Information....9444
Specifications....9455
Service Information....9465
Exhaust Brake Switch Test....9495
RESCM Checks....9505
Switch Pack Preliminary Check....9522
Switch Pack Test....9523
System Pressure Test Chart....9594
Expected System Static Pressure ....9648
System Performance Test Specifications....9650
Oil Capacity by Component....9681
Air gauge feature codes....9767
Air 1 gauge fault codes....9768
Check for short to GND in Primary Air Pressure signal circuit....9773
Check for short to GND in Primary Air Pressure signal circuit B40....9774
Check for VREF and GND at Primary Air Pressure Transducer....9775
Check for Open or high resistance in Primary Air Pressure signal circuit....9776
Check for Open or high resistance in Primary Air Pressure signal circuit A40....9777
Check for Open or high resistance in Primary Air Pressure signal circuit B40....9778
Body Controller output test....9779
Air gauge feature codes....9780
Air 2 gauge fault codes....9781
Check for short to GND in Secondary Air Pressure signal circuit....9786
Check for short to GND in Secondary Air Pressure signal circuit B40A....9787
Check for VREF and GND at Secondary Air Pressure Transducer....9788
Check for Open or high resistance in Secondary Air Pressure signal circuit....9789
Check for Open or high resistance in Secondary Air Pressure signal circuit A40A....9790
Check for Open or high resistance in Secondary Air Pressure signal circuit B40A....9791
Body Controller output test....9791
Gauge Table....9793
Gauge Response to Faults....9794
Axle Temperature Sensor Voltage Checks....9802
Rear- Rear Axle Temperature Sensor Voltage Checks....9805
Air Pressure Transducer Voltage Checks....9808
Feature Codes....9809
Compass Module Voltage Checks....9810
DEF level feature codes....9811
DEF level fault codes....9811
Coolant temperature feature codes....9813
Coolant temperature fault codes....9813
Oil pressure feature codes....9814
Oil pressure fault codes....9814
Oil temperature feature codes....9815
Oil temperature fault codes....9815
Engine speed feature codes....9816
Engine speed fault codes....9816
Fuel gauge feature codes....9817
Fuel gauge fault codes....9817
Fault codes....9823
Ambient Air Temperature Sensor Table....9824
Transmission temperature feature codes....9826
Transmission temperature fault codes....9826
Transmission oil temp sensor resistance specification....9830
Measure resistance of transmission oil temperature circuit at Connector 1702....9831
Measure resistance of transmission oil temperature sensor....9831
Vehicle speed feature codes....9832
Vehicle speed fault codes....9832
Feature Codes....9835
Dome and Courtesy Light Fault Codes....9835
Door Switch Short Circuit Tests....9837
Door Switch Open Circuit Tests....9837
Dome Light Short Circuit Test....9837
Dome Light Open Circuit Test....9838
Back Up Light Fault Codes....9839
Backup Light Relay Tests....9841
Backup Light Ball Switch Tests....9842
Software Feature Codes....9843
Normal Operation....9849
Symptom Diagnostics....9849
Fault Code Diagnostics....9850
Normal Operation....9867
Full Power Hydraulic Brakes....9868
Full Power Hydraulic Brakes Fault Codes....9868
Feature Codes....9894
Fog Light Symptom Diagnostics....9894
Fog Light Fault Code Diagnostics....9894
Feature Codes....9930
Low Beam Headlight Diagnostics....9931
High Beam Headlight Diagnostics....9932
Feature Codes....9999
Park / Marker Lights....10000
Feature Codes....10026
Snow Plow Light Symptom Diagnostics....10027
Diagnostic Section....10046
Software Feature Codes....10046
Turn Signal Input and Front Turn Lamp Diagnostics....10056
Combined Stop and Turn Lamps....10103
Separate Stop and Turn Lamps....10133
Feature Codes....10157
Trailer Lights Symptom Diagnostics....10158
Feature Codes....10210
Diagnostic Trouble Codes....10210
Trailer Auxiliary Power Circuit Preliminary Checks....10211
Feature Code....10213
Diagnostic Trouble Codes....10213
Electric Trailer Brake Preliminary Check....10214
Feature Codes....10218
Dome and Courtesy Light Fault Codes....10218
Work Light System Preliminary Checks....10219
Work Light Switch Test....10220
Work Light Open Circuit Test....10220
Work Light Short Circuit Test....10221
Park Position Unlock Solenoid Checks — Eaton T-Handle & Allison Column Shifters....10235
LCT Column Shifter Interlock Checks....10236
TCM Power, Ground and Data Link Circuit Checks....10237
Shift Selector Power and Ground Circuit Checks....10238
Diagnostic Section....10242
Software Feature Codes....10242
Feature Codes....10260
Windshield Wiper Diagnostics....10261
Washer Pump Diagnostics....10262
Windshield Wiper Input Switch....10262
Torque Chart....10426
Troubleshooting Table....10445
Specifications....10446
Torque Chart....10447
Troubleshooting Chart....10766
Torque Chart....10772
Lubrication Table....10853
Specifications Table....10854
Torque Chart....10855
Specifications Table....10973
Torque Chart....10974
Troubleshooting Chart....11038
Specifications....11043
Gear Ratio Table....11043
Torque Chart....11044
Troubleshooting Chart....11112
Specifications....11117
Gear Ratios Table....11118
Torque Chart....11119
Example of Shim Selection....11167
Possible Combinations that meet required shim stack:....11167
Kit 2540....11176
PTO Switch Option....11177
PTO Yoke Options and Dimensions....11181
PTO MDP-10–AF-100 Components....11184
Transfer Case Oil Change Intervals....11200
Transfer Case Oil Specifications (NOTES 1, 2, 3)....11201
Transfer Case Oil Capacities....11201
Dry Weight....11201
Torque Chart....11203
Torque Chart....11242
1087481R1 - 1000 Through 4000, 7000, 8000 Series Electrical Circuit Diagrams CTS-4417Circuit Diagrams....11267
Blank Page....11268
4328434 - New Truck Processing Technical Manual....11437
toc....11439
Table of Contents....11439
Introduction....11441
Safety....11441
UNDECKING AND STORAGE....11442
INTRODUCTION....11442
ASSISTANCE TO DEALER ....11442
DEALER RESPONSIBILITIES FOR UNDECKING EXPENSE....11442
CORRECT UNDECKING FACILITY CONFIGURATION....11442
LOAD LIMIT....11443
NEW VEHICLE RECEIVING PROCEDURES....11444
CARRIER DELIVERY and INSPECTION RESPONSIBILITIES ....11444
DEALER RECEIVING RESPONSIBILITIES ....11444
DEALER DELIVERY and INSPECTION RESPONSIBILITIES ....11444
VEHICLE STORAGE....11445
Storage Duration — Two Months Or Less....11445
Storage Duration — Over Two Months....11447
Storage Facilities....11447
NEW TRUCK RECEIVING AND DAMAGE CLAIM PROCESSING....11448
INTRODUCTION....11448
Exceptions....11448
Concealed Damage:....11448
CARRIER'S UNDECKING RESPONSIBILITIES....11448
VEHICLE RECEIVING / INSPECTION....11449
AFTER-HOURS DELIVERY....11449
DELIVERIES TO BODY COMPANIES OR FLEET LOCATIONS....11450
CONCEALED DAMAGE....11451
CARRIER DELIVERY RECEIPT....11451
Important:....11451
FILLING OUT THE DELIVERY RECEIPT....11451
FILING A DAMAGE AND LOSS CLAIM....11452
Supporting Documents....11453
VEHICLES NOT BUILT TO ORDER....11454
INTRODUCTION....11454
TRUCKS NOT BUILT TO ORDER — U.S. AND CANADA....11454
CHECKING ORDER CONFIRMATION — U.S. and CANADA....11454
CLAIM PROCEDURES (USE “TRUCK NOT BUILT TO ORDER” CLAIM FORM)....11455
U.S. AND CANADA:....11455
CLAIM FORM — TRUCK NOT BUILT TO ORDER....11457
ORDER CONTENT CONFIRMATION REPORT....11458
VEHICLE SAFETY CERTIFICATION....11462
INTRODUCTION....11462
INTERNATIONAL® MODEL LINEUP....11462
PENALTIES FOR VIOLATIONS....11463
CERTIFICATION....11463
PREPARATION AND DELIVERY....11464
INTRODUCTION....11464
NEW VEHICLE PRE-DELIVERY SERVICE ....11464
PREPARATION AND DELIVERY (P&D) REIMBURSEMENT (U.S. ONLY)....11464
NON-REIMBURSEMENT ADDENDUM ....11464
“Will Call”- Truck Specialty Center (TSC)....11465
Vehicle Identification Label....11465
CTS-1122, PRE-DELIVERY SERVICE IDENTIFICATION STICKER ....11465
New Vehicle Processing Documentation....11466
Quality Inspection Report....11466
FINAL DELIVERY GUIDELINES....11467
INTRODUCTION....11467
FINAL DELIVERY GUIDELINES....11467
Introduction....11467
Before Vehicle Pick-Up Or Delivery....11467
During Vehicle Pick-Up Or Delivery....11467
tables....11443
Table 1VEHICLE HOIST REQUIREMENT CHART....11443
CTS-5122K - 2000 , 4000 and 8000 Series September 1993 and Later Electrical Circuit Diagrams....11468
Blank Page....11469
CTS-5122T - 2000, 4000, 8000 Series Built After February 1, 1996 Electrical Circuit Diagrams....11662
CTS4425 - Electrical System Troubleshooting Guide - U-HAUL 4600UH Service Manual....11938
Blank Page....11939
CTS4425.pdf....0
Blank Page....11941
S02012 - Meritor Medium Duty Front Drive Steer Axle (Dec 2001) Service Manual....12098
S02014 - Carraro Axle Repair Manual (Feb 2009) Service Manual....12181
02EZL WSM_HS6.12-CA368083-CA368084_Doc270024-1ed-v02.pdf....0
Indice-Index....12187
A INFORMAZIONI GENERALI....12188
A.1 Utilizzo del manuale....12189
A.2 Proprietà delle informazioni....12190
A.3 Convenzioni e definizioni....12191
A.4 Indicazioni generali....12193
A.5 Indicazioni speciali....12194
A General information....12188
A.1 Manual use....12189
A.2 Information property....12190
A.3 Agreements and definitions....12191
A.4 General description....12193
A.5 Special recommendations....12194
B INFORMAZIONI SULLA SICUREZZA....12196
B.1 Indicazioni generali per la sicurezza....12197
B.2 Simboli di sicurezza....12198
B.3 Precauzioni generali....12199
B Safety instructions....12196
B.1 General safety recommendations....12197
B.2 Safety symbols....12198
B.3 General precautions....12199
C CARATTERISTICHE GENERALI....12201
C.1 Uso previsto....12202
C.2 Identificazione del prodotto....12202
C.3 Descrizione generale....12203
C.4 Caratteristiche Tecniche....12204
C.5 Grasso al montaggio....12211
C.6 Adesivi e coppie di serraggio....12212
C General specifications....12201
C.1 Intended use....12202
C.2 Product identification....12202
C.3 General description....12203
C.4 Technical Features....12204
C.5 Maintenance and oil change....12208
C.6 Grease in assembly....12211
C.7 Adhesives and tightening torques....12212
D SMONTAGGIO E ASSEMBLAGGIO....12216
D.1 Gruppo freno....12217
D.2 Gruppo mozzo ruota....12221
D.3 Gruppo calotta....12228
D.4 Gruppo supporto differenziale....12237
D.5 Gruppo differenziale....12246
D.6 Gruppo pignone....12250
D.7 Gruppo trave....12260
D.8 Convergenza/angolo di sterzata....12262
D.9 Interventi speciali....12265
D.10 Prove dopo montaggio....12272
D Disassembly and assembly....12216
D.1 Brake group....12217
D.2 Wheel hub group....12221
D.3 Swivel housing group....12228
D.4 Differential support group....12237
D.5 Differential group....12246
D.6 Pinion group....12250
D.7 Axle beam group....12260
D.8 Toe-in/steering angle....12262
D.9 Special repair operations....12265
D.10 Testing after assembly....12272
E RICERCA GUASTI....12273
E.1 Controllo ed esame dei guasti....12276
E.2 Diagnosi per problemi all'assale....12280
E Troubleshooting....12273
E.1 Troubleshooting....12278
E.2 Axle problem and diagnosis....12281
F ATTREZZATURE SPECIALI....12282
F.1 Attrezzature speciali....12283
F Special tools....12282
F.1 Special tools....12283
G TEMPI DI RIPARAZIONE....12289
G.1 Prontuario dei tempi di riparazione....12290
G Service operations time....12289
G.1 Service operations time schedule....12290
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual....12293
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual....12314
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual....12328
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual....12369
S04004 - Air Compressor_ Bendix 2150, Supersedes CTS-5058 (March 1996) Service Manual....12403
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual....12435
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual....12479
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual....12484
S04010 - Air Compressor_ Bendix TU-FLO 501, Supersedes CTS-5145 (March 1996) Service Manual....12507
S04011 - Air Compressor_ Midland Models EL-1300 and EL-1600, Supersedes CTS-5146 (March 1996) Service Manual....12537
S04016K - Caliper Disc Brakes, Supersedes CTS-5009K (March 1996) Service Manual....12564
S04017Y - Hydro-Max Brake Booster and Master Cylinder, Supersedes CTS-5018K (Dec 2000) Service Manual....12600
S04018W - Reconditioning Rotors, Supersedes CTS-5086W (June 1998) Service Manual....12635
S04020X - DCM and DDM Drum Type Parking Brake, Supersedes CTS-5135TA (July 1997) Service Manual....12658
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual....12684
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual....12710
S04033 - Antilock Brakes_Traction Control_ Bendix - Troubleshooting, Supersedes CTS-5250 (June 1996) Service Manual....12736
S04038 - EC-17 Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Technical Manual....12780
S040393 - Lucas Varity _ TRW Hydraulic Antilock Brake System (Dec 2003) Technical Manual....12849
S04044 - Bosch Parking Brake_ Manual or Power Brake (Oct 2008) Service Manual....12963
S04045 - Meritor _ WABCO Hydraulic ABS for Medium-Duty Trucks, Buses and Motor Home Chassis (June 2000) Technical Manual....12976
S04050 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual....13032
S04051 - Full Power Hydraulic ABS Brake System (Dec 2006) Service Manual....13173
S04053 - ECE-13 Brake System (2010) Service Manual....13314
S04055 - MCAC 465 Air Compressor (Dec 2010) Service Manual....13350
toc....13352
Table of Contents....13352
1. DESCRIPTION....13354
1.1. Components....13355
Cylinder Head....13355
Crankcase....13356
1.2. Name Plate....13356
2. Compressor Maintenance....13357
3. Remove and Install Procedures....13358
3.1. MCAC 476 Air Compressor....13359
MCAC 476 Air Compressor – Removal....13359
MCAC 476 Air Compressor – Installation....13360
3.2. MCAC 476 Air Compressor Disassembly....13361
Cylinder Head Disassembly....13361
Crankcase Disassembly....13363
Drive Gear Removal....13364
Air Cylinder Cover Removal....13365
Crankcase Removal....13366
Air Cylinder Removal....13367
Air Cylinder Disassembly....13368
Clutch Housing Disassembly....13369
Piston Removal....13370
3.3. MCAC 476 Air Compressor – Assembly....13371
Crankcase Assembly....13371
Clutch Housing Assembly....13372
Air Cylinder Assembly....13373
Air Cylinder Installation....13374
Crankshaft Installation....13375
Air Cylinder Cover Installation....13376
Center Shaft Installation....13377
Center Shaft Nut Installation....13378
Cylinder Head Assembly (Lower)....13379
Cylinder Head Assembly (Upper)....13380
4. Troubleshooting....13381
4.1. Troubleshooting Table....13381
4.2. Tests....13385
Oil Leakage at the Head Gasket Test....13385
Air Brake System and Accessory Leakage Test....13385
Air Compressor Discharge Temperature and Air Dryer Inlet Tempera....13386
Governor Malfunction Test....13387
Governor Control Line Test....13387
Compressor Clutch Operation - No Air Charging Test....13387
Compressor Clutch Operation - Continuous Air Charging Test....13387
tables....13388
Table 3Torque Chart....13388
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual....13389
S05012 - Steering Column Assembly, Tilt_Telescoping Supersedes CTS-5167 (May 1996) Service Manual....13466
S05013 - Steering Column Assembly, Standard and Tilt, Supersedes CTS-5168 (April 1996) Service Manual....13480
S05016 - Steering Wheel Removal and Installation (Sept 2010) Service Manual....13495
S05021 - Steering Wheel and Steering Column Assembly (July 2012) Service Manual....13508
toc....13510
Table of Contents....13510
1. DESCRIPTION....13512
1.1. STEERING WHEEL....13512
1.2. CLOCK SPRING....13512
1.3. STEERING COLUMN....13513
2. REMOVE AND INSTALL PROCEDURES....13514
2.1. STEERING WHEEL....13515
Steering Wheel – Removal....13515
Steering Wheel – Installation....13518
2.2. CLOCK SPRING....13519
Clock Spring – Removal....13519
Clock Spring – Installation....13521
2.3. STEERING COLUMN....13523
Steering Column – Removal....13523
Steering Column – Installation....13525
3. CHECKS AND ADJUSTMENTS....13526
3.1. STEERING WHEEL....13526
Steering Wheel – Check....13526
Steering Wheel – Adjust....13526
tables....13527
Table 1Torque Chart....13527
S05022 - Steering Wheel _ Column Assembly _ Power Steering Reservoir (Jan 2011) Brazilian Market Service Manual....13528
S05025 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual....13550
toc....13552
tables....13569
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual....13570
S08034X - Instruments, Supersedes CTS-5088K (Oct 1999) Service Manual....13651
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual....13689
S08155X - Instruments (New Data Link Driven Instrument Cluster), Supersedes CTS-5228 (Oct 1999) Technical Manual....13718
S08186 - 2000, 4000, 8000 Models Built October 1, 1998 To September 30, 1999 Electrical Circuit Diagrams....13842
toc....13844
Table of Contents....13844
INSTRUCTIONS AND CHARTS (Chapter 1)....13852
1.1. Circuit Identification Chart, P. 1....13852
1.2. Circuit Identification Chart, P. 2....13853
1.3. Circuit Identification Chart, P. 3....13854
1.4. Circuit Diagram Instructions, P. 4....13855
1.5. Circuit Diagram Instructions, P. 5....13856
1.6. Schematic Symbols, P. 6....13857
1.7. Relay Function/Bus Bar Configuration (Fuse Block Connector)....13858
1.8. Fuse Block Connector/Connection Tables, P. 8....13859
1.9. Lamp Bulb Chart, P. 9....13860
1.10. Fuse/Circuit Breaker Chart/Labels, P. 10....13861
1.11. Relay Mounting Locations/Labels, P. 11....13862
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....13863
2.1. Accessory, P. 1....13863
2.2. Accessory (Cont.), P. 2....13864
2.3. Battery, P. 3....13865
2.4. Battery (Cont.), P. 4....13866
2.5. Ignition, P. 5....13867
2.6. Ignition (Cont.), P. 6....13868
2.7. Ignition (Cont.), P. 7....13869
2.8. Ground, P. 8....13870
2.9. Ground (Cont.), P. 9....13871
CAB ACCESSORIES (Chapter 3)....13872
3.1. Power Window, P. 1....13872
3.2. Horn, Single & Dual, P. 2....13873
3.3. Mirrors, Heated W/Power Mirror, P. 3....13874
3.4. Mirrors, Lighted, P. 4....13875
3.5. Owner/Operator Connections — Rear Cab Junction Block, Acces....13876
3.6. Radio, Cab, 2 Speakers, AM-FM Cassette Radio & CB Radio 2–W....13877
3.7. Radio, Cab, 4 Speakers, AM-FM Cassette Premium Radio, P. 7....13878
3.8. Radio, Sleeper, AM-FM Cassette Radio W/Sleeper Speakers, P.....13879
3.9. Cigar Lighter, Power Seat, P. 9....13880
3.10. Radio, Sleeper, AM-FM Cassette Premium Radio W/Sleeper Spe....13881
3.11. Sleeper Cab, 42 Inch, P. 11....13882
3.12. Sleeper Cab, 42 Inch (Cont.), P. 12....13883
3.13. Turn Signals W/International T/S Switch W/Tractor & N/Pede....13884
3.14. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....13885
3.15. Turn Signals W/International T/S Switch W/Tractor/Truck & ....13886
3.16. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....13887
3.17. Turn Signals W/Sig-Stat 910/915 T/S Switch W/ & N/Pedestal....13888
3.18. Windshield Wiper & Washer (Elect) W/International T/S Swit....13889
3.19. Windshield Washer (Elect) W/Air Wipers & W/International T....13890
3.20. Windshield Washer (Elect) W/Air Wipers & W/Sig–Stat T/S Sw....13891
3.21. Windshield Wiper W/Intermittent Wiper/Washer W/Sig–Stat T/....13892
12V CHARGING + CRANKING SYSTEM (Chapter 4)....13893
4.1. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/I....13893
4.2. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/N....13894
4.3. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/C....13895
4.4. Charging System (12V) Delco (90 AMP) CS-130 & 21SI (65, 100....13896
4.5. Cranking System (12V) (8100) W/ISM, P. 5....13897
4.6. Cranking System (12V) (8100) C-10, C-12, P. 6....13898
4.7. Cranking System (12V) (2500, 2600) W/ISM, N14E PLUS, P. 7....13899
4.8. Cranking System (12V) (2500, 2600) W/C-10, C-12, P. 8....13900
4.9. Cranking System (12V) W/T 444E, I6 HEUI, P. 9....13901
4.10. Ether Start W/ISM, C-10, C-12, I6 HEUI, P. 10....13902
FANS (Chapter 5)....13903
5.1. Horton Engine Fan With Cummins N14E PLUS W/ & N/Air Conditi....13903
5.2. Horton Engine Fan With Cummins ISM Engine W/ & N/Air Condit....13904
5.3. Radiator Shutter W/ISM, N14E PLUS, P 3....13905
5.4. Horton Engine Fan With Cat. C-10, C-12 W/ & N/Air Condition....13906
5.5. Shutter & Fan Wiring W/I6 HEUI, T 444E, P. 5....13907
ELECTRONIC ENGINES (Chapter 6)....13908
6.1. Engine Controls, Cummins N14E PLUS, P. 1....13908
6.2. Engine Controls, Cummins N14E PLUS (Cont.), P. 2....13909
6.3. Engine Controls, Cummins ISM Engine, P. 3....13910
6.4. Engine Controls, Cummins ISM Engine (Cont.), P. 4....13911
6.5. Engine Controls, Cummins ISM Engine (Cont.), P. 5....13912
6.6. Engine Brake N/Electronic Transmission, Cummins N14E PLUS, ....13913
6.7. Engine Brake N/Electronic Transmission, Cummins ISM, P. 7....13914
6.8. Engine Brake, Caterpillar C-10, C-12, P. 8....13915
6.9. Cruise Control, Caterpillar C-10, C-12, P. 9....13916
6.10. Engine Controls, Caterpillar C-10, C-12, P. 10....13917
6.11. Engine Shutdown Warning Lights, Low Coolant Switch, Caterp....13918
6.12. Low Air Pressure (Brake) Alarm & Brake Systems Warning Lig....13919
6.13. Module Power & Ground System W/T 444E, I6 HEUI, P. 13....13920
6.14. Accelerator, BAP & Ambient Air Systems W/T 444E & I6 HEUI ....13921
6.15. Accelerator, BAP & Ambient Air Temp. Sensor W/T 444E & I6 ....13922
6.16. Cruise Control, Body Builder Connections W/T 444E, I6 HEUI....13923
GAUGES (Chapter 7)....13924
7.1. Oil Temperature Gauges — Fwd/RR & RR/RR Axles W/6x4, Rear A....13924
7.2. Engine Oil W/ISM Engine & Transmission Oil Temperature Gaug....13925
7.3. Engine Oil Temperature Gauge W/N14E PLUS Engine, P. 3....13926
7.4. Engine Oil Temperature Gauge W/C-10, C-12, P. 4....13927
7.5. Engine Water Temp., Tach, Gauge, Left Turn, HI Beam Ind. W/....13928
7.6. Ammeter Wiring, P. 6....13929
7.7. Fuel Gauge, Speedometer (N/T 444E), Voltmeter, Right Turn I....13930
7.8. Speedometer, Tachometer, HI Beam, Right & Left T/S Ind. Lig....13931
7.9. Pyrometer Gauge N/T 444E, I6 HEUI, P. 9....13932
WARNING LIGHTS (Chapter 8)....13933
8.1. Windshield Washer Low Fluid Warning Light, Power Divider Lo....13933
8.2. Fuel Filter Wiring System W/T 444E, I6 HEUI, P. 2....13934
8.3. Diagnostic/Programmable Conn., W/T 444E, I6 HEUI, P. 3....13935
8.4. Surge Tank W/T 444E & I6 HEUI (Plastic or Metal Tanks), P. ....13936
8.5. Engine Warning Lights/Alarm & Test Switch W/T 444E & I6 HEU....13937
CHASSIS ACCESSORIES (Chapter 9)....13938
9.1. Air Suspension W/Air Hydraulic Brakes, P. 1....13938
9.2. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....13939
9.3. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....13940
9.4. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....13941
9.5. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....13942
9.6. Allison Automatic (Electronic) Transmission W/I6 or V8, P. ....13943
9.7. Allison Automatic (Electronic) Transmission Retarder Contro....13944
9.8. Allison Automatic (Electronic) Transmission Retarder Contro....13945
9.9. Allison Automatic (Electronic) Transmission Retarder, P. 9....13946
9.10. Auto Neutral, P. 10....13947
9.11. Allison Automatic (Electronic) Transmission WTEC III HD, P....13948
9.12. Allison Automatic (Electronic) Transmission WTEC III HD (C....13949
9.13. Allison Automatic (Electronic) Transmission WTEC III HD (C....13950
9.14. Allison Automatic (Electronic) Transmission WTEC III HD (C....13951
9.15. Exhaust Brake, I6 HEUI W/Air ABS, W/Allison WT Transmissio....13952
9.16. Exhaust Brake, I6 HEUI W/Air ABS, N/Allison WT Transmissio....13953
9.17. Exhaust Brake W/Hyd. Brakes N/AT-MT Retarders or MD Transm....13954
9.18. Exhaust Brake Solenoid, I6 HEUI, N/ABS, N/Allison WT Trans....13955
9.19. Allison Automatic Transmission System W/I6 HEUI, T 444E, P....13956
9.20. Axle, Two Speed, Wiring (Air) W/Allison (Elect.) Auto Tran....13957
9.21. Axle, Two Speed, Wiring (Hyd.) W/Allison (Elect.) Auto Tra....13958
9.22. Axle, Two Speed, Electric W/T 444E & I6 HEUI, P. 22....13959
9.23. Axle, Two Speed, Electric (Air) & Air Dryer W/Auto or Manu....13960
9.24. Axle, Two Speed, Electric (Hydraulic) W/Auto or Manual Tra....13961
9.25. Brake System, Hydraulic, P. 25....13962
9.26. Bendix Automatic Drain Valve (DV-2) W/Heater W/ & N/Exhaus....13963
9.27. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Air ABS, ....13964
9.28. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Hyd. ABS,....13965
9.29. Locking Differential W/Allison WT Transmission, P. 29....13966
9.30. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13967
9.31. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13968
9.32. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13969
9.33. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....13970
9.34. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....13971
9.35. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....13972
9.36. Brake System, Hydraulic W/4000 & W/ or N/ABS, P. 36....13973
9.37. Antilock Hydraulic Brakes (4 Channel) W/4000, P. 37....13974
9.38. Antilock Hydraulic Brakes (4 Channel) W/4000 (Cont.), P. 3....13975
9.39. Transfer Case Shift System Front Axle Warning Light, P. 39....13976
9.40. Trailer Connection W/Regular Cab & W/Sleeper Box, P. 40....13977
9.41. Trailer Connection W/Frame Mounted 7–Way & W/Tractor, P. 4....13978
9.42. Trailer Connection W/Frame Mounted 7–Way & W/Truck & W/Air....13979
9.43. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco, P. 43....13980
9.44. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco (Cont.), ....13981
9.45. Air Suspension, Main Cab Overlay Control Harness, P. 45....13982
9.46. Meritor G Series Transmission, P. 46....13983
LIGHT SYSTEMS (Chapter 10)....13984
10.1. Back-Up Lights, P. 1....13984
10.2. Clearance, Marker & Tail Lights W/Tractor N/T 444E, I6 HEU....13985
10.3. Clearance, Marker & Tail Lights W/Truck N/T 444E, I6 HEUI,....13986
10.4. Clearance, Marker & Tail Lights W/Tractor W/T 444E, I6 HEU....13987
10.5. Clearance, Marker & Tail Lights W/Truck W/T 444E, I6 HEUI,....13988
10.6. Cab Dome and Courtesy Lights, P. 6....13989
10.7. Work Light W/Tractor & W/Reg. Cab, Sleeper Cab, P. 7....13990
10.8. Work Light W/Truck, P. 8....13991
10.9. Fog Light System W/ & N/DRL (USA) & N/T 444E, I6 HEUI, P. ....13992
10.10. Fog Light System W/ & N/DRL (Canada) & N/T 444E, I6 HEUI,....13993
10.11. Fog Light System W/ & N/DRL (USA) & W/T 444E, I6 HEUI, P.....13994
10.12. Fog Light System W/DRL (Canada) & W/T 444E, I6 HEUI, P. 1....13995
10.13. Headlight System N/DRL W/International Turn Signal Switch....13996
10.14. Headlight System N/DRL W/International Turn Signal Switch....13997
10.15. Headlight System N/DRL W/Sig-Stat 910 T/S Sw. W/Flr. Mtd.....13998
10.16. Headlight System N/DRL W/Sig-Stat 915 T/S Sw. W/Push Btn.....13999
10.17. Headlight System W/DRL (Canada) W/Sig-Stat 910 T/S Sw. W/....14000
10.18. Headlight System W/DRL (Canada) W/Sig-Stat 915 T/S Sw. W/....14001
10.19. Headlight System W/DRL (USA) W/Sig-Stat 910 T/S Sw. W/Air....14002
10.20. Headlight System W/DRL (USA) W/Sig-Stat 915 T/S Sw. W/Air....14003
10.21. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Hyd. Br....14004
10.22. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Hyd. Brake....14005
10.23. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14006
10.24. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14007
10.25. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14008
10.26. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14009
10.27. Additional Headlight Wiring W/Dual Drive Cab, P. 27....14010
10.28. Hydraulic Park Brake Ind. Light W/Key Sw. or Push Button ....14011
10.29. Panel Lights, P. 29....14012
10.30. Stop Light Switch W/T 444E & I6 HEUI W/Air Brakes, P. 30....14013
10.31. Stop Light Switch Truck W/Standard Air Brakes W/Internati....14014
10.32. Stop Light Switch Truck W/Standard Air Brakes W/Sig-Stat ....14015
10.33. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14016
10.34. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14017
HEATER AND AIR CONDITIONER (Chapter 11)....14018
11.1. Heater / Air Conditioner, P. 1....14018
11.2. Heater Only, P. 2....14019
CONNECTOR COMPOSITES (Chapter 12)....14020
12.1. Dash Connector (2) (N/T 444E or I6 HEUI), P. 1....14020
12.2. Dash Connector (2) (W/T 444E or I6 HEUI), P. 2....14021
12.3. Dash Connector Engine Connections (2A) (N/T 444E or I6 HEU....14022
12.4. Dash Connector Engine Connections (2A) (W/T 444E or I6 HEU....14023
12.5. Connector Composites (3 & 3A), P. 5....14024
12.6. Connector Composite (3J), P. 6....14025
12.7. Connector Composites (11), (12), (13), P. 7....14026
12.8. Connector Composites (14), (14A), (15), (16), (17), (18), ....14027
12.9. Connector Composites (20), (21), P. 9....14028
12.10. Connector Composites (23), (24), (26), P. 10....14029
12.11. Connector Composites (27), (28), (29), (30), (31), (32), ....14030
12.12. Connector Composites (33), (34), (35), (36), (37), (38), ....14031
12.13. Connector Composites (44), (46), (47 & 48), (49), (50), (....14032
12.14. Connector Composites (53), (54), (55), (56), (57), (58), ....14033
12.15. Connector Composites (66), (67), (69), (70), (71), P. 15....14034
12.16. Connector Composites (72), (73), (74), (75), (76), (77), ....14035
12.17. Connector Composites (80), (83), (84 & 85), (86), (90), (....14036
12.18. Connector Composites (98), (99), (100), (101), (102), (10....14037
12.19. Connector Composites (105), (106), (107), (108), (109), (....14038
12.20. Connector Composites (117), (119), (121), (122), (123), (....14039
12.21. Connector Composites (132), (133), (135), (136), P. 21....14040
12.22. Connector Composites (137), (141), (142), (143), (144), (....14041
12.23. Connector Composites (147), (148), (149), (153), P. 23....14042
12.24. Connector Composites (153), (154), (156), (157), (158), (....14043
12.25. Connector Composites (160), (161), (162), (163), (164), (....14044
12.26. Connector Composites (169), (170), (171), (172), (173), (....14045
12.27. Connector Composites (179), (180), (181), (182), (183), (....14046
12.28. Connector Composites (194A), (199), (203), (210), (212), ....14047
12.29. Connector Composites (214M), (218), (219), (220), (221), ....14048
12.30. Connector Composites (223), (225), (226), (237), P. 30....14049
12.31. Connector Composites (252), (257), (258), (259), (260), (....14050
12.32. Connector Composites (270), (271), (272), (273), (274A), ....14051
12.33. Connector Composites (274), (275), (276), (277), (279), P....14052
12.34. Connector Composites (280), (284), (286), (287), P. 34....14053
12.35. Connector Composites (288), (289), (290), (291), (292), (....14054
12.36. Connector Composites (294), (295), (296), (297), (298), (....14055
12.37. Connector Composites (304), (305), (306), (309), (310), (....14056
12.38. Connector Composites (311), (312), (313), (314), (315), (....14057
12.39. Connector Composites (320), (323), (325), P. 39....14058
12.40. Connector Composites (325), (326), (327), (328), (329), (....14059
12.41. Connector Composites (332), (333), (335), (336), (337), P....14060
12.42. Connector Composites (338), (339), (340), (341), (342), (....14061
12.43. Connector Composites (345), (346), (347), (348), (349), (....14062
12.44. Connector Composites (355), (356), (357), (358), (359), (....14063
12.45. Connector Composites (367), (368), (369), (370), (372), (....14064
12.46. Connector Composites (377), (377A), (377B), P. 46....14065
12.47. Connector Composites (379), (382), (382A), P. 47....14066
12.48. Connector Composites (383), (384), (386), (387), (389), (....14067
12.49. Connector Composites (391), (392), P. 49....14068
12.50. Connector Composites (396), (399), (400), (401), P. 50....14069
12.51. Connector Composites (402), (403), (404), P. 51....14070
12.52. Connector Composites (406), (413), (417), P. 52....14071
12.53. Connector Composite (418), P. 53....14072
12.54. Connector Composites (419), (420), (421), (422), P. 54....14073
12.55. Connector Composites (423), (425), (426), (427), (428), P....14074
12.56. Connector Composites (430), (431), (432), (433), (434), (....14075
12.57. Connector Composites (447), (449), (457), P. 57....14076
12.58. Connector Composites (458), (459), (460), (463), (465), (....14077
12.59. Connector Composites (467), (468), (469), (473), (480), (....14078
12.60. Connector Composites (492), (493), (494), (495), P. 60....14079
12.61. Connector Composites (499), (500), (501), (502), (503), (....14080
12.62. Connector Composites (506), (507), (508), (510), (511), (....14081
12.63. Connector Composites (555), (557), (558), (569), (570), (....14082
12.64. Connector Composite (615), P. 64....14083
12.65. Connector Composites (631), (632), P. 65....14084
12.66. Connector Composites (633), (634), P. 66....14085
12.67. Connector Composites (636), (637), (639), P. 67....14086
12.68. Connector Composites (646), (646A), (647), (648), (649), ....14087
12.69. Connector Composites (661), (662), (667), (675), (683), (....14088
12.70. Connector Composites (700), (701), (702), (703), (707), P....14089
12.71. Connector Composites (708), (734), (758), (759), (760), (....14090
12.72. Connector Composites (766), (767), (768), (769), (770), (....14091
12.73. Connector Composites (775), (776), (777), (778), (789), (....14092
12.74. Connector Composites (791), (792), (807), (917), (918), (....14093
12.75. Connector Composites (926), (958), (959), (960), (960A), ....14094
12.76. Connector Composites (1000), (1001), (1002), (1003), (100....14095
12.77. Connector Composites (1014), (1015), P. 77....14096
12.78. Connector Composites (1016), (1017), (1091), P. 78....14097
12.79. Connector Composites (1093), (1094), (1095), (1097), (109....14098
12.80. Connector Composites (1110M), (1113F), (1117), (1119), (1....14099
12.81. Connector Composites (1125), (1126), (1128), (1129), (113....14100
12.82. Connector Composites (1132), (1133), (1134), (1135), (302....14101
S08186X - 2000, 4000, 8000 Models Built October 1, 1999 and After Electrical Circuit Diagrams....14102
toc....14104
Table of Contents....14104
INSTRUCTIONS AND CHARTS (Chapter 1)....14112
1.1. Circuit Identification Chart, p. 1....14112
1.2. Circuit Identification Chart, p. 2....14113
1.3. Circuit Identification Chart, p. 3....14114
1.4. Circuit Diagram Instructions, p. 4....14115
1.5. Circuit Diagram Instructions, p. 5....14116
1.6. Schematic Symbols, p. 6....14117
1.7. Relay Function/Bus Bar Configuration (Fuse Block Connector)....14118
1.8. Fuse Block Connector/Connection Tables, p. 8....14119
1.9. Lamp Bulb Chart, p. 9....14120
1.10. Fuse/Circuit Breaker Chart/Labels, p. 10....14121
1.11. Relay Mounting Locations/Labels, p. 11....14122
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....14123
2.1. Accessory, p. 1....14123
2.2. Accessory (Cont.), p. 2....14124
2.3. Battery, p. 3....14125
2.4. Battery (Cont.), p. 4....14126
2.5. Ignition, p. 5....14127
2.6. Ignition (Cont.), p. 6....14128
2.7. Ignition (Cont.), p. 7....14129
2.8. Ground, p. 8....14130
2.9. Ground (Cont.), p. 9....14131
CAB ACCESSORIES (Chapter 3)....14132
3.1. Power Window, p. 1....14132
3.2. Horn, Single & Dual, p. 2....14133
3.3. Mirrors, Heated W/Power Mirror, p. 3....14134
3.4. Mirrors, Lighted, p. 4....14135
3.5. Owner/Operator Connections — Rear Cab Junction Block, Acces....14136
3.6. Radio, Cab, 2 Speakers, AM-FM Cassette Radio & CB Radio 2–W....14137
3.7. Radio, Cab, 4 Speakers, AM-FM Cassette Premium Radio, p. 7....14138
3.8. Radio, Sleeper, AM-FM Cassette Radio W/Sleeper Speakers, p.....14139
3.9. Cigar Lighter, Power Seat, p. 9....14140
3.10. Radio, Sleeper, AM-FM Cassette Premium Radio W/Sleeper Spe....14141
3.11. Sleeper Cab, 42 Inch, p. 11....14142
3.12. Sleeper Cab, 42 Inch (Cont.), p. 12....14143
3.13. Turn Signals W/International T/S Switch W/Tractor & N/Pede....14144
3.14. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14145
3.15. Turn Signals W/International T/S Switch W/Tractor/Truck & ....14146
3.16. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14147
3.17. Turn Signals W/Sig-Stat 910/915 T/S Switch W/ & N/Pedestal....14148
3.18. Windshield Wiper & Washer (Elect) W/International T/S Swit....14149
3.19. Windshield Washer (Elect) W/Air Wipers & W/International T....14150
3.20. Windshield Washer (Elect) W/Air Wipers & W/Sig–Stat T/S Sw....14151
3.21. Windshield Wiper W/Intermittent Wiper/Washer W/Sig–Stat T/....14152
12V CHARGING + CRANKING SYSTEM (Chapter 4)....14153
4.1. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/I....14153
4.2. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/N....14154
4.3. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/C....14155
4.4. Charging System (12V) Delco (90 AMP) CS-130 & 21SI (65, 100....14156
4.5. Cranking System (12V) (8100) W/ISM, p. 5....14157
4.6. Cranking System (12V) (8100) C-10, C-12, p. 6....14158
4.7. Cranking System (12V) (2500, 2600) W/ISM, N14E PLUS, p. 7....14159
4.8. Cranking System (12V) (2500, 2600) W/C-10, C-12, p. 8....14160
4.9. Cranking System (12V) W/T 444E, I6 HEUI, p. 9....14161
4.10. Ether Start W/ISM, C-10, C-12, I6 HEUI, p. 10....14162
4.11. Auto Neutral (813AAS), p. 11....14163
FANS (Chapter 5)....14164
5.1. Horton Engine Fan With Cummins N14E PLUS W/ & N/Air Conditi....14164
5.2. Horton Engine Fan With Cummins ISM Engine W/ & N/Air Condit....14165
5.3. Radiator Shutter W/ISM, N14E PLUS, p. 3....14166
5.4. Horton Engine Fan With Cat. C-10, C-12 W/ & N/Air Condition....14167
5.5. Shutter & Fan Wiring W/I6 HEUI, T 444E, p. 5....14168
ELECTRONIC ENGINES (Chapter 6)....14169
6.1. Engine Controls, Cummins N14E PLUS, p. 1....14169
6.2. Engine Controls, Cummins N14E PLUS (Cont.), p. 2....14170
6.3. Engine Controls, Cummins ISM Engine, p. 3....14171
6.4. Engine Controls, Cummins ISM Engine (Cont.), p. 4....14172
6.5. Engine Controls, Cummins ISM Engine (Cont.), p. 5....14173
6.6. Engine Brake N/Electronic Transmission, Cummins N14E PLUS, ....14174
6.7. Engine Brake N/Electronic Transmission, Cummins ISM, p. 7....14175
6.8. Engine Brake, Caterpillar C-10, C-12, p. 8....14176
6.9. Cruise Control, Caterpillar C-10, C-12, p. 9....14177
6.10. Engine Controls, Caterpillar C-10, C-12, p. 10....14178
6.11. Engine Shutdown Warning Lights, Low Coolant Switch, Caterp....14179
6.12. Low Air Pressure (Brake) Alarm & Brake Systems Warning Lig....14180
6.13. Module Power & Ground System W/T 444E, I6 HEUI, p. 13....14181
6.14. Accelerator, BAP & Ambient Air Systems W/T 444E & I6 HEUI ....14182
6.15. Accelerator, BAP & Ambient Air Temp. Sensor W/T 444E & I6 ....14183
6.16. Cruise Control, Body Builder Connections W/T 444E, I6 HEUI....14184
GAUGES (Chapter 7)....14185
7.1. Oil Temperature Gauges — Fwd/RR & RR/RR Axles W/6x4, Rear A....14185
7.2. Engine Oil W/ISM Engine & Transmission Oil Temperature Gaug....14186
7.3. Engine Oil Temperature Gauge W/N14E PLUS Engine, p. 3....14187
7.4. Engine Oil Temperature Gauge W/C-10, C-12, p. 4....14188
7.5. Engine Water Temp., Tach, Gauge, Left Turn, HI Beam Ind. W/....14189
7.6. Ammeter Wiring, p. 6....14190
7.7. Fuel Gauge, Speedometer (N/T 444E), Voltmeter, Right Turn I....14191
7.8. Speedometer, Tachometer, HI Beam, Right & Left T/S Ind. Lig....14192
7.9. Pyrometer Gauge N/T 444E, I6 HEUI, p. 9....14193
WARNING LIGHTS (Chapter 8)....14194
8.1. Windshield Washer Low Fluid Warning Light, Power Divider Lo....14194
8.2. Fuel Filter Wiring System W/T 444E, I6 HEUI, p. 2....14195
8.3. Diagnostic/Programmable Conn., W/T 444E, I6 HEUI, p. 3....14196
8.4. Surge Tank W/T 444E & I6 HEUI (Plastic or Metal Tanks), p. ....14197
8.5. Engine Warning Lights/Alarm & Test Switch W/T 444E & I6 HEU....14198
8.6. Air Actuated and Hydraulic Actuated Park Brake With Hydraul....14199
CHASSIS ACCESSORIES (Chapter 9)....14200
9.1. Air Suspension W/Air Hydraulic Brakes, p. 1....14200
9.2. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....14201
9.3. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....14202
9.4. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....14203
9.5. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....14204
9.6. Allison Automatic (Electronic) Transmission W/I6 or V8, p. ....14205
9.7. Allison Automatic (Electronic) Transmission Retarder Contro....14206
9.8. Allison Automatic (Electronic) Transmission Retarder Contro....14207
9.9. Allison Automatic (Electronic) Transmission Retarder, p. 9....14208
9.10. Auto Neutral, p. 10....14209
9.11. Allison Automatic (Electronic) Transmission WTEC III HD, p....14210
9.12. Allison Automatic (Electronic) Transmission WTEC III HD (C....14211
9.13. Allison Automatic (Electronic) Transmission WTEC III HD (C....14212
9.14. Allison Automatic (Electronic) Transmission WTEC III HD (C....14213
9.15. Exhaust Brake, I6 HEUI W/Air ABS, W/Allison WT Transmissio....14214
9.16. Exhaust Brake, I6 HEUI W/Air ABS, N/Allison WT Transmissio....14215
9.17. Exhaust Brake W/Hyd. Brakes N/AT-MT Retarders or MD Transm....14216
9.18. Exhaust Brake Solenoid, I6 HEUI, N/ABS, N/Allison WT Trans....14217
9.19. Allison Automatic Transmission System W/I6 HEUI, T 444E, p....14218
9.20. Axle, Two Speed, Wiring (Air) W/Allison (Elect.) Auto Tran....14219
9.21. Axle, Two Speed, Wiring (Hyd.) W/Allison (Elect.) Auto Tra....14220
9.22. Axle, Two Speed, Electric W/T 444E & I6 HEUI, p. 22....14221
9.23. Axle, Two Speed, Electric (Air) & Air Dryer W/Auto or Manu....14222
9.24. Axle, Two Speed, Electric (Hydraulic) W/Auto or Manual Tra....14223
9.25. Brake System, Hydraulic, p. 25....14224
9.26. Bendix Automatic Drain Valve (DV-2) W/Heater W/ & N/Exhaus....14225
9.27. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Air ABS, ....14226
9.28. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Hyd. ABS,....14227
9.29. Locking Differential W/Allison WT Transmission, p. 29....14228
9.30. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14229
9.31. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14230
9.32. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14231
9.33. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14232
9.34. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....14233
9.35. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....14234
9.36. Brake System, Hydraulic W/4000 & W/ or N/ABS, p. 36....14235
9.37. Antilock Hydraulic Brakes (4 Channel) W/4000, p. 37....14236
9.38. Antilock Hydraulic Brakes (4 Channel) W/4000 (Cont.), p. 3....14237
9.39. Transfer Case Shift System Front Axle Warning Light, p. 39....14238
9.40. Trailer Connection W/Regular Cab & W/Sleeper Box, p. 40....14239
9.41. Trailer Connection W/Frame Mounted 7–Way & W/Tractor, p. 4....14240
9.42. Trailer Connection W/Frame Mounted 7–Way & W/Truck & W/Air....14241
9.43. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco, p. 43....14242
9.44. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco (Cont.), ....14243
9.45. Air Suspension, Main Cab Overlay Control Harness, p. 45....14244
9.46. Meritor G Series Transmission, p. 46....14245
9.47. Allison LCT With Hydraulic Brakes, p. 47....14246
9.48. Allison LCT With Hydraulic Brakes (Cont.), p. 48....14247
9.49. Allison LCT With Hydraulic Brakes (Cont.), p. 49....14248
9.50. Allison LCT With Hydraulic Brakes (Cont.), p. 50....14249
9.51. Allison LCT With Hydraulic Brakes (Cont.), p. 51....14250
9.52. Allison LCT With Hydraulic Brakes (Cont.), p. 52....14251
9.53. Allison LCT With Hydraulic Brakes (Cont.), p. 53....14252
9.54. Dual Neutral, p. 54....14253
LIGHT SYSTEMS (Chapter 10)....14254
10.1. Back-Up Lights, p. 1....14254
10.2. Clearance, Marker & Tail Lights W/Tractor N/T 444E, I6 HEU....14255
10.3. Clearance, Marker & Tail Lights W/Truck N/T 444E, I6 HEUI,....14256
10.4. Clearance, Marker & Tail Lights W/Tractor W/T 444E, I6 HEU....14257
10.5. Clearance, Marker & Tail Lights W/Truck W/T 444E, I6 HEUI,....14258
10.6. Cab Dome and Courtesy Lights, p. 6....14259
10.7. Work Light W/Tractor & W/Reg. Cab, Sleeper Cab, p. 7....14260
10.8. Work Light W/Truck, p. 8....14261
10.9. Fog Light System W/ & N/DRL (USA) & N/T 444E, I6 HEUI, p. ....14262
10.10. Fog Light System W/ & N/DRL (Canada) & N/T 444E, I6 HEUI,....14263
10.11. Fog Light System W/ & N/DRL (USA) & W/T 444E, I6 HEUI, p.....14264
10.12. Fog Light System W/DRL (Canada) & W/T 444E, I6 HEUI, p. 1....14265
10.13. Headlight System N/DRL W/International Turn Signal Switch....14266
10.14. Headlight System N/DRL W/International Turn Signal Switch....14267
10.15. Headlight System N/DRL W/Sig-Stat 910 T/S Sw. W/Flr. Mtd.....14268
10.16. Headlight System N/DRL W/Sig-Stat 915 T/S Sw. W/Push Btn.....14269
10.17. Headlight System W/DRL (Canada) W/Sig-Stat 910 T/S Sw. W/....14270
10.18. Headlight System W/DRL (Canada) W/Sig-Stat 915 T/S Sw. W/....14271
10.19. Headlight System W/DRL (USA) W/Sig-Stat 910 T/S Sw. W/Air....14272
10.20. Headlight System W/DRL (USA) W/Sig-Stat 915 T/S Sw. W/Air....14273
10.21. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Hyd. Br....14274
10.22. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Hyd. Brake....14275
10.23. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14276
10.24. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14277
10.25. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14278
10.26. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14279
10.27. Additional Headlight Wiring W/Dual Drive Cab, p. 27....14280
10.28. Hydraulic Park Brake Ind. Light W/Key Sw. or Push Button ....14281
10.29. Panel Lights, p. 29....14282
10.30. Stop Light Switch W/T 444E & I6 HEUI W/Air Brakes, p. 30....14283
10.31. Stop Light Switch Truck W/Standard Air Brakes W/Internati....14284
10.32. Stop Light Switch Truck W/Standard Air Brakes W/Sig-Stat ....14285
10.33. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14286
10.34. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14287
HEATER AND AIR CONDITIONER (Chapter 11)....14288
11.1. Heater/Air Conditioner, p. 1....14288
11.2. Heater Only, p. 2....14289
CONNECTOR COMPOSITES (Chapter 12)....14290
12.1. Dash Connector (2) (N/T 444E or I6 HEUI)....14290
12.2. Dash Connector (2) (W/T 444E or I6 HEUI)....14291
12.3. Dash Connector Engine Connections (2A) (N/T 444E or I6 HEU....14292
12.4. Dash Connector Engine Connections (2A) (W/T 444E or I6 HEU....14293
12.5. Connector Composites (3 & 3A)....14294
12.6. Connector Composite (3J)....14295
12.7. Connector Composites (11), (12), (13)....14296
12.8. Connector Composites (14), (14A), (15), (16), (17), (18), ....14297
12.9. Connector Composites (20), (21)....14298
12.10. Connector Composites (23), (24), (26)....14299
12.11. Connector Composites (27), (28), (29), (30), (31), (32)....14300
12.12. Connector Composites (33), (34), (35), (36), (37), (38), ....14301
12.13. Connector Composites (47 & 48), (47A), (47B), (49), (50),....14302
12.14. Connector Composites (53), (54), (55), (56), (57), (58), ....14303
12.15. Connector Composites (66), (67), (69), (70), (71)....14304
12.16. Connector Composites (72), (73), (74), (75), (76), (77), ....14305
12.17. Connector Composites (80), (83), (84 & 85), (86), (90), (....14306
12.18. Connector Composites (98), (99), (100), (101), (102), (10....14307
12.19. Connector Composites (105), (106), (107), (108), (109), (....14308
12.20. Connector Composites (117), (119), (121), (122), (123), (....14309
12.21. Connector Composites (132), (133), (135), (136)....14310
12.22. Connector Composites (137), (141), (142), (143), (144), (....14311
12.23. Connector Composites (147), (148), (149), (153)....14312
12.24. Connector Composites (153), (154), (156), (157), (158), (....14313
12.25. Connector Composites (160), (161), (162), (163), (164), (....14314
12.26. Connector Composites (169), (170), (171), (172), (173), (....14315
12.27. Connector Composites (179), (180), (181), (182), (183), (....14316
12.28. Connector Composites (194A), (199), (203), (210), (212), ....14317
12.29. Connector Composites (214M), (218), (219), (220), (221), ....14318
12.30. Connector Composites (223), (225), (226), (231), (232M), ....14319
12.31. Connector Composites (252), (257), (258), (259), (260), (....14320
12.32. Connector Composites (270), (271), (272), (273), (274A), ....14321
12.33. Connector Composites (274), (275), (276), (277), (279)....14322
12.34. Connector Composites (280), (284), (286), (287)....14323
12.35. Connector Composites (288), (289), (290), (291), (292), (....14324
12.36. Connector Composites (294), (295), (296), (297), (298), (....14325
12.37. Connector Composites (304), (305), (306), (309), (310), (....14326
12.38. Connector Composites (311), (312), (313), (314), (315), (....14327
12.39. Connector Composites (320), (323), (325)....14328
12.40. Connector Composites (325), (326), (327), (328), (329), (....14329
12.41. Connector Composites (332), (333), (335), (336), (337)....14330
12.42. Connector Composites (338), (339), (340), (341), (342), (....14331
12.43. Connector Composites (345), (346), (347), (348), (349), (....14332
12.44. Connector Composites (355), (356), (357), (358), (359), (....14333
12.45. Connector Composites (367), (368), (369), (370), (372), (....14334
12.46. Connector Composites (377), (377A), (377B)....14335
12.47. Connector Composites (379), (382), (382A)....14336
12.48. Connector Composites (383), (384), (386), (386A), (386B)....14337
12.49. Connector Composites (387), (389), (390), (391), (392)....14338
12.50. Connector Composites (396), (399), (400), (401)....14339
12.51. Connector Composites (402), (403), (404)....14340
12.52. Connector Composites (406), (413), (417)....14341
12.53. Connector Composite (418)....14342
12.54. Connector Composites (420), (421), (422)....14343
12.55. Connector Composites (423), (425), (426), (427), (428)....14344
12.56. Connector Composites (430), (431), (432), (433), (434), (....14345
12.57. Connector Composites (447), (449), (457)....14346
12.58. Connector Composites (458), (459), (460), (463), (465), (....14347
12.59. Connector Composites (467), (468), (469), (473), (480), (....14348
12.60. Connector Composites (492), (493), (494), (495)....14349
12.61. Connector Composites (499), (500), (501), (502), (503), (....14350
12.62. Connector Composites (506), (507), (508), (510), (511), (....14351
12.63. Connector Composites (555), (557), (558), (569), (570), (....14352
12.64. Connector Composite (615)....14353
12.65. Connector Composites (631), (632)....14354
12.66. Connector Composites (633), (634)....14355
12.67. Connector Composites (636), (637), (639)....14356
12.68. Connector Composites (646), (646A), (647), (648), (649), ....14357
12.69. Connector Composites (661), (662), (667), (675), (683), (....14358
12.70. Connector Composites (700), (701), (702), (703), (707)....14359
12.71. Connector Composites (708), (734), (758), (759), (760), (....14360
12.72. Connector Composites (766), (767), (768), (769), (770), (....14361
12.73. Connector Composites (775), (776), (777), (778), (789), (....14362
12.74. Connector Composites (792), (807), (830A), (830B), (917),....14363
12.75. Connector Composites (926), (958), (959), (960), (960A), ....14364
12.76. Connector Composites (995), (996), (1000), (1001), (1002)....14365
12.77. Connector Composites (1014), (1015)....14366
12.78. Connector Composites (1016), (1017), (1091)....14367
12.79. Connector Composites (1093), (1094), (1095), (1097), (109....14368
12.80. Connector Composites (1110M), (1113F), (1117), (1119), (1....14369
12.81. Connector Composites (1125), (1126), (1128), (1129), (113....14370
12.82. Connector Composites (1132), (1133), (1134), (1135), (302....14371
12.83. Connector Composites (3024), (3025), (3026), (3027), (302....14372
12.84. Connector Composites (3031), (3032), (3033), (3034)....14373
12.85. Connector Composites (3035), (3038), (3039), (3040)....14374
12.86. Connector Composites (3043), (3044), (3047), (3084), (308....14375
S08230 - Electrical System Troubleshooting Guide, Supersedes CTS-5300 (July 1999) Service Manual....14376
S082503 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built Before 05_20_2003....15088
S082503Z.PDF (p.1-140)....15088
3200 4000 7000 8000 (May 2003) Electrical Troubleshooting (S082503A).pdf (p.141-1320)....15228
S082503AA.PDF (p.1-140)....15228
S082503AB.PDF (p.141-340)....15368
S082503AC.PDF (p.341-444)....15568
S082503AD.PDF (p.445-628)....15672
S082503AE.PDF (p.629-830)....15856
S082503AF.PDF (p.831-964)....16058
S082503AG.PDF (p.965-1180)....16192
S082503B.PDF (p.1321-1510)....16408
S082503C.PDF (p.1511-1612)....16598
S082503D.PDF (p.1613-1794)....16700
S082503E.PDF (p.1795-1990)....16882
S082503F.PDF (p.1991-2124)....17078
S082503G.PDF (p.2125-2332)....17212
S082503 - Electrical System Troubleshooting Guide Models Built 10_16_2000 to 05_20_2003 (Jan 2008) Service Manual....17420
S082503Z....17420
S082503B....17560
S082503C....17750
S082503D....17852
S082503E....18034
S082503F....18230
S082503G....18364
S082504 - ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models 05_20_2003 to 02_28_2007....18572
S082504Z.PDF (p.1-332)....18572
S082504B.PDF (p.333-620)....18904
S082504C.PDF (p.621-824)....19192
S082504D.PDF (p.825-1172)....19396
S082504 - Electrical System Troubleshooting Guide Models Built 05_20_2003 to 02_28_2007 (Jan 2008) Service Manual....19744
S082504Z....19744
S082504B....20076
S082504C....20364
S082504D....20568
S08285 - 4200, 4300, 4400 Models Built October 16, 2000 to December 31, 2001 Electrical Circuit Diagrams (Jan 2001)....20916
S08285A....20916
S08285B....20974
S08285C....21023
S082852 - 4000 Series (Jan 2002 to Sep 2002) Wiring Diagrams....21080
S082852Z.PDF (p.1-63)....21080
S082852B.PDF (p.64-119)....21143
S082852C.PDF (p.120-183)....21199
S082852 - 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600 Models Built January 1, 2002 To September 30, 2002 Electrical Circuit Diagrams (Jan 2002) Service Manual....21263
S082852Z....21263
S082852B....21326
S082852C....21382
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built October 1, 2002 to September 15, 2003 Electrical Circuit Diagrams (Oct 2002) Manual....21446
S082852AA....21446
S082852AB....21511
S082852AC....21569
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES Built October 1, 2002 and After ELECTRICAL CIRCUIT DIAGRAMS....21633
S082852AA.PDF (p.1-65)....21633
S082852AB.PDF (p.66-123)....21698
S082852AC.PDF (p.124-187)....21756
S082853 - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built September 16, 2003 to March 10, 2004 Electrical Circuit Diagrams....21820
S082853Z....21820
S082853B....21889
S082853C....21963
S082854 - 4000 Series (2004 to 2005) Wiring Diagrams....22028
S08300 - Body Builder Electrical Data Book for Models Built January 2001 to February 28, 2007 Supersedes PBB-73000B (Aug 2008) Service Manual....22243
S08300z0805....22243
S08300b0805....22370
S08300c0805....22527
S08308 - Diamond Logic PowerPack 3 Dynamic Power System Service _ Troubleshooting Guide (Feb 2006) Service Manual....22679
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes (June 2005) Service Manual....22691
S08315 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, MXT, RXT Models Built Oct. 1, 2005 to Feb. 28, 2007 Electrical Circuit Diagrams....22702
S08322 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600, RXT Models Built March 1, 2007 to March 18, 2008 Electrical Circuit Diagrams....22991
S08322a....22991
S08322b....23105
S08322c....23213
S08322 - 4000 Series (March 2007 to March 2008) Wiring Diagrams....23342
3200 RXT 4000 7000 8000 (March 2007 to March 2008) Wiring Diagrams (S08322a).pdf (p.1-114)....23342
S08322b.pdf (p.115-222)....23456
S08322c.pdf (p.223-351)....23564
S08323A - (2007) 3000 4000 7000 8000 BE CE DuraStar WorkStar TranStar - Body Builder Data Book....23693
S08324 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, CXT, DuraStar, RXT, TranStar, and WorkStar Models Built After March 01, 2007 Electrical System Troubleshooting Guide....23969
toc....23973
SAFETY INFORMATION....23973
INTRODUCTION....23975
1. MANUAL INTRODUCTION....23977
Electronic Gauge Cluster....23979
1. Description And Operation....23981
1.1. Overview....23981
1.2. Operation....23981
1.3. EGC Diagram....23982
1.4. Data Link Communication....23982
2. Feature Codes....23982
3. Cluster Features....23983
3.1. Gauges....23983
3.2. Warning and Indicator Lamps....23989
Flashing of Diagnostic Lamps ....23989
Individual Warning Lamps....23989
In-Gauge Warning Lamps....24006
Direct Drive Warning Lamps....24006
3.3. Digital Display....24007
Display Control....24007
Display Lighting....24007
Initial Display Mode....24008
Informational Display Screens (Quadrant 1)....24008
Standard Selections....24008
Optional Selections....24008
Odometer/Trip Functions....24008
Hours Functions....24009
Fuel Economy....24009
Fuel Used (2010 and beyond Clusters)....24010
Compass/Outside Temperature (Quadrant 3)....24010
General Text and Warning Messages (Quadrant 2)....24011
HVAC Graphics....24015
Transmission Gear Displays (Quadrant 4)....24015
3.4. Audible Alarm....24016
One-time Five-short-beeps Alarm....24016
Repetitive One-short-beep Alarm....24016
One-time Ten-short-beeps Alarm ....24017
One-time Three-long-beeps Alarm....24017
Repetitive Short Duration Blips ....24017
3.5. Switches....24017
Headlight/Park Light Switch....24018
Panel Dimmer Switch....24018
Right Side Optional Switches....24018
Left Side Optional Switches....24018
3.6. Analog Inputs....24018
Pressure Sensors....24018
Outside Temperature....24019
3.7. Outputs....24019
Headlight Enable....24019
3.8. Digital Inputs....24019
3.9. Panel Dimming and Gauge Backlighting....24019
Panel Lighting....24019
3.10. Error Operation....24020
Lost Communication....24020
EGC Internal Failure....24020
Gauge Faults....24020
Digital Display....24021
3.11. Full Power, Low Power, and Standby Modes....24021
4. Cluster Programming....24023
5. User Programmable Parameters....24023
6. Caution — Handling the EGC....24024
7. Diagnostics....24024
7.1. Gauge Sweep....24024
7.2. On-Board Diagnostics....24024
7.3. Off-Board Diagnostics....24024
7.4. Diamond Logic Builder (DLB)....24025
7.5. Diagnostic Trouble Codes....24025
7.6. Displaying Fault Codes....24029
Definitions:....24030
Failure Mode Indicators (FMI):....24031
Source Addresses (SA)....24032
7.7. Clearing Fault Codes....24033
8. Troubleshooting....24033
8.1. EGC Preliminary System Check....24033
8.2. EGC Power and Data Link Voltage Checks....24035
8.3. Gauge Troubleshooting....24035
Gauge Troubleshooting Procedure....24035
Diagnostic Trouble Codes and Related Voltage Checks for the Sens....24039
8.4. Warning Lamp Troubleshooting Procedure....24052
8.5. In-Gauge Warning Lamps....24054
8.6. Direct Drive Warning Lamps....24055
Direct Drive Warning Lamp Troubleshooting:....24056
8.7. EGC Backlighting Inoperative....24056
8.8. EGC Switches....24057
Push Button Switch Troubleshooting....24057
Rocker Switch Troubleshooting....24057
8.9. Digital Display....24057
Display Control....24058
8.10. Audible Alarm....24058
8.11. Outside Temperature Display Malfunction....24059
8.12. Lost SAE J1939 Data Link Communication....24060
9. Body Controller Signals....24061
Lighting Systems....24063
1. snowplow auxiliary lighting....24067
1.1. system description....24067
Overview....24067
Operation....24067
1.2. feature codes....24067
1.3. user programmable parameters....24068
1.4. diagnostic trouble codes....24069
1.5. troubleshooting....24070
Snow plow lighting preliminary checks....24071
Auxiliary Lights Relay Tests....24072
2. back up lights....24073
2.1. system description....24073
Overview....24073
Operation....24073
2.2. feature code....24074
2.3. user programmable parameters....24074
2.4. diagnostic trouble codes....24074
2.5. troubleshooting....24075
Back Up Lights Preliminary Checks....24075
Back Up Lights Test....24076
Backup Light Relay Tests....24077
Backup Light Ball Switch Tests....24077
3. Dome and courtesy lights....24077
3.1. system description....24077
Overview....24077
Operation....24078
3.2. feature code....24078
3.3. USER PROGRAMMABLE PARAMETERS....24078
3.4. diagnostic trouble codes....24079
3.5. troubleshooting....24080
Dome and Courtesy Lights Preliminary Checks....24080
Door Switch Circuit Tests....24081
Dome Light Circuit Tests....24082
4. fog lights....24083
4.1. system description....24083
Overview....24083
Operation....24084
4.2. feature codes....24084
4.3. user programmable parameters....24084
4.4. diagnostic trouble codes....24084
4.5. troubleshooting....24085
Fog Light System Preliminary Checks....24086
Fog Light Switch Test....24086
Fog Light Open Circuit Test....24087
Fog Light Short Circuit Test....24088
5. Headlights and DTRL....24088
5.1. system description....24088
Overview....24088
Operation....24088
5.2. feature codes....24089
5.3. user programmable parameters....24089
5.4. diagnostic trouble codes....24090
5.5. troubleshooting....24091
Headlight System Preliminary Checks....24092
Headlight Switch and Headlight Dimmer Tests....24093
Headlight Open Circuit Test....24094
Headlight Short Circuit Test....24095
6. STOP, TURN, AND HAZARDS....24095
6.1. system description....24095
Overview....24095
Operation....24095
6.2. feature codes....24095
6.3. user programmable parameters....24097
6.4. diagnostic trouble codes....24097
6.5. troubleshooting....24099
Stop, Turn, and Hazards System Preliminary Checks....24099
Turn Signal Switch Test....24101
Hazard Switch Test....24101
Brake Switch Test....24102
Output Open Circuit Test....24102
Output Short Circuit Test....24103
7. TAIL, MARKER, PARK, AND CLEARANCE LIGHTING....24103
7.1. system description....24103
Overview....24103
Operation....24104
7.2. feature codes....24104
7.3. user programmable parameters....24105
7.4. diagnostic trouble codes....24105
7.5. troubleshooting....24106
Tail, Marker, Park, and Clearance Lighting Preliminary Checks....24107
Headlight Switch Tests....24107
Interrupt Switch Tests....24108
Park Light Open Circuit Tests....24109
Park Light Short Circuit Tests....24109
8. work lights....24109
8.1. system description....24109
Overview....24109
Operation....24110
8.2. feature codes....24110
8.3. user programmable parameters....24111
8.4. diagnostic trouble codes....24111
8.5. troubleshooting....24112
Work Light System Preliminary Checks....24112
Work Light Switch Test....24113
Work Light Open Circuit Test....24113
Work Light Short Circuit Test....24114
Auxiliary Gauge Switch Pack....24115
1. Description And Operation....24117
1.1. Overview....24117
1.2. Operation....24117
1.3. AGSP Diagram....24117
1.4. Data Link Communication....24117
2. Feature Codes....24118
3. Features....24118
3.1. Gauges....24118
3.2. In-Gauge Warning Lamps....24119
3.3. Hybrid Display....24119
3.4. Switches....24120
3.5. Panel Dimming and Gauge Backlighting....24120
3.6. Error Operation....24120
Lost Communication....24121
Gauge Faults....24121
4. AGSP Programming....24122
5. User Programmable Parameters....24122
6. Caution — Handling the AGSP....24122
7. Diagnostics....24122
7.1. Gauge Sweep....24122
7.2. On-Board Diagnostics....24123
7.3. Off-Board Diagnostics....24123
7.4. Diamond Logic Builder (DLB)....24123
7.5. Diagnostic Trouble Codes....24123
8. Troubleshooting....24126
8.1. AGSP Preliminary System Check....24126
8.2. AGSP Power and Data Link Voltage Checks....24127
8.3. Gauge Troubleshooting Procedure....24127
8.4. Troubleshooting Specific Gauges....24129
8.5. In-Gauge Warning Lamps....24136
8.6. Panel Dimming and Gauge Backlighting....24137
8.7. AGSP Switches....24137
8.8. Lost SAE J1939 Data Link Communication....24137
9.1. Body Controller Signals....24137
Cab Features....24139
1. cigar lighter and power feed....24145
1.1. System description....24145
Overview....24145
Cigar Lighter Operation....24145
Cigar Lighter Power Source and Two Post Power Source Operation....24145
1.2. feature codes....24145
1.3. user programmable parameters....24145
1.4. diagnostic trouble codes....24145
1.5. diagnostics....24145
Cigar Lighter and Power Feed Preliminary Check....24145
Cigar Lighter Tests....24146
Cigar Lighter Power Source Test....24147
Two Post Power Source Test....24147
2. C.b. Power radio....24149
2.1. system description....24149
Overview....24149
Operation....24149
2.2. feature codes....24149
2.3. user programmable parameters....24149
2.4. diagnostic trouble codes....24149
2.5. diagnostics....24149
C.B. Radio Power Source Preliminary Check....24149
C.B. Power Connector Tests....24150
3. compass and temperature display....24152
3.1. system description....24152
Overview....24152
Temperature Display Operation....24152
Compass Display Operation....24152
3.2. feature codes....24152
3.3. USER PROGRAMMABLE PARAMETERS....24152
3.4. Diagnostic Trouble Codes....24152
3.5. diagnostics....24153
Compass/Temperature Display Preliminary Check....24154
Compass/Temperature Display Voltage Checks....24154
4. power windows and locks....24155
4.1. system description....24155
Overview....24155
Power Window Operation....24155
Power Door Lock Operation....24155
4.2. feature codes....24156
4.3. user programmable parameters....24158
4.4. diagnostic trouble codes....24158
4.5. Troubleshooting....24161
Power Window and Lock Preliminary Check....24162
Power Door Lock Tests....24163
Power Window Test....24164
5. cruise control....24165
5.1. system description....24165
Overview....24165
Operation....24165
5.2. feature codes....24165
5.3. user programmable parameters....24166
5.4. diagnostic trouble codes....24166
5.5. Troubleshooting....24167
Cruise Control Preliminary Check....24168
Cruise Control Switch Tests....24169
6. Theft deterrent....24171
6.1. system description....24171
Overview....24171
Operation....24171
6.2. feature codes....24172
6.3. User programmable parameters....24173
6.4. diagnostic trouble codes....24174
6.5. troubleshooting....24175
Theft Deterrent Preliminary Check....24175
Theft Deterrent System Test....24175
7. electric horn....24177
7.1. system description....24177
Overview....24177
Operation....24177
7.2. feature codes....24177
7.3. User programmable parameters....24177
7.4. diagnostic trouble codes....24178
7.5. troubleshooting....24179
Electric Horn Preliminary Check....24179
Electric Horn Test....24180
8. air horn....24182
8.1. system description....24182
Overview....24182
Operation....24182
8.2. feature codes....24182
8.3. User programmable parameters....24182
8.4. diagnostic trouble codes....24182
8.5. troubleshooting....24183
Air Horns Preliminary Check....24183
Air Horn Test....24184
9. power mirrors....24185
9.1. system description....24185
Overview....24185
Operation....24185
9.2. feature codes....24185
9.3. User programmable parameters....24185
9.4. diagnostic trouble codes....24185
9.5. troubleshooting....24185
Power Mirror Preliminary Check....24186
Power Mirror Test....24187
10. Heated Mirror....24189
10.1. system description....24189
Overview....24189
Operation....24189
10.2. feature codes....24189
10.3. User programmable parameters....24191
10.4. diagnostic trouble codes....24191
10.5. troubleshooting....24192
Heated Mirror Preliminary Check....24192
Heated Mirrors Test....24193
Left Heated Mirror Test....24193
Right Heated Mirror Test....24194
11. radio (entertainment), speakers....24195
11.1. system description....24195
Overview....24195
Operation....24195
11.2. feature codes....24195
11.3. User programmable parameters....24195
11.4. diagnostic trouble codes....24195
11.5. troubleshooting....24195
Radio Preliminary Check....24196
Radio Test....24196
12. Two-way radio....24198
12.1. system description....24198
Overview....24198
Operation....24198
12.2. feature codes....24198
12.3. User programmable parameters....24198
12.4. diagnostic trouble codes....24198
12.5. troubleshooting....24198
Two-Way Radio Circuit Tests....24198
13. Windshield wiper and washer pump....24200
13.1. system description....24200
Overview....24200
Wiper Operation....24200
Park Operation....24200
Washer Operation....24200
13.2. feature codes....24200
13.3. User programmable parameters....24201
13.4. diagnostic trouble codes....24202
NO TITLE....24204
13.5. troubleshooting....24204
Wiper and Washer Preliminary Check....24204
Washer Test....24206
Wiper Park Test....24206
Wiper Switch Test....24207
Wiper Motor Test....24208
14. Roof auxiliary load and air shield light....24210
14.1. system description....24210
Overview....24210
Roof Auxiliary Load Operation....24210
Air Shield Light Operation....24210
14.2. Feature codes....24210
14.3. User programmable parameters....24210
14.4. diagnostic trouble code....24210
Roof Auxiliary Load Feature....24210
Lighted Air Shield....24211
14.5. troubleshooting....24211
Roof Auxiliary Load Preliminary Check....24211
Roof Auxiliary Load Test....24212
IP Mounted Roof Auxiliary Load Switch Test....24212
Lighted Air Shield Preliminary Check....24213
Lighted Air Shield Test....24214
15. self contained air seat....24215
15.1. system description....24215
Overview....24215
Operation....24215
15.2. Feature codes....24215
15.3. User programmable parameters....24215
15.4. diagnostic trouble code....24215
15.5. troubleshooting....24215
Self Contained Air Seats Preliminary Check....24215
Self Contained Air Seat Test....24216
16. Heated seats....24217
16.1. system description....24217
Overview....24217
Operation....24217
16.2. Feature codes....24217
16.3. User programmable parameters....24217
16.4. diagnostic trouble code....24217
16.5. troubleshooting....24217
Heated Seats Preliminary Check....24217
Heated Seat Test....24218
17. seat belt and seat sensor....24219
17.1. system description....24219
Overview....24219
Operation....24219
17.2. feature codes....24219
17.3. User programmable parameters....24219
17.4. diagnostic trouble code....24220
17.5. troubleshooting....24220
Seat Belt Preliminary Check....24220
Seat Belt Test....24221
18. brake light switch....24222
18.1. system description....24222
Overview....24222
Operation....24222
18.2. Feature codes....24222
18.3. User programmable parameters....24222
18.4. diagnostic trouble code....24222
18.5. troubleshooting....24224
Brake Switch Preliminary Check....24224
Brake Switch Test....24225
19. Clutch switch....24226
19.1. system description....24226
Overview....24226
Operation....24226
19.2. Feature codes....24226
19.3. User programmable parameters....24226
19.4. diagnostic trouble code....24226
19.5. troubleshooting....24227
Clutch Switch Preliminary Checks....24228
No Engine Crank Clutch Switch Test....24229
Cruise Control Clutch Switch Test....24229
20. load shedding....24230
20.1. system description....24230
Overview....24230
Operation....24230
20.2. Feature codes....24230
20.3. User programmable parameters....24230
20.4. diagnostic trouble code....24230
20.5. troubleshooting....24231
Latching Relay Diagnostics....24232
Chassis Features....24233
1. trailer turn signal relays....24239
1.1. System description....24239
Overview....24239
Operation....24239
1.2. feature codes....24239
1.3. user programmable parameters....24239
1.4. diagnostic trouble codes....24239
1.5. troubleshooting....24240
Trailer Turn Signal Relay System Preliminary Checks....24241
Left Trailer Turn Signal Inop Test....24242
Right Trailer Turn Signal Inop Test....24243
2. trailer auxiliary power circuit....24244
2.1. System description....24244
Overview....24244
Operation....24244
2.2. feature codes....24244
2.3. user programmable parameters....24244
2.4. diagnostic trouble codes....24244
2.5. troubleshooting....24245
Trailer Auxiliary Power Circuit Preliminary Checks....24245
Trailer Auxiliary Circuit Tests....24245
3. Auto Neutral (Feature Code 0595AYP)....24247
3.1. Description And Operation....24247
Overview....24247
Operation....24247
3.2. Feature Codes....24248
3.3. User Programmable Parameters....24248
3.4. Diagnostics....24249
Diamond Logic Builder (DLB)....24249
Diagnostic Trouble Codes....24249
Displaying Diagnostic Trouble Codes....24250
3.5. Troubleshooting....24250
Auto Neutral Preliminary System Check....24250
Auto Neutral Does Not Engage....24251
Auto Neutral Does Not Disengage....24252
Auto Neutral Warning Lamp Inoperative....24253
3.6. Body Controller Signals....24253
3.7. Body Controller Functions....24254
Activate Auto Neutral....24254
Error Operation....24255
4. Axle Load Monitor....24256
4.1. Description And Operation....24256
Overview....24256
Operation....24256
4.2. Feature Codes....24256
4.3. User Programmable Parameters....24257
4.4. Diagnostics....24258
Diamond Logic Builder (DLB)....24258
Diagnostic Trouble Codes....24258
Displaying Diagnostic Trouble Codes....24260
4.5. Troubleshooting....24260
Axle Load Monitor Preliminary Check....24260
Axle Pressure Transducer Voltage Checks....24261
4.6. Body Controller Signals....24261
4.7. Body Controller Functions....24262
To activate the axle load monitor feature, the following conditi....24262
5. REMOTE POWER MODULE....24263
5.1. Description and Operation....24263
Overview....24263
Operation....24263
RPM Addressing....24264
5.2. Feature Codes....24264
5.3. User Programmable Parameters....24264
5.4. Diagnostics....24265
Diamond Logic Builder (DLB)....24265
Diagnostic Trouble Codes....24265
Displaying Diagnostic Trouble Codes....24268
5.5. Troubleshooting....24268
Remote Power Module Preliminary Check....24268
RPM Power, Ground and Data Link Circuits....24269
5.6. Body Controller Signals....24270
5.7. Body Controller Functions....24270
6. auxiliary power source....24271
6.1. System description....24271
Overview....24271
Operation....24271
6.2. feature codes....24271
6.3. user programmable parameters....24271
6.4. diagnostic trouble codes....24271
6.5. troubleshooting....24271
Auxiliary Power Source Preliminary Check....24272
Aux Power Source Tests....24272
7. Two-speed axle switch....24274
7.1. System description....24274
Overview....24274
Operation....24274
7.2. feature codes....24274
7.3. user programmable parameters....24274
7.4. diagnostic trouble codes....24274
7.5. troubleshooting....24275
Two-Speed Switch Preliminary Check....24275
Two-Speed Switch Test....24275
8. Air Dryer and heated drain valve....24276
8.1. System description....24276
Overview....24276
Operation....24276
8.2. feature codes....24276
8.3. user programmable parameters....24276
8.4. diagnostic trouble codes....24276
8.5. troubleshooting....24276
Air Dryer and Heated Drain Valve Preliminary Check....24276
Heated Drain Valve Test....24277
Air Dryer Test....24277
9. fuel transfer pump....24279
9.1. System description....24279
Overview....24279
Operation....24279
9.2. feature codes....24279
9.3. user programmable parameters....24279
9.4. diagnostic trouble codes....24281
9.5. troubleshooting....24281
Fuel Transfer Pump Preliminary Check....24282
Fuel Transfer Pump Won’t Run Test....24282
Fuel Transfer Pump Continuously Runs Test....24284
10. water in fuel monitor....24285
10.1. System description....24285
Overview....24285
Operation....24285
10.2. feature codes....24285
10.3. user programmable parameters....24285
10.4. diagnostic trouble codes....24285
10.5. troubleshooting....24286
Water in Fuel Preliminary Check....24286
Water Probe Test....24287
11. electric trailer brake....24288
11.1. System description....24288
Overview....24288
Operation....24288
11.2. feature codes....24288
11.3. user programmable parameters....24288
11.4. diagnostic trouble codes....24288
11.5. troubleshooting....24289
Electric Trailer Brake Preliminary Check....24289
Electric Trailer Brake Test....24290
12. air solenoid....24292
12.1. System description....24292
Overview....24292
Operation....24292
12.2. feature codes....24292
12.3. user programmable parameters....24293
12.4. diagnostic trouble codes....24294
12.5. Troubleshooting....24302
Air Solenoid Preliminary Check....24302
Air Solenoid Diagnosis....24302
13. Suspension dump....24304
13.1. System description....24304
Overview....24304
Operation....24304
13.2. feature code....24304
13.3. user programmable parameters....24304
13.4. diagnostic trouble codes....24305
13.5. Troubleshooting....24306
Suspension Dump Test....24307
14. Customer Installed Lift Gate Power Source....24309
14.1. System description....24309
Overview....24309
Operation....24309
14.2. feature code....24309
14.3. user programmable parameters....24309
14.4. diagnostic trouble codes....24310
14.5. Troubleshooting....24310
Lift Gate Test....24311
15. Fifth Wheel Slide, Air Controlled....24312
15.1. System description....24312
Overview....24312
Operation....24312
15.2. FEATURE CODE....24312
15.3. user programmable parameters....24312
15.4. diagnostic trouble codes....24313
15.5. Troubleshooting....24313
Fifth Wheel Slide Preliminary Check....24314
Fifth Wheel Slide Test....24314
16. Differential Lock Air controlled....24315
16.1. System description....24315
Overview....24315
Operation....24315
16.2. FEATURE CODE....24316
16.3. user programmable parameters....24316
16.4. diagnostic trouble codes....24317
16.5. Troubleshooting....24318
Differential Lock Preliminary Check....24319
(0595ACT) Differential Lock Test....24319
(0595ACU) Differential Lock Test....24320
17. Power Divider Lock (PDL) Air Controlled....24321
17.1. System description....24321
Overview....24321
Operation....24321
17.2. FEATURE CODE....24321
17.3. user programmable parameters....24322
17.4. diagnostic trouble codes....24323
17.5. Troubleshooting....24323
Power Divider Lock Preliminary Check....24324
Power Divider Lock Test....24324
18. Remote start/stop....24325
18.1. System Description....24325
Overview....24325
Operation....24325
18.2. FEATURE CODE....24325
18.3. user programmable parameters....24326
18.4. Diagnostic Trouble Codes....24326
18.5. Troubleshooting....24327
Remote Start/Stop Preliminary Check....24327
Remote Start/Stop System Tests....24329
19. Power Take Off (PTO)....24331
19.1. Description and Operation....24331
Overview....24331
Operation....24331
19.2. Feature Codes....24332
19.3. User Programmable Parameters....24340
19.4. Diagnostics....24341
Diamond Logic Builder (DLB)....24341
Diagnostic Trouble Codes....24341
Displaying Diagnostic Trouble Codes....24352
19.5. Troubleshooting....24352
Power Take Off (PTO) Preliminary Check....24352
19.6. Body Controller Signals....24354
19.7. Body Controller Functions....24356
20. Wheelchair Lift Interlock....24357
20.1. Description And Operation....24357
Overview....24357
Operation....24357
20.2. Feature Codes....24358
20.3. User Programmable Parameters....24358
20.4. Diagnostics....24358
Diamond Logic Builder (DLB)....24358
Diagnostic Trouble Codes....24358
Displaying Diagnostic Trouble Codes....24359
20.5. Troubleshooting....24359
Wheelchair Lift Interlock Preliminary System Check....24359
20.6. Body Controller Signals....24362
20.7. Body Controller Functions....24363
Activate Wheelchair Lift Solenoid....24363
Activate Audible Alarm....24364
TRANSMISSIONS....24365
1. Description and Operation....24367
1.1. Overview....24367
1.2. Operation....24367
2. Feature Codes....24369
2.1. Available Body Controller Configurations....24369
2.2. User Programmable Parameters....24371
3. Diagnostics....24372
3.1. Diamond Logic Builder (DLB)....24372
3.2. Diagnostic Trouble Codes....24372
3.3. Displaying Diagnostic Trouble Codes....24373
4. Troubleshooting....24374
4.1. Preliminary System Check — All Transmissions....24374
4.2. Park Position Unlock Solenoid Checks — Eaton T-Handle & All....24379
4.3. LCT Column Shifter Interlock Checks....24380
4.4. TCM Power, Ground and Data Link Circuit Checks....24380
4.5. Shift Selector Power and Ground Circuit Checks....24381
4.6. Body Controller Signals....24381
4.7. Body Controller Functions....24382
Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....24382
PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....24382
Multiplexing (Data Links)....24383
1. multiplexing (data links)....24385
1.1. Description....24385
Overview....24385
Operation....24385
1.2. troubleshooting....24387
J1939 Data Link Terminating Resistors....24387
Body Controller....24388
Electronic Engines....24389
1. REMOTE ENGINE SPEED CONTROL MODULE (RESCM)....24391
1.1. Description and Operation....24391
Overview....24391
Operation....24391
1.2. Feature Codes....24392
1.3. User Programmable Parameters....24392
1.4. Diagnostics....24392
Diamond Logic Builder (DLB)....24392
Diagnostic Trouble Codes....24392
Displaying Diagnostic Trouble Codes....24397
1.5. Troubleshooting....24397
RESCM Preliminary Check....24397
RESCM Power, Ground and Data Link Circuits....24398
1.6. Body Controller Signals....24399
1.7. Body Controller Functions....24400
2. Aftertreatment....24401
2.1. Description And Operation....24401
Overview....24401
Operation....24401
2.2. Aftertreatment Definitions....24402
2.3. Soot Accumulation Level Indications....24402
2.4. Feature Related Text Messages in the Gauge Cluster....24403
2.5. Feature Codes....24404
2.6. User Programmable Parameters....24405
2.7. Diagnostics....24405
Diamond Logic Builder (DLB)....24406
Diagnostic Trouble Codes....24406
Displaying Diagnostic Trouble Codes....24409
2.8. Troubleshooting....24409
Preliminary System Check — Aftertreatment....24409
Parked Regeneration Switch Test....24410
Parked Regeneration Switch Indicator Test....24411
Inhibit Regeneration Switch Test....24411
Inhibit Regeneration Switch Indicator Test....24412
DPF Status Warning Lamp Test....24412
HEST Warning Lamp Test....24412
Lamp Check....24413
Lost Communication and Warning Lamp Diagnostics....24413
2.9. Body Controller Signals....24413
2.10. Body Controller Functions....24415
Parked Regeneration....24415
Inhibit Regeneration....24416
Parked Regeneration Switch Indicator....24416
Inhibit Regeneration Switch Indicator....24417
DPF Status Warning Lamp....24418
HEST Warning Lamp....24418
Audible Alarm....24419
Switch Packs (J1708 Data Links)....24421
1. switch packs (j1708 data link)....24423
1.1. Description....24423
Overview....24423
Operation....24423
1.2. troubleshooting....24423
Switch Pack Preliminary Check....24424
Switch Pack Test....24424
12 Volt Power Distribution and Grounds....24425
1. 12-Volt power distribution and grounds....24427
1.1. Description....24427
Overview....24427
Operation....24427
1.2. troubleshooting....24427
Battery Power Distribution Check....24428
Accessory Power Distribution Preliminary Check....24428
Accessory Power Test....24428
Ignition Power Distribution Preliminary Check....24429
Ignition Power Test....24430
Ground Test....24431
Fans and Engine Accessories....24433
1. Engine Cooling Fan Control....24435
1.1. Description And Operation....24435
Overview....24435
Operation....24435
1.2. Feature Codes....24435
1.3. User Programmable Parameters....24436
1.4. Diagnostics....24436
Diagnostic Trouble Codes....24436
Displaying Diagnostic Trouble Codes....24437
1.5. Troubleshooting....24437
Preliminary Check — Engine Cooling Fan....24437
1.6. Body Controller Signals....24438
1.7. Body Controller Functions....24440
Fan Control — General Information....24440
ON/OFF Fan Control....24440
Low Air Pressure Engine Fan Override (0595BBB)....24441
Variable Speed Fan Control (0595AYH)....24442
2. Snow Valve (Engine Intake) (non Big Bore Engines)....24444
2.1. Description And Operation....24444
Overview....24444
Operation....24444
2.2. Feature Codes....24444
2.3. User Programmable Parameters....24444
2.4. Diagnostics....24445
Diagnostic Trouble Codes....24445
2.5. Troubleshooting....24445
Snow Valve Preliminary Check....24445
Snow Valve Mechanical Checks....24445
Snow Valve Module Checks....24446
2.6. Body Controller Signals....24446
2.7. Body Controller Functions....24446
3. Snow Valve (Engine Intake) (Big Bore Engines)....24447
3.1. Description And Operation....24447
Overview....24447
Operation....24447
3.2. Feature Codes....24448
3.3. User Programmable Parameters....24448
3.4. Diagnostics....24448
Diamond Logic Builder (DLB)....24448
Diagnostic Trouble Codes....24449
Displaying Diagnostic Trouble Codes....24449
3.5. Troubleshooting....24449
Snow Valve Preliminary Check....24449
Snow Valve Mechanical Checks....24450
Snow Valve Switch Test....24451
Snow Valve Module Checks....24451
3.6. Body Controller Signals....24453
3.7. Body Controller Functions....24453
To activate the feature, the following conditions must be true:....24453
If the conditions to activate the feature (above) are true, then....24453
If any of the following conditions occur, then the feature will ....24454
If any of the conditions to deactivate the feature (above) are t....24454
4. Exhaust Brake....24455
4.1. Description And Operation....24455
Overview....24455
Operation....24455
4.2. Feature Codes....24455
4.3. User Programmable Parameters....24456
4.4. Diagnostics....24456
Diamond Logic Builder (DLB)....24456
Diagnostic Trouble Codes....24456
Displaying Diagnostic Trouble Codes....24456
4.5. Troubleshooting....24457
Exhaust Brake Preliminary Check....24457
Exhaust Brake Switch Test....24458
4.6. Body Controller Signals....24458
4.7. Body Controller Functions....24459
To activate the exhaust brake feature, the following conditions ....24459
If the conditions to activate the feature (above) are true, then....24459
Battery, Charging, and Cranking System....24461
1. battery....24463
1.1. Description....24463
Overview....24463
Operation....24463
1.2. diagnostic trouble codes....24464
1.3. troubleshooting....24464
NO TITLE....24464
2. charging system....24465
2.1. Description....24465
Overview....24465
Operation....24465
2.2. diagnostic trouble codes....24465
2.3. troubleshooting....24466
3. ENGINE CRANKING....24466
3.1. Description....24466
Overview....24466
Operation....24466
3.2. troubleshooting....24467
4. Power pack 3....24467
4.1. Description....24467
Overview....24467
Operation....24467
4.2. troubleshooting....24468
tables....23983
Table 1Gauge Table....23983
Table 2Warning and Indicator Lamp Table – Type A....23990
Table 3Warning and Indicator Lamp Table – Type B....23998
Table 5General Text and Warning Messages requested by means of a....24011
Table 6General Text and Warning Messages Generated by the Electr....24012
Table 18Fuel Level Sensor Voltage Checks....24041
Table 20Transmission Oil Temperature Sensor Voltage Checks....24043
Table 22Axle Temperature Sensor Voltage Checks....24045
Table 24Axle Temperature Sensor Voltage Checks....24047
Table 26Air Pressure Transducer Voltage Checks....24051
Table 27Direct Drive Warning Lamp Table....24055
Table 29Ambient Air Temperature Sensor Test....24060
Table 30Ambient Air Temperature Sensor Table....24060
Table 32Feature Codes....24068
Table 33Diagnostic Trouble Codes....24069
Table 34Snow plow lighting preliminary checks....24071
Table 35Auxiliary Lights Relay Tests....24072
Table 36Diagnostic Trouble Codes....24074
Table 37Back Up Lights Preliminary Checks....24075
Table 38Back Up Lights Test....24076
Table 39Backup Light Relay Tests....24077
Table 40Backup Light Ball Switch Tests....24077
Table 41Feature Code....24078
Table 42Diagnostic Trouble Codes....24080
Table 43Dome and Courtesy Lights Preliminary Checks....24081
Table 44Door Switch Short Circuit Tests....24082
Table 45Door Switch Open Circuit Tests....24082
Table 46Dome Light Short Circuit Test....24083
Table 47Dome Light Open Circuit Test....24083
Table 48Feature Codes....24084
Table 49Diagnostic Trouble Codes....24085
Table 50Fog Light System Preliminary Checks....24086
Table 51Fog Light Switch Test....24087
Table 52Fog Light Open Circuit Test....24087
Table 53Fog Light Short Circuit Test....24088
Table 54Feature Codes....24089
Table 55Diagnostic Trouble Codes....24090
Table 56Headlight System Preliminary Checks....24092
Table 57Headlight Switch and Headlight Dimmer Test....24093
Table 58Headlight Open Circuit Test....24094
Table 59Headlight Short Circuit Test....24095
Table 60Feature Codes....24096
Table 61Diagnostic Trouble Codes....24098
Table 62Stop, Turn, and Hazards System Preliminary Checks....24100
Table 63Turn Signal Switch Test....24101
Table 64Hazard Switch Test....24101
Table 65Brake Switch Test....24102
Table 66Output Open Circuit Test....24102
Table 67Output Short Circuit Test....24103
Table 68Feature Codes....24104
Table 69Diagnostic Trouble Codes....24106
Table 70Tail, Marker, Park, and Clearance Lighting Preliminary C....24107
Table 71Headlight Switch Tests....24107
Table 72Interrupt Switch Tests....24108
Table 73Park Light Open Circuit Tests....24109
Table 74Park Light Short Circuit Tests....24109
Table 75Feature Codes....24110
Table 76Diagnostic Trouble Codes....24111
Table 77Work Light System Preliminary Checks....24112
Table 78Work Light Switch Test....24113
Table 79Work Light Open Circuit Test....24114
Table 80Work Light Short Circuit Test....24114
Table 82Gauge Table....24119
Table 88Axle Temperature Sensor Voltage Checks....24130
Table 90Axle Temperature Sensor Voltage Checks....24133
Table 93Cigar Lighter and Power Feed Preliminary Check....24146
Table 94Cigar Lighter Tests....24146
Table 95Cigar Lighter Power Source Tests....24147
Table 96Two Post Power Source Tests....24147
Table 97C.B. Radio Power Source Preliminary Check....24149
Table 98C.B. Radio Power Connector Tests....24150
Table 99Feature Codes....24152
Table 100Diagnostic Trouble Codes....24152
Table 101Compass/Temperature Display Preliminary Check....24154
Table 102Compass/Temperature Display Voltage Checks....24154
Table 103Feature Codes....24156
Table 104Diagnostic Trouble Codes....24158
Table 105Power Locks Preliminary Check....24162
Table 106Power Windows Preliminary Check....24162
Table 107One Door Lock Inop Test....24163
Table 108All Door Locks Inop Test....24163
Table 109One Power Window Inop Test....24164
Table 110All Power Windows Inop Test....24164
Table 111Feature Codes....24165
Table 112Diagnostic Trouble Codes....24166
Table 113Cruise Control Preliminary Check....24168
Table 114Steering Wheel Mounted Cruise Control Command Switch Te....24169
Table 115Steering Wheel Mounted Cruise Control Command Switch Te....24170
Table 116Feature Codes....24172
Table 117Theft Deterrent Preliminary Check....24175
Table 118Theft Deterrent System Test....24175
Table 119Feature Codes....24177
Table 120Diagnostic Trouble Codes....24179
Table 121Electric Horn Preliminary Check....24179
Table 122Electric Horn Test....24180
Table 123Feature Codes....24182
Table 124Diagnostic Trouble Codes....24183
Table 125Air Horns Preliminary Checks....24183
Table 126Air Horn Test....24184
Table 127Power Mirror Preliminary Check....24186
Table 128Power Mirror Tests....24187
Table 129Feature Codes....24189
Table 130Diagnostic Trouble codes....24191
Table 131Heated Mirror Preliminary Check....24192
Table 132Heated Mirrors Test....24193
Table 133Left Heated Mirror Test....24193
Table 134Right Heated Mirror Test....24194
Table 135Radio Preliminary Check....24196
Table 136Radio Test....24196
Table 137Two-Way Radio Circuit Tests....24198
Table 138Feature Codes....24200
Table 139Diagnostic Trouble Codes....24202
Table 140Wiper and Washer Preliminary Check....24204
Table 141Washer Test....24206
Table 142Wiper Park Test....24206
Table 143Wiper Switch Test....24207
Table 144Wiper Motor Test....24208
Table 145Feature Codes....24210
Table 146Lighted Air Shield DTC....24211
Table 147Roof Auxiliary Load Preliminary Check....24211
Table 148Roof Auxiliary Load Test....24212
Table 149IP Mounted Roof Auxiliary Load Switch Test....24212
Table 150Lighted Air Shield Preliminary Check....24213
Table 151Lighted Air Shield Test....24214
Table 152Self Contained Air Seats Preliminary Check....24215
Table 153Self Contained Air Seat Test....24216
Table 154Heated Seats Preliminary Check....24217
Table 155Heated Seat Test....24218
Table 157Seat Belt Preliminary Check....24220
Table 1580595BAG Seat Belt Test....24221
Table 159Feature Codes....24222
Table 160Diagnostic Trouble Codes....24222
Table 161Brake Switch Preliminary Check....24224
Table 162Brake Switch Test....24225
Table 163Feature Code....24226
Table 164Diagnostic Trouble Codes....24227
Table 165Clutch Switch Preliminary Checks....24228
Table 166No Engine Crank Clutch Switch Test....24229
Table 167Cruise Control Clutch Switch Test....24229
Table 168Feature Code....24230
Table 169Diagnostic Trouble Codes....24231
Table 170Feature Code....24239
Table 171Diagnostic Trouble codes....24239
Table 172Trailer Turn Signal Relay System Preliminary Checks....24241
Table 173Left Trailer Turn Signal Inop Test....24242
Table 174Right Trailer Turn Signal Inop Test....24243
Table 175Feature Codes....24244
Table 176Diagnostic Trouble Codes....24245
Table 177Trailer Auxiliary Power Circuit Preliminary Checks....24245
Table 178Trailer Auxiliary Circuit Tests....24245
Table 188Axle Pressure Transducer Voltage Checks....24261
Table 192RPM Checks....24269
Table 193Feature Codes....24271
Table 194Auxiliary Power Source Preliminary Check....24272
Table 195Aux Power Source Tests....24272
Table 197Diagnostic Trouble Codes....24274
Table 198Two-Speed Switch Preliminary Check....24275
Table 199Two-Speed Switch Test....24275
Table 200Air Dryer and Heated Drain Valve Preliminary Check....24276
Table 201Heated Drain Valve Test....24277
Table 202Air Dryer Test....24277
Table 203Feature Codes....24279
Table 204Diagnostic Trouble Codes....24281
Table 205Fuel Transfer Pump Preliminary Check....24282
Table 206Fuel Transfer Pump Won’t Run Test....24282
Table 207Fuel Transfer Pump Continuously Runs Test....24284
Table 208Feature Code....24285
Table 210Water in Fuel Preliminary Check....24286
Table 211Water Probe Test....24287
Table 212Feature Code....24288
Table 213Diagnostic Trouble Codes....24289
Table 214Electric Trailer Brake Preliminary Check....24289
Table 215Electric Trailer Brake Test....24290
Table 216Feature Code....24292
Table 217Diagnostic Trouble Codes....24294
Table 218Air Solenoid Preliminary Check....24302
Table 219Feature Code....24304
Table 220Diagnostic Trouble Codes....24305
Table 221Suspension Dump Preliminary Check....24307
Table 222Suspension Dump Test....24307
Table 223Feature Code....24309
Table 224Diagnostic Trouble Codes....24310
Table 225Lift Gate Preliminary Check....24311
Table 226Lift Gate Test....24311
Table 227Feature Code....24312
Table 228Diagnostic Trouble Codes....24313
Table 229Fifth Wheel Slide Preliminary Check....24314
Table 230Fifth Wheel Slide Test....24314
Table 231Feature Code....24316
Table 232Diagnostic Trouble Codes....24317
Table 233Differential Lock Preliminary Check....24319
Table 234(0595ACT) Differential Lock Test....24319
Table 235(0595ACU) Differential Lock Test....24320
Table 236Feature Code....24322
Table 237Diagnostic Trouble Codes....24323
Table 238Power Divider Lock Preliminary Check....24324
Table 239Power Divider Lock Test....24324
Table 240Feature Code....24326
Table 241Diagnostic Trouble Codes....24327
Table 242Remote Start/Stop Preliminary Check....24327
Table 243Remote Start/Stop System Tests....24329
Table 247PTO Hour Meter/ PTO Indicator Checks....24354
Table 249Additional Signals Used for PTO Operation....24356
Table 254Wheelchair Lift Interlock Checks....24361
Table 256Additional Signals Used for Wheelchair Lift Interlock O....24363
Table 260Park Position Unlock Solenoid Checks — Eaton T-Handle &....24379
Table 261LCT Column Shifter Interlock Checks....24380
Table 262TCM Power, Ground and Data Link Circuit Checks....24380
Table 263Shift Selector Power and Ground Circuit Checks....24381
Table 269RESCM Checks....24398
Table 276Parked Regeneration (Particulate_Trap_Regeneration_Forc....24410
Table 277Inhibit Regeneration (Particulate_Trap_Regeneration_Inh....24411
Table 279Switch Pack Preliminary Check....24424
Table 280Switch Pack Test....24424
Table 281Battery Power Distribution Check....24428
Table 282Accessory Power Distribution Check....24428
Table 283Accessory Power Test....24428
Table 284Ignition Power Distribution Check....24429
Table 285Ignition Power Test....24430
Table 286Ground Test....24431
Table 292 Snow Valve Mechanical Checks....24445
Table 293 Snow Valve Module Checks....24446
Table 298 Snow Valve Mechanical Checks....24450
Table 299 Snow Valve Switch Test....24451
Table 300 Snow Valve Module Checks....24451
Table 305 Exhaust Brake Switch Test....24458
Table 307Diagnostic Trouble codes....24464
Table 308Diagnostic Trouble codes....24465
S08327 - 2007-2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual....24471
S08333 - 4300 Eaton Hybrid Drive System Built November 2006 through February 2007 Electrical Circuit Diagrams....24604
S08357 - 2011 DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE Model 4400....24615
S08359 - 4400 LHD Euro III Model Built After July, 2011 Electrical Circuit Diagrams (Brazil Market) Circuit Diagrams....24857
S08361 - DIAGNOSTIC_TROUBLESHOOTING MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — DuraStar, TerraStar, TranStar, and WorkStar Built May 2010 and Later....25262
toc....25266
SAFETY INFORMATION....25266
MANUAL INTRODUCTION....25268
1. Manual Introduction....25270
2. Vehicle Electrical System Overview....25271
3. Electrical Circuit Diagram Book....25271
3.1. CIRCUIT DIAGRAMS....25271
Circuit Diagram Instructions....25272
3.2. CONNECTOR BODY COMPOSITE....25275
4. Troubleshooting....25276
4.1. Verify The Problem....25276
4.2. Important Steps Before Performing Circuit Tests....25276
4.3. Review Feature Operation....25277
4.4. Check the Circuit Diagram....25277
4.5. Performing Circuit And System Tests....25278
4.6. Perform The Repair....25278
4.7. Verify The Repair....25278
5. Electrical Test Equipment....25278
5.1. EZ-TECH® Electronic Service Tool (EST)....25278
5.2. Body Controller Breakout Box (ZTSE4477)....25278
5.3. FLUKE 88 Digital Multimeter (DMM)....25279
5.4. MIDTRONICS EXP-1000HD....25280
5.5. Jumper Wires, Test Leads, And Test Lights....25281
Jumper Wires....25281
Test Leads....25282
Test Lights....25283
5.6. Ohm's Law Review....25283
5.7. Voltmeter....25285
Measuring Voltage....25285
5.8. Ammeter....25288
Measuring Amperage....25288
5.9. Ohmmeter....25290
Measuring Resistance....25290
Checking For Open Circuits....25292
Checking For Short Circuits....25293
6. Bench Testing Relays....25294
ELECTRONIC GAUGE CLUSTER....25298
1. Electronic Gauge Cluster....25300
1.1. System Description....25300
Overview....25300
Operation....25300
1.2. Feature Codes....25305
1.3. User Programmable Parameters....25306
1.4. Diagnostic Trouble Codes....25311
1.5. Troubleshooting....25319
Preliminary Checks....25319
Electronic Gauge Cluster Circuit Test....25321
EGC Backlight Circuit Test....25323
EGC Gauge Test....25323
Warning Lamp Test....25325
Fuel Level Gauge Circuit Test....25326
Transmission Oil Temperature Circuit Tests....25327
Front Rear and Rear Rear Axle Temperature Circuit Tests....25328
Air Pressure Transducer Circuit Tests....25329
Park Brake Switch Circuit Test....25332
Air Restriction Gauge Circuit Test....25333
Engine Coolant Level Monitor Circuit Test....25333
1.6. Electronic Gauge Cluster Programming....25334
SWITCH PACKS (J1708 DATA LINK)....25336
1. Switch Packs....25338
1.1. Description....25338
Overview....25338
Operation....25338
1.2. Diagnostic Trouble Codes....25338
1.3. Troubleshooting....25339
Switch Pack Preliminary Check....25340
Switch Pack Circuit Test....25340
J1708 Data Link Circuit Test....25341
LIGHTING SYSTEM....25342
1. Backup Lights....25346
1.1. System Description....25346
Overview....25346
Operation....25346
1.2. Feature Code....25346
1.3. user programmable parameters....25347
1.4. diagnostic trouble codes....25347
1.5. Troubleshooting....25347
Backup Lights Preliminary Checks....25348
Backup Light Circuit Test (Automatic Transmission)....25348
Backup Light Switch Test (Manual Transmission)....25350
2. Dome And Courtesy Lights....25351
2.1. System Description....25351
Overview....25351
Operation....25351
2.2. Feature Code....25352
2.3. User Programmable Parameters....25352
2.4. Diagnostic Trouble Codes....25352
2.5. Troubleshooting ....25353
Dome and Courtesy Lights Preliminary Checks....25353
Door Switch Circuit Tests....25354
Cab Dome Light Circuit Test....25355
Courtesy Lights Circuit Test....25357
3. Fog Lights....25357
3.1. System Description....25357
Overview....25357
Operation....25357
3.2. Feature Codes....25358
3.3. User Programmable Parameters ....25358
3.4. Diagnostic Trouble Codes....25358
3.5. Troubleshooting....25359
Fog Light System Preliminary Check....25359
Fog Light Switch Test....25360
Fog Light Circuit Test....25361
4. Headlights And Daytime Running Lights (DTRL)....25362
4.1. system description....25362
Overview....25363
Operation....25363
4.2. Feature Codes....25363
4.3. User Programmable Parameters....25363
4.4. Diagnostic Trouble Codes....25363
4.5. Troubleshooting....25365
Headlight System Preliminary Check....25366
Headlight Switch Test....25367
Turn Signal Switch Circuit Test....25368
Right Headlight Circuit Test....25369
Left Headlight Circuit Test....25371
5. Stop, Turn, And Hazard Lights....25371
5.1. System Description....25371
Overview....25371
Operation....25372
5.2. Feature Codes....25372
5.3. User Programmable Parameters....25372
5.4. Diagnostic Trouble Codes....25372
5.5. Troubleshooting....25375
Stop, Turn, and Hazards System Preliminary Check....25375
Turn Signal Switch Circuit Test....25376
Brake Switch Circuit Test....25378
Left Front Turn Signal Circuit Test....25380
Right Front Turn Signal Circuit Test....25380
Left Rear Turn Signal Circuit Test....25381
Right Rear Turn Signal Circuit Test....25382
6. Tail, Marker, Park, And Clearance Lighting....25382
6.1. System Description....25382
Overview....25382
Operation....25383
6.2. Feature Codes....25383
6.3. User Programmable Parameters....25383
6.4. Diagnostic Trouble Codes....25383
6.5. Troubleshooting....25384
Tail, Marker, Park, and Clearance Lighting Preliminary Check....25384
Headlight Switch Test....25384
Tail Light Circuit Test....25386
Park, Marker, Clearance, and Identification Lights Circuit Test....25386
7. Work Light....25387
7.1. System Description....25387
Overview....25387
Operation....25387
7.2. Feature Codes....25387
7.3. User Programmable Parameters....25387
7.4. Diagnostic Trouble Codes....25388
7.5. Troubleshooting....25388
Work Light System Preliminary Check....25389
Work Light Switch Test....25389
Work Light Circuit Tests....25390
8. Roof Auxiliary Load And Air Shield Light....25391
8.1. System Description....25391
Overview....25391
Roof Auxiliary Load Operation....25391
Air Shield Light Operation....25391
8.2. Feature Codes....25391
8.3. User Programmable Parameters....25392
8.4. Diagnostic Trouble CodeS....25392
Roof Auxiliary Load ....25392
Lighted Air Shield....25392
8.5. Troubleshooting....25392
Roof Auxiliary Load Preliminary Check....25392
Lighted Air Shield Preliminary Check....25393
Roof Auxiliary Load Switch Test....25394
Roof Auxiliary Load Circuit Test....25395
Lighted Air Shield Circuit Test....25395
9. Trailer Lighting....25396
9.1. System Description....25396
Overview....25396
Operation....25396
9.2. Feature Codes....25396
9.3. User Programmable Parameters....25396
9.4. Diagnostic Trouble CodeS....25396
9.5. Troubleshooting....25398
Trailer Lights Preliminary Check....25398
Trailer Socket Circuit Test....25398
Trailer Left Turn Relay Circuit Test....25400
Trailer Right Turn Relay Circuit Test....25401
Trailer Marker Light Relay Circuit Test....25402
Trailer Tail Light Relay Circuit Test....25403
Trailer Stop Light Relay Circuit Test....25404
Trailer ABS ECU Relay Circuit Test....25405
10. Auxiliary Snowplow Lighting....25405
10.1. System Description....25405
Overview....25405
Operation....25405
10.2. Feature Code....25406
10.3. user programmable parameters....25406
10.4. diagnostic trouble codes....25406
10.5. Troubleshooting....25407
Auxiliary Snowplow Lights Preliminary Checks....25407
Snowplow Switch Test....25408
Snowplow Lights Circuit Test....25408
CAB FEATURES....25410
1. Cigar Lighter And Power Feed....25416
1.1. System Description....25416
Overview....25416
Cigar Lighter Operation....25416
Cigar Lighter Power Source and Two-Post Power Source Operation....25416
1.2. Feature Codes....25416
1.3. User Programmable Parameters....25416
1.4. Diagnostic Trouble Codes....25416
1.5. Troubleshooting....25416
Cigar Lighter and Power Feed Preliminary Check....25416
Cigar Lighter Circuit Test....25417
Two-Post Power Source Circuit Test....25417
2. CB Power Radio....25418
2.1. System Description....25418
Overview....25418
Operation....25418
2.2. Feature Codes....25418
2.3. User Programmable Parameters....25418
2.4. Diagnostic Trouble Codes....25418
2.5. Troubleshooting....25418
CB Radio Power Source Preliminary Check....25419
CB Radio Circuit Test....25419
3. Compass And Temperature Display....25419
3.1. System Description....25419
Overview....25419
Temperature Display Operation....25420
Compass Display Operation....25420
3.2. Feature Codes....25420
3.3. User Programmable Parameters....25420
3.4. Diagnostic Trouble Codes....25420
3.5. Troubleshooting....25422
Compass and Temperature Display Preliminary Check....25422
Compass / Temperature Display Circuit Tests....25422
Compass Calibration....25424
Ambient Temperature Sensor Circuit Test....25425
4. Power Windows And Locks....25426
4.1. System Description....25426
Overview....25426
Power Window Operation....25426
Power Door Lock Operation....25427
4.2. Feature Codes....25427
4.3. User Programmable Parameters....25427
4.4. Diagnostic Trouble Codes....25428
4.5. Troubleshooting....25430
Power Window and Lock Preliminary Check....25431
Locks and Windows Inoperative Circuit Test....25431
Power Window Circuit Test....25432
Power Door Lock Circuit Test....25433
5. Electric Horn....25433
5.1. System Description....25433
Overview....25433
Operation....25433
5.2. Feature Codes....25433
5.3. User Programmable Parameters....25433
5.4. Diagnostic Trouble Codes....25435
5.5. Troubleshooting....25435
Electric Horn Preliminary Check....25435
Electric Horn Circuit Test....25436
6. Air Horn....25437
6.1. System Description....25437
Overview....25437
Operation....25437
6.2. Feature Codes....25437
6.3. User Programmable Parameters....25437
6.4. Diagnostic Trouble Codes....25437
6.5. Troubleshooting....25438
Air Horn Preliminary Check....25438
Air Horn Circuit Test....25439
7. Power Mirrors....25439
7.1. System Description....25439
Overview....25439
Operation....25439
7.2. Feature Codes....25440
7.3. User Programmable Parameters....25440
7.4. Diagnostic Trouble Codes....25440
7.5. Troubleshooting....25440
Power Mirror Preliminary Check....25441
Driver Power Mirror Circuit Test....25441
Passenger Power Mirror Circuit Test....25442
8. Heated Mirror....25443
8.1. System Description....25443
Overview....25443
Operation....25443
8.2. Feature Codes....25443
8.3. User Programmable Parameters....25443
8.4. Diagnostic Trouble Codes....25443
8.5. Troubleshooting....25444
Heated Mirror Preliminary Check....25444
Heated Mirror Switch Test....25445
Driver Heated Mirror Circuit Test....25445
Passenger Heated Mirror Circuit Test....25446
Heated Windshield Circuit Test....25446
9. Radio (Entertainment), Speakers....25448
9.1. System Description....25448
Overview....25448
Operation....25449
9.2. Feature Codes....25449
9.3. User Programmable Parameters....25449
9.4. Diagnostic Trouble Codes....25449
9.5. Troubleshooting....25449
Radio Preliminary Check....25449
Radio Circuit Test (16 Way Connector)....25450
Radio Circuit Test (12 Way Connector)....25450
Speaker Circuit Test (16 Way Connector)....25450
Speaker Circuit Test....25451
10. Two-Way Radio....25452
10.1. System Description....25452
Overview....25452
Operation....25452
10.2. Feature Codes....25453
10.3. User Programmable Parameters....25453
10.4. diagnostic trouble codes....25453
10.5. Troubleshooting....25453
Two-Way Radio Circuit Test....25453
11. Windshield Wiper And Washer Pump....25453
11.1. System Description....25453
Overview....25453
Wiper Operation....25454
Park Operation....25454
Washer Operation....25454
11.2. Feature Codes....25454
11.3. User Programmable Parameters....25454
11.4. Diagnostic Trouble Codes....25456
11.5. Troubleshooting....25457
Wiper and Washer Preliminary Check....25457
Washer Pump Circuit Test....25458
Wiper Switch Circuit Test....25459
Wiper Motor Circuit Test....25460
12. Park Brake And Brake Switch....25460
12.1. System Description....25460
Overview....25461
Operation....25461
12.2. Feature Codes....25461
12.3. User Programmable Parameters....25461
12.4. Diagnostic Trouble CodeS....25462
12.5. Troubleshooting....25463
Brake Switch Preliminary Check....25463
Brake Switch Test....25464
Park Brake Switch Test....25465
13. Clutch Switch....25467
13.1. System Description....25467
Overview....25467
Operation....25467
13.2. Feature Codes....25467
13.3. User Programmable Parameters....25468
13.4. Diagnostic Trouble CodeS....25468
13.5. Troubleshooting....25469
Clutch Switch Preliminary Checks....25469
Engine Crank Clutch Switch Test....25470
Cruise Control Clutch Switch Test....25472
14. Load Shedding....25472
14.1. System Description....25472
Overview....25473
Operation....25473
14.2. Feature Codes....25473
14.3. User Programmable Parameters....25473
14.4. Diagnostic Trouble CodeS....25473
14.5. Troubleshooting....25474
Latching Relay Circuit Test....25474
15. Vehicle Data Recorder....25475
15.1. System Description....25475
Overview....25475
Operation....25476
15.2. Feature Code....25476
15.3. User Programmable Parameters....25476
15.4. Diagnostic Trouble Codes....25476
15.5. Troubleshooting....25476
Vehicle Data Recorder Preliminary Check....25476
Vehicle Data Recorder Circuit Test....25477
VDR Brake Pressure Switch Circuit Test....25478
VDR Headlight Input Relay Circuit Test....25479
16. Theft Deterrent System....25480
16.1. System Description....25480
Overview....25480
Operation....25480
16.2. FEATURE CODE....25480
16.3. user programmable parameters....25480
16.4. diagnostic trouble codes....25480
16.5. Troubleshooting....25481
Theft Deterrent Preliminary Check....25482
Theft Deterrent System Test....25482
17. Seat Belt And Seat Sensor....25483
17.1. System Description....25483
Overview....25483
Operation....25484
17.2. Feature Code....25484
17.3. User Programmable Parameters....25484
17.4. Diagnostic Trouble Codes....25485
17.5. Troubleshooting....25485
Seat Belt Preliminary Check....25485
Seat Belt Indicator Circuit Test....25486
18. Self-Contained Air Seat....25487
18.1. System Description....25487
Overview....25487
Operation....25487
18.2. Feature Code....25487
18.3. User Programmable Parameters....25487
18.4. Diagnostic Trouble Codes....25487
18.5. Troubleshooting....25487
Driver and Passenger Self-Contained Air Seats Preliminary Check....25487
Driver and Passenger Self-Contained Air Seat Test....25488
19. Heated Seats....25489
19.1. System Description....25489
Overview....25489
Operation....25489
19.2. Feature Codes....25489
19.3. User Programmable Parameters....25489
19.4. Diagnostic Trouble CodeS....25489
19.5. Troubleshooting....25489
Driver and Passenger Heated Seats Preliminary Check....25489
Driver and Passenger Heated Seat Test....25489
CHASSIS FEATURES....25492
1. Heated Air Dryer and drain valve....25496
1.1. System Description....25496
Overview....25496
Operation....25496
1.2. Feature Codes....25496
1.3. User Programmable Parameters....25496
1.4. diagnostic trouble codes....25496
1.5. Troubleshooting....25496
Air Dryer and Heated Drain Valve Preliminary Check....25496
Heated Drain Valve Circuit Test....25497
Air Dryer Circuit Test....25498
2. Air Solenoid....25498
2.1. System Description....25498
Overview....25498
Operation....25498
2.2. Feature Codes....25499
2.3. User Programmable Parameters....25499
2.4. Diagnostic Trouble Codes....25499
2.5. Troubleshooting....25504
Air Solenoid Preliminary Check....25505
Air Solenoid Circuit Test....25505
3. Suspension Dump....25506
3.1. System Description....25506
Overview....25506
Operation....25506
3.2. Feature Code....25507
3.3. User Programmable Parameters....25507
3.4. Diagnostic Trouble Codes....25508
3.5. Troubleshooting....25509
Suspension Dump Preliminary Check....25509
Suspension Dump Test....25510
4. Differential Lock....25511
4.1. System description....25511
Overview....25511
Operation....25511
4.2. Feature Code....25512
4.3. User Programmable Parameters....25512
4.4. Diagnostic Trouble Codes....25513
4.5. Troubleshooting....25514
Differential Lock Preliminary Check....25515
Differential Lock Test....25515
5. Power Divider Lock....25516
5.1. System Description....25516
Overview....25516
Operation....25516
5.2. FEATURE CODE....25517
5.3. User Programmable Parameters....25517
5.4. Diagnostic Trouble Codes....25517
5.5. Troubleshooting....25518
Power Divider Lock Preliminary Check....25519
Power Divider Lock Test....25519
6. Power Take Off....25520
6.1. System Description....25520
Overview....25520
Operation....25520
6.2. Feature Code....25520
6.3. User Programmable Parameters....25520
6.4. Diagnostic Trouble Codes....25521
6.5. Troubleshooting....25522
Power Take Off Preliminary Check....25523
Power Take Off Circuit Test....25523
7. Anti-Lock Braking System ....25524
7.1. System Description....25524
Overview....25524
Operation....25524
Communication....25525
7.2. Feature Code....25525
7.3. User Programmable Parameters....25526
7.4. Diagnostic Trouble Codes....25526
7.5. Troubleshooting....25527
Anti-Lock Braking System Preliminary Check....25527
Bendix® ABS Circuit Tests....25528
Wabco® ABS Module Circuit Test....25531
8. Fifth Wheel Slide and jaw lock release....25532
8.1. System Description....25532
Overview....25532
Operation....25533
8.2. Feature Code....25533
8.3. User Programmable Parameters....25533
8.4. Diagnostic Trouble Codes....25534
8.5. Troubleshooting....25535
Fifth Wheel Slide Preliminary Check....25535
Fifth Wheel Slide Circuit Test....25535
Fifth Wheel Jaw Lock Release Circuit Test....25536
9. Fuel Heater....25536
9.1. System Description....25536
Overview....25537
Operation....25537
9.2. Feature Code....25537
9.3. User Programmable Parameters....25537
9.4. Diagnostic Trouble Codes....25537
9.5. Troubleshooting....25537
Fuel Heater Preliminary Check....25537
Fuel Heater Circuit Test ....25538
10. Remote Power Module....25538
10.1. System Description....25538
Overview....25539
Operation....25539
10.2. Feature Code....25539
10.3. User Programmable Parameters....25540
10.4. Diagnostic Trouble Codes....25540
10.5. Troubleshooting....25543
RPM Preliminary Check....25544
RPM Circuit Test....25544
11. remote start / stop....25546
11.1. System description....25546
Overview....25546
Operation....25547
11.2. FEATURE CODE....25547
11.3. user programmable parameters....25548
11.4. diagnostic trouble codes....25548
11.5. Troubleshooting....25548
Remote Start / Stop Preliminary Check....25549
Remote Start / Stop Test....25549
12. Two-speed axle ....25551
12.1. System description....25551
Overview....25551
Operation....25551
12.2. feature codes....25551
12.3. user programmable parameters....25551
12.4. diagnostic trouble codes....25551
12.5. troubleshooting....25552
Two-Speed Switch Preliminary Check....25552
Two-Speed Switch Test....25552
13. Customer installed lift gate power source....25553
13.1. System description....25553
Overview....25553
Operation....25553
13.2. FEATURE CODE....25553
13.3. user programmable parameters....25554
13.4. diagnostic trouble codes....25554
13.5. Troubleshooting....25555
Lift Gate Preliminary Check....25555
Lift Gate Circuit Test ....25556
14. Auto neutral ....25556
14.1. System description....25556
Overview....25556
Operation....25556
14.2. FEATURE CODE....25557
14.3. user programmable parameters....25557
14.4. diagnostic trouble codes....25557
14.5. Troubleshooting....25557
Auto Neutral Preliminary Check....25558
Auto Neutral Switch Test ....25558
Auto Neutral Circuit Test....25558
15. Axle Load Monitor....25560
15.1. System Description....25560
Overview....25560
Operation....25560
15.2. Feature Code....25560
15.3. User Programmable Parameters....25561
15.4. Diagnostic Trouble Codes....25562
15.5. Troubleshooting....25563
Axle Load Monitor Preliminary Check....25563
Axle Pressure Transducer Circuit Test....25563
16. water-in-fuel monitor ....25564
16.1. System Description....25564
Overview....25564
Operation....25564
16.2. Feature Code....25564
16.3. User Programmable Parameters....25564
16.4. Diagnostic Trouble Codes....25564
16.5. Troubleshooting....25565
Water-In-Fuel Monitor Preliminary Check....25565
Water Probe Circuit Test....25566
TRANSMISSIONS....25568
1. Transmission....25570
1.1. System Description....25570
Overview....25570
Operation....25570
1.2. Feature Code....25571
1.3. user programmable parameters....25571
1.4. Diagnostic Trouble Codes....25571
1.5. Troubleshooting....25573
Transmission Preliminary Check....25573
Eaton UltraShift®® TCM Circuit Test....25574
Eaton UltraShift® Selector Circuit Test....25577
Eaton T-Handle Shifter Circuit Test....25580
Eaton Hybrid TCM Circuit Test....25580
Allison TCU Circuit Test with IBB Engine....25582
Allison Shift Selector with IBB Engine ....25584
Allison TCU Circuit Test with I6/V8 Engine....25586
Allison Shifter with I6/V8 Engine....25587
Shifter Ignition Relay Circuit Test....25588
Park Position Unlock Solenoid Test....25590
1.6. Body Controller Signals....25590
Body Controller Signals....25591
MULTIPLEXING (DATA LINKS)....25592
1. Multiplexing (Data Links)....25594
1.1. Description....25594
Overview....25594
Operation....25594
1.2. Troubleshooting....25595
J1939 Data Link Terminating Resistors....25595
Body Controller....25596
J1939 Data Link Circuit Test....25596
J1708 Data Link Circuit Test....25597
12-VOLT POWER DISTRIBUTION AND GROUND....25598
1. 12-Volt Power Distribution and Grounds....25600
1.1. Description....25600
Overview....25600
Operation....25600
1.2. Troubleshooting....25600
Battery Power Distribution Check....25601
Accessory Power Distribution Preliminary Check....25601
Accessory Power Circuit Test....25602
Body Controller Accessory Feed Input Circuit Test....25603
Ignition Power Distribution Preliminary Check....25604
Ignition Power Circuit Test....25604
Ground Circuit Test....25606
FANS AND ENGINE ACCESSORIES....25608
1. Fan System....25610
1.1. System Description....25610
Overview....25610
Operation....25610
1.2. Feature Code....25610
1.3. User Programmable Parameters....25611
1.4. Diagnostic Trouble Codes....25611
1.5. Troubleshooting....25611
Fan System Preliminary Check....25612
Fan Override Switch Test....25612
2. Compression / Exhaust Brake....25613
2.1. System Description....25613
Overview....25613
Operation....25613
2.2. Feature Code....25613
2.3. User Programmable Parameters....25614
2.4. Diagnostic Trouble Codes....25614
2.5. Troubleshooting....25614
Compression / Exhaust Brake Preliminary Check....25615
Compression / Exhaust Brake Switch Test....25615
3. Aftertreatment ....25615
3.1. System Description....25615
Overview....25615
Operation....25616
3.2. Feature Code....25618
3.3. User Programmable Parameters....25618
3.4. Diagnostic Trouble Codes....25618
3.5. Troubleshooting....25619
Aftertreatment Preliminary Check....25620
Inhibit Regeneration Switch Test....25620
Parked Regeneration Switch Test....25621
Warning Lamp Test....25621
4. Cruise Control....25622
4.1. system description....25622
Overview....25622
Operation....25622
4.2. feature codes....25623
4.3. User Programmable Parameters....25623
4.4. diagnostic trouble codes....25623
4.5. Troubleshooting....25624
Cruise Control Preliminary Check....25625
Cruise Control Switch Test....25626
5. Snow Valve....25627
5.1. System Description....25627
Overview....25627
Operation....25627
5.2. Feature Code....25628
5.3. User Programmable Parameters....25628
5.4. Diagnostic Trouble Codes....25628
5.5. Troubleshooting....25628
Snow Valve Preliminary Check....25628
Snow Valve Module Circuit Test....25629
BATTERY, CHARGING, AND CRANKING SYSTEM....25630
1. Battery System....25632
1.1. Description....25632
Overview....25632
Operation....25632
1.2. Diagnostic Trouble Codes....25633
1.3. Troubleshooting....25633
Battery Test....25633
Battery Test Results....25634
Cable Drop Test....25634
Battery Pack Test....25634
Battery Pack Test Results....25634
2. Charging System....25635
2.1. Description....25635
Overview....25635
Operation....25635
2.2. Diagnostic Trouble Codes....25635
2.3. Troubleshooting....25636
Charging System Test....25636
Charging System Test Results....25636
3. Cranking System....25637
3.1. Description....25637
Overview....25637
Operation....25637
3.2. Troubleshooting....25638
Starting System Test....25638
Starting System Test Results....25638
4. Powerpack 3....25638
4.1. Description....25638
Overview....25639
Operation....25639
4.2. Troubleshooting....25639
VEHICLE AND DRIVER INFORMATION DISPLAY....25640
1. vehicle information display....25642
1.1. System description....25642
Overview....25642
Operation....25642
1.2. FEATURE CODE....25642
1.3. user programmable parameters....25643
1.4. diagnostic trouble codes....25643
1.5. Troubleshooting....25643
Vehicle Information Display Preliminary Check....25643
Vehicle Information Display Circuit Test....25643
2. Driver information display....25644
2.1. System description....25644
Overview....25644
Operation....25645
2.2. FEATURE CODE....25645
2.3. user programmable parameters....25645
2.4. diagnostic trouble codes....25645
2.5. Troubleshooting....25645
Driver Information Display Preliminary Check....25646
Driver Information Display Circuit Test....25646
tables....25283
Table 1Ohm's Law....25283
Table 2Relay Bench Test....25296
Table 3Gauges and Signal Paths....25301
Table 4Warning Lamp and Signal Path....25302
Table 5Audible Alarms....25304
Table 6Electronic Gauge Cluster Feature Codes....25305
Table 7Diagnostic Trouble Codes....25311
Table 8EGC Preliminary Checks....25319
Table 9Electronic Gauge Cluster Circuit Test....25321
Table 10EGC Backlighting Circuit Test....25323
Table 11EGC Gauge Test....25324
Table 12Warning Lamp Test....25325
Table 13Fuel Level Gauge Circuit Test....25326
Table 14Transmission Oil Temperature Circuit Test....25327
Table 15Rear Rear Axle Temperature Circuit Test....25328
Table 16Front Rear Axle Temperature Circuit Test....25329
Table 17Air Pressure Transducer Circuit Test....25330
Table 18Park Brake Switch Circuit Test....25332
Table 19 Air Restriction Gauge Circuit Test....25333
Table 20Low Coolant Sensor Circuit Test....25333
Table 21Diagnostic Trouble Codes....25338
Table 22Switch Pack Preliminary Check....25340
Table 23Switch Pack Circuit Test....25340
Table 24J1708 Data Link Circuit Test....25341
Table 25Feature Code....25346
Table 26Diagnostic Trouble Codes....25347
Table 27Backup Lights Preliminary Checks....25348
Table 28 Backup Light Circuit Test....25348
Table 29Backup Light Switch Test....25350
Table 30Feature Code....25352
Table 31Diagnostic Trouble Codes....25352
Table 32Dome and Courtesy Lights Preliminary Checks....25353
Table 33Door Switch Circuit Test....25354
Table 34Cab Dome Light Circuit Test....25355
Table 35Courtesy Lights Circuit Test....25357
Table 36Feature Codes....25358
Table 37Diagnostic Trouble Codes....25358
Table 38Fog Light System Preliminary Check....25359
Table 39Fog Light Switch Test....25360
Table 40Fog Light Circuit Test....25361
Table 41Feature Codes....25363
Table 42Diagnostic Trouble Codes....25364
Table 43Headlight System Preliminary Check....25366
Table 44Headlight Switch Test....25367
Table 45Turn Signal Switch Circuit Test....25368
Table 46Right Headlight Circuit Test....25369
Table 47Left Headlight Circuit Test....25371
Table 48Feature Codes....25372
Table 49Diagnostic Trouble Codes....25372
Table 50Stop, Turn, and Hazards System Preliminary Check....25375
Table 51Turn Signal Switch Circuit Test....25376
Table 52Brake Switch Circuit Test....25378
Table 53Left Front Turn Signal Circuit Test....25380
Table 54Right Front Turn Signal Circuit Test....25381
Table 55Left Rear Turn Signal Circuit Test....25381
Table 56Right Rear Turn Signal Circuit Test....25382
Table 57Feature Codes....25383
Table 58Diagnostic Trouble Codes....25383
Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....25384
Table 60Headlight Switch Test....25385
Table 61Tail Light Circuit Test....25386
Table 62Park, Marker, Clearance, and Identification Lights Circu....25386
Table 63Feature Codes....25387
Table 64Diagnostic Trouble Codes....25388
Table 65Work Light System Preliminary Check....25389
Table 66Work Light Switch Test....25389
Table 67Work Light Circuit Test....25390
Table 68Feature Codes....25391
Table 69Lighted Air Shield DTC....25392
Table 70Roof Auxiliary Load Preliminary Check....25392
Table 71Lighted Air Shield Preliminary Check....25393
Table 72Roof Auxiliary Load Switch Test....25394
Table 73Roof Auxiliary Load Circuit Test....25395
Table 74Lighted Air Shield Circuit Test....25395
Table 75Feature Codes....25396
Table 76Diagnostic Trouble Codes....25397
Table 77Trailer Lights Preliminary Check....25398
Table 78Trailer Socket Circuit Test....25398
Table 79Trailer Left Turn Relay Circuit Test....25400
Table 80Trailer Right Turn Relay Circuit Test....25401
Table 81Trailer Marker Light Relay Circuit Test....25402
Table 82Trailer Tail Light Relay Circuit Test....25403
Table 83Trailer Stop Light Relay Circuit Test....25404
Table 84Trailer ABS ECU Relay Circuit Test....25405
Table 85Feature Code....25406
Table 86Diagnostic Trouble Codes....25406
Table 87Auxiliary Snowplow Lights Preliminary Checks....25407
Table 88 Snowplow Switch Test....25408
Table 89Snowplow Lights Circuit Test....25408
Table 90Cigar Lighter and Power Feed Preliminary Check....25417
Table 91Cigar Lighter Circuit Test....25417
Table 92Two-Post Power Source Circuit Test....25417
Table 93CB Radio Power Source Preliminary Check....25419
Table 94CB Radio Circuit Test....25419
Table 95Feature Codes....25420
Table 96Diagnostic Trouble Codes....25420
Table 97Compass and Temperature Display Preliminary Check....25422
Table 98Compass Display Circuit Test....25423
Table 99Ambient Temperature Sensor Circuit Test....25426
Table 100Feature Codes....25427
Table 101Diagnostic Trouble Codes....25428
Table 102Power Locks Preliminary Check....25431
Table 103Power Windows Preliminary Check....25431
Table 104Locks and Windows Inoperative Circuit Test....25431
Table 105Power Window Circuit Test....25432
Table 106Power Door Lock Circuit Test....25433
Table 107Feature Codes....25433
Table 108Diagnostic Trouble Codes....25435
Table 109Electric Horn Preliminary Check....25435
Table 110Electric Horn Circuit Test....25436
Table 111Feature Codes....25437
Table 112Diagnostic Trouble Codes....25438
Table 113Air Horn Preliminary Checks....25438
Table 114Air Horn Circuit Test....25439
Table 115Power Mirror Preliminary Check....25441
Table 116Driver Power Mirror Circuit Test....25441
Table 117Passenger Power Mirror Circuit Test....25442
Table 118Feature Codes....25443
Table 119Diagnostic Trouble codes....25444
Table 120Heated Mirror Preliminary Check....25444
Table 121Heated Mirror Switch Test....25445
Table 122Driver Heated Mirror Circuit Test....25445
Table 123Passenger Heated Mirror Circuit Test....25446
Table 124Heated Windshield Circuit Test....25447
Table 125Radio Preliminary Check....25449
Table 126Radio Circuit Test (16 Way Connector)....25450
Table 127Radio Circuit Test (12 Way Connector)....25450
Table 128Speaker Circuit Test (16 Way Connector)....25451
Table 129Speaker Circuit Test (12 Way Connector)....25452
Table 130Two-Way Radio Circuit Test....25453
Table 131Feature Codes....25454
Table 132Diagnostic Trouble Codes....25456
Table 133Wiper and Washer Preliminary Check....25457
Table 134Washer Pump Circuit Test....25458
Table 135Wiper Switch Circuit Test....25459
Table 136Wiper Motor Circuit Test....25460
Table 137Feature Codes....25461
Table 138Diagnostic Trouble Codes....25462
Table 139Brake Switch Preliminary Check....25463
Table 140Brake Switch Circuit Test....25464
Table 141Park Brake Switch Circuit Test....25465
Table 142Feature Code....25468
Table 143Diagnostic Trouble Codes....25468
Table 144Clutch Switch Preliminary Checks....25469
Table 145Engine Crank Clutch Switch Test....25470
Table 146Cruise Control Clutch Switch Test....25472
Table 147Feature Code....25473
Table 148Diagnostic Trouble Codes....25474
Table 149Latching Relay Circuit Test....25475
Table 150Vehicle Data Recorder Preliminary Check....25476
Table 151 Vehicle Data Recorder Circuit Test....25477
Table 152VDR Brake Pressure Switch Circuit Test....25478
Table 153VDR Headlight Input Relay Circuit Test....25479
Table 154Feature Code....25480
Table 155Diagnostic Trouble Codes....25481
Table 156Theft Deterrent Preliminary Check....25482
Table 157Theft Deterrent System Test....25482
Table 158Feature Code....25484
Table 159Seat Belt Preliminary Check....25485
Table 160Seat Belt Indicator Circuit Test....25486
Table 161Driver and Passenger Self-Contained Air Seats Prelimina....25487
Table 162Driver and Passenger Self-Contained Air Seat Test....25488
Table 163Driver and Passenger Heated Seats Preliminary Check....25489
Table 164Driver and Passenger Heated Seat Test....25490
Table 165Air Dryer and Heated Drain Valve Preliminary Check....25496
Table 166Heated Drain Valve Circuit Test....25497
Table 167Air Dryer Circuit Test....25498
Table 168Feature Codes....25499
Table 169Diagnostic Trouble Codes....25499
Table 170Air Solenoid Preliminary Check....25505
Table 171Air Solenoid Circuit Test....25506
Table 172Feature Code....25507
Table 173Diagnostic Trouble Codes....25508
Table 174Suspension Dump Preliminary Check....25510
Table 175Suspension Dump Test....25510
Table 176Feature Codes....25512
Table 177Diagnostic Trouble Codes....25513
Table 178Differential Lock Preliminary Check....25515
Table 179Differential Lock Test....25515
Table 180Feature Code....25517
Table 181Diagnostic Trouble Codes....25518
Table 182Power Divider Lock Preliminary Check....25519
Table 183Power Divider Lock Test....25519
Table 184Feature Code....25520
Table 185Diagnostic Trouble Codes....25521
Table 186Power Take Off Preliminary Check....25523
Table 187Power Take Off Circuit Test....25523
Table 188Feature Code....25525
Table 189Diagnostic Trouble Codes....25527
Table 190Anti-Lock Braking System Preliminary Check....25527
Table 191Bendix® ABS Module Circuit Test....25528
Table 192Bendix® Steering Wheel Sensor Circuit Test....25530
Table 193Bendix® Yaw Sensor Circuit Test....25530
Table 194Wabco® ABS Module Circuit Test....25531
Table 195Feature Code....25533
Table 196Diagnostic Trouble Codes....25534
Table 197Fifth Wheel Slide Preliminary Check....25535
Table 198Fifth Wheel Slide Circuit Test....25535
Table 199Fifth Wheel Jaw Lock Release Circuit Test....25536
Table 200Fuel Heater Preliminary Check....25537
Table 201Fuel Heater Circuit Test ....25538
Table 202Diagnostic Trouble Codes....25540
Table 203RPM Preliminary Check....25544
Table 204RPM Circuit Test....25544
Table 205Feature Code....25547
Table 206Diagnostic Trouble Codes....25548
Table 207Remote Start / Stop Preliminary Check....25549
Table 208Remote Start / Stop Test....25549
Table 209Feature Codes....25551
Table 210Diagnostic Trouble Codes....25551
Table 211Two-Speed Switch Preliminary Check....25552
Table 212Two-Speed Switch Test....25552
Table 213Feature Code....25553
Table 214Diagnostic Trouble Codes....25554
Table 215Lift Gate Preliminary Check....25555
Table 216Lift Gate Test ....25556
Table 217Feature Code....25557
Table 218Diagnostic Trouble Codes....25557
Table 219Auto Neutral Preliminary Check....25558
Table 220Auto Neutral Switch Test ....25558
Table 221Auto Neutral Circuit Test ....25558
Table 222Feature Code....25560
Table 223Diagnostic Trouble Codes....25562
Table 224Axle Load Monitor Preliminary Check....25563
Table 225Axle Pressure Transducer Circuit Test....25563
Table 226Diagnostic Trouble Codes....25565
Table 227Water-In-Fuel Monitor Preliminary Check....25565
Table 228Water Probe Circuit Test....25566
Table 229Feature Code....25571
Table 230Diagnostic Trouble Codes....25572
Table 231Transmission Preliminary Check....25573
Table 232Eaton UltraShift® TCM Circuit Test....25575
Table 233Eaton UltraShift® Selector Circuit Test....25577
Table 234Eaton UltraShift® Selector Lighting Circuit Test ....25579
Table 235Eaton T-Handle Shifter Circuit Test....25580
Table 236Eaton T-Handle Shifter Lighting Circuit Test....25580
Table 237Eaton Hybrid TCM Circuit Test....25581
Table 238Allison TCU Circuit Test with IBB Engine....25583
Table 239Allison Shift Selector Circuit Test....25584
Table 240Allison Shift Selector Lighting Circuit Test....25586
Table 241Allison TCU Circuit Test with I6/V8 Engine....25586
Table 242Allison Column Mounted Shifter ....25587
Table 243Allison T-Handle Shifter ....25588
Table 244Shifter Ignition Relay Circuit Test....25589
Table 245Park Position Unlock Solenoid Test....25590
Table 246Body Controller Signals....25591
Table 247J1939 Data Link Circuit Test....25597
Table 248J1708 Data Link Circuit Test....25597
Table 249Battery Power Distribution Preliminary Check....25601
Table 250Accessory Power Distribution Check....25601
Table 251Accessory Power Circuit Test....25602
Table 252Body Controller Accessory Feed Input Circuit Test....25603
Table 253Ignition Power Distribution Check....25604
Table 254Ignition Power Circuit Test....25604
Table 255Ground Circuit Test....25606
Table 256Feature Code....25611
Table 257Diagnostic Trouble Codes....25611
Table 258Fan System Preliminary Check....25612
Table 259Fan Override Switch Test....25612
Table 260Feature Code....25613
Table 261Diagnostic Trouble Codes....25614
Table 262Compression / Exhaust Brake Preliminary Check....25615
Table 263Compression Brake Switch Test....25615
Table 264Soot Accumulation Level Indications....25617
Table 265Feature Code....25618
Table 266Diagnostic Trouble Codes....25618
Table 267Aftertreatment Preliminary Check....25620
Table 268Inhibit Regeneration Switch Test....25620
Table 269Parked Regeneration Switch Test....25621
Table 270Warning Lamp Test....25621
Table 271Feature Code....25623
Table 272Diagnostic Trouble Codes....25624
Table 273Cruise Control Preliminary Check....25625
Table 274Cruise Control Switch Test....25626
Table 275Feature Code....25628
Table 276Snow Valve Preliminary Check....25628
Table 277Snow Valve Module Circuit Test....25629
Table 278Diagnostic Trouble Codes....25633
Table 279Diagnostic Trouble Codes....25635
Table 280Feature Code....25643
Table 281Vehicle Information Display Preliminary Check....25643
Table 282Vehicle Information Display Circuit Test....25643
Table 283Feature Code....25645
Table 284Driver Information Display Preliminary Check....25646
Table 285Driver Information Display Circuit Test....25646
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Manual....25650
toc....25654
SAFETY INFORMATION....25654
MANUAL INTRODUCTION....25656
1. Manual Introduction....25658
2. Vehicle Electrical System Overview....25659
3. Electrical Circuit Diagram Book....25659
3.1. CIRCUIT DIAGRAMS....25659
Circuit Diagram Instructions....25660
3.2. CONNECTOR BODY COMPOSITE....25663
4. Troubleshooting....25664
4.1. Verify The Problem....25664
4.2. Important Steps Before Performing Circuit Tests....25664
4.3. Review Feature Operation....25665
4.4. Check the Circuit Diagram....25665
4.5. Performing Circuit And System Tests....25666
4.6. Perform The Repair....25666
4.7. Verify The Repair....25666
5. Electrical Test Equipment....25666
5.1. EZ-TECH® Electronic Service Tool (EST)....25666
5.2. Body Controller Breakout Box (ZTSE4477)....25666
5.3. FLUKE 88 Digital Multimeter (DMM)....25667
5.4. MIDTRONICS EXP-1000HD....25668
5.5. Jumper Wires, Test Leads, And Test Lights....25669
Jumper Wires....25669
Test Leads....25670
Test Lights....25671
5.6. Ohm's Law Review....25671
5.7. Voltmeter....25673
Measuring Voltage....25673
5.8. Ammeter....25676
Measuring Amperage....25676
5.9. Ohmmeter....25678
Measuring Resistance....25678
Checking For Open Circuits....25680
Checking For Short Circuits....25681
6. Bench Testing Relays....25682
ELECTRONIC GAUGE CLUSTER....25686
1. Electronic Gauge Cluster....25688
1.1. System Description....25688
Overview....25688
Operation....25688
1.2. Feature Codes....25693
1.3. User Programmable Parameters....25694
1.4. Diagnostic Trouble Codes....25699
1.5. Troubleshooting....25707
Preliminary Checks....25707
Electronic Gauge Cluster Circuit Test....25709
EGC Backlight Circuit Test....25711
EGC Gauge Test....25711
Warning Lamp Test....25713
Fuel Level Gauge Circuit Test....25714
Transmission Oil Temperature Circuit Tests....25715
Front Rear and Rear Rear Axle Temperature Circuit Tests....25716
Air Pressure Transducer Circuit Tests....25717
Park Brake Switch Circuit Test....25720
Air Restriction Gauge Circuit Test....25721
Engine Coolant Level Monitor Circuit Test....25721
1.6. Electronic Gauge Cluster Programming....25722
SWITCH PACKS (J1708 DATA LINK)....25724
1. Switch Packs....25726
1.1. Description....25726
Overview....25726
Operation....25726
1.2. Diagnostic Trouble Codes....25726
1.3. Troubleshooting....25727
Switch Pack Preliminary Check....25728
Switch Pack Circuit Test....25728
J1708 Data Link Circuit Test....25729
LIGHTING SYSTEM....25730
1. Backup Lights....25734
1.1. System Description....25734
Overview....25734
Operation....25734
1.2. Feature Code....25734
1.3. user programmable parameters....25735
1.4. diagnostic trouble codes....25735
1.5. Troubleshooting....25735
Backup Lights Preliminary Checks....25736
Backup Light Circuit Test (Automatic Transmission)....25736
Backup Light Switch Test (Manual Transmission)....25738
2. Dome And Courtesy Lights....25739
2.1. System Description....25739
Overview....25739
Operation....25739
2.2. Feature Code....25740
2.3. User Programmable Parameters....25740
2.4. Diagnostic Trouble Codes....25740
2.5. Troubleshooting ....25741
Dome and Courtesy Lights Preliminary Checks....25741
Door Switch Circuit Tests....25742
Cab Dome Light Circuit Test....25743
Courtesy Lights Circuit Test....25745
3. Fog Lights....25745
3.1. System Description....25745
Overview....25745
Operation....25745
3.2. Feature Codes....25746
3.3. User Programmable Parameters ....25746
3.4. Diagnostic Trouble Codes....25746
3.5. Troubleshooting....25747
Fog Light System Preliminary Check....25747
Fog Light Switch Test....25748
Fog Light Circuit Test....25749
4. Headlights And Daytime Running Lights (DTRL)....25750
4.1. system description....25750
Overview....25751
Operation....25751
4.2. Feature Codes....25751
4.3. User Programmable Parameters....25751
4.4. Diagnostic Trouble Codes....25751
4.5. Troubleshooting....25753
Headlight System Preliminary Check....25754
Headlight Switch Test....25755
Turn Signal Switch Circuit Test....25756
Right Headlight Circuit Test....25757
Left Headlight Circuit Test....25759
5. Stop, Turn, And Hazard Lights....25759
5.1. System Description....25759
Overview....25759
Operation....25760
5.2. Feature Codes....25760
5.3. User Programmable Parameters....25760
5.4. Diagnostic Trouble Codes....25760
5.5. Troubleshooting....25763
Stop, Turn, and Hazards System Preliminary Check....25763
Turn Signal Switch Circuit Test....25764
Brake Switch Circuit Test....25766
Left Front Turn Signal Circuit Test....25768
Right Front Turn Signal Circuit Test....25768
Left Rear Turn Signal Circuit Test....25769
Right Rear Turn Signal Circuit Test....25770
6. Tail, Marker, Park, And Clearance Lighting....25770
6.1. System Description....25770
Overview....25770
Operation....25771
6.2. Feature Codes....25771
6.3. User Programmable Parameters....25771
6.4. Diagnostic Trouble Codes....25771
6.5. Troubleshooting....25772
Tail, Marker, Park, and Clearance Lighting Preliminary Check....25772
Headlight Switch Test....25772
Tail Light Circuit Test....25774
Park, Marker, Clearance, and Identification Lights Circuit Test....25774
7. Work Light....25775
7.1. System Description....25775
Overview....25775
Operation....25775
7.2. Feature Codes....25775
7.3. User Programmable Parameters....25775
7.4. Diagnostic Trouble Codes....25776
7.5. Troubleshooting....25776
Work Light System Preliminary Check....25777
Work Light Switch Test....25777
Work Light Circuit Tests....25778
8. Roof Auxiliary Load And Air Shield Light....25779
8.1. System Description....25779
Overview....25779
Roof Auxiliary Load Operation....25779
Air Shield Light Operation....25779
8.2. Feature Codes....25779
8.3. User Programmable Parameters....25780
8.4. Diagnostic Trouble CodeS....25780
Roof Auxiliary Load ....25780
Lighted Air Shield....25780
8.5. Troubleshooting....25780
Roof Auxiliary Load Preliminary Check....25780
Lighted Air Shield Preliminary Check....25781
Roof Auxiliary Load Switch Test....25782
Roof Auxiliary Load Circuit Test....25783
Lighted Air Shield Circuit Test....25783
9. Trailer Lighting....25784
9.1. System Description....25784
Overview....25784
Operation....25784
9.2. Feature Codes....25784
9.3. User Programmable Parameters....25784
9.4. Diagnostic Trouble CodeS....25784
9.5. Troubleshooting....25786
Trailer Lights Preliminary Check....25786
Trailer Socket Circuit Test....25786
Trailer Left Turn Relay Circuit Test....25788
Trailer Right Turn Relay Circuit Test....25789
Trailer Marker Light Relay Circuit Test....25790
Trailer Tail Light Relay Circuit Test....25791
Trailer Stop Light Relay Circuit Test....25792
Trailer ABS ECU Relay Circuit Test....25793
10. Auxiliary Snowplow Lighting....25793
10.1. System Description....25793
Overview....25793
Operation....25793
10.2. Feature Code....25794
10.3. user programmable parameters....25794
10.4. diagnostic trouble codes....25794
10.5. Troubleshooting....25795
Auxiliary Snowplow Lights Preliminary Checks....25795
Snowplow Switch Test....25796
Snowplow Lights Circuit Test....25796
CAB FEATURES....25798
1. Cigar Lighter And Power Feed....25804
1.1. System Description....25804
Overview....25804
Cigar Lighter Operation....25804
Cigar Lighter Power Source and Two-Post Power Source Operation....25804
1.2. Feature Codes....25804
1.3. User Programmable Parameters....25804
1.4. Diagnostic Trouble Codes....25804
1.5. Troubleshooting....25804
Cigar Lighter and Power Feed Preliminary Check....25804
Cigar Lighter Circuit Test....25805
Two-Post Power Source Circuit Test....25805
2. CB Power Radio....25806
2.1. System Description....25806
Overview....25806
Operation....25806
2.2. Feature Codes....25806
2.3. User Programmable Parameters....25806
2.4. Diagnostic Trouble Codes....25806
2.5. Troubleshooting....25806
CB Radio Power Source Preliminary Check....25807
CB Radio Circuit Test....25807
3. Compass And Temperature Display....25807
3.1. System Description....25807
Overview....25807
Temperature Display Operation....25808
Compass Display Operation....25808
3.2. Feature Codes....25808
3.3. User Programmable Parameters....25808
3.4. Diagnostic Trouble Codes....25808
3.5. Troubleshooting....25810
Compass and Temperature Display Preliminary Check....25810
Compass / Temperature Display Circuit Tests....25810
Compass Calibration....25812
Ambient Temperature Sensor Circuit Test....25813
4. Power Windows And Locks....25814
4.1. System Description....25814
Overview....25814
Power Window Operation....25814
Power Door Lock Operation....25815
4.2. Feature Codes....25815
4.3. User Programmable Parameters....25815
4.4. Diagnostic Trouble Codes....25816
4.5. Troubleshooting....25818
Power Window and Lock Preliminary Check....25819
Locks and Windows Inoperative Circuit Test....25819
Power Window Circuit Test....25820
Power Door Lock Circuit Test....25821
5. Electric Horn....25821
5.1. System Description....25821
Overview....25821
Operation....25821
5.2. Feature Codes....25821
5.3. User Programmable Parameters....25821
5.4. Diagnostic Trouble Codes....25823
5.5. Troubleshooting....25823
Electric Horn Preliminary Check....25823
Electric Horn Circuit Test....25824
6. Air Horn....25825
6.1. System Description....25825
Overview....25825
Operation....25825
6.2. Feature Codes....25825
6.3. User Programmable Parameters....25825
6.4. Diagnostic Trouble Codes....25825
6.5. Troubleshooting....25826
Air Horn Preliminary Check....25826
Air Horn Circuit Test....25827
7. Power Mirrors....25827
7.1. System Description....25827
Overview....25827
Operation....25827
7.2. Feature Codes....25828
7.3. User Programmable Parameters....25828
7.4. Diagnostic Trouble Codes....25828
7.5. Troubleshooting....25828
Power Mirror Preliminary Check....25829
Driver Power Mirror Circuit Test....25829
Passenger Power Mirror Circuit Test....25830
8. Heated Mirror....25831
8.1. System Description....25831
Overview....25831
Operation....25831
8.2. Feature Codes....25831
8.3. User Programmable Parameters....25831
8.4. Diagnostic Trouble Codes....25831
8.5. Troubleshooting....25832
Heated Mirror Preliminary Check....25832
Heated Mirror Switch Test....25833
Driver Heated Mirror Circuit Test....25833
Passenger Heated Mirror Circuit Test....25834
Heated Windshield Circuit Test....25834
9. Radio (Entertainment), Speakers....25836
9.1. System Description....25836
Overview....25836
Operation....25837
9.2. Feature Codes....25837
9.3. User Programmable Parameters....25837
9.4. Diagnostic Trouble Codes....25837
9.5. Troubleshooting....25837
Radio Preliminary Check....25837
Radio Circuit Test (16 Way Connector)....25838
Radio Circuit Test (12 Way Connector)....25838
Speaker Circuit Test (16 Way Connector)....25838
Speaker Circuit Test....25839
10. Two-Way Radio....25840
10.1. System Description....25840
Overview....25840
Operation....25840
10.2. Feature Codes....25841
10.3. User Programmable Parameters....25841
10.4. diagnostic trouble codes....25841
10.5. Troubleshooting....25841
Two-Way Radio Circuit Test....25841
11. Windshield Wiper And Washer Pump....25841
11.1. System Description....25841
Overview....25841
Wiper Operation....25842
Park Operation....25842
Washer Operation....25842
11.2. Feature Codes....25842
11.3. User Programmable Parameters....25842
11.4. Diagnostic Trouble Codes....25844
11.5. Troubleshooting....25845
Wiper and Washer Preliminary Check....25845
Washer Pump Circuit Test....25846
Wiper Switch Circuit Test....25847
Wiper Motor Circuit Test....25848
12. Park Brake And Brake Switch....25848
12.1. System Description....25848
Overview....25849
Operation....25849
12.2. Feature Codes....25849
12.3. User Programmable Parameters....25849
12.4. Diagnostic Trouble CodeS....25850
12.5. Troubleshooting....25851
Brake Switch Preliminary Check....25851
Brake Switch Test....25852
Park Brake Switch Test....25853
13. Clutch Switch....25855
13.1. System Description....25855
Overview....25855
Operation....25855
13.2. Feature Codes....25855
13.3. User Programmable Parameters....25856
13.4. Diagnostic Trouble CodeS....25856
13.5. Troubleshooting....25857
Clutch Switch Preliminary Checks....25857
Engine Crank Clutch Switch Test....25858
Cruise Control Clutch Switch Test....25860
14. Load Shedding....25860
14.1. System Description....25860
Overview....25861
Operation....25861
14.2. Feature Codes....25861
14.3. User Programmable Parameters....25861
14.4. Diagnostic Trouble CodeS....25861
14.5. Troubleshooting....25862
Latching Relay Circuit Test....25862
15. Vehicle Data Recorder....25863
15.1. System Description....25863
Overview....25863
Operation....25864
15.2. Feature Code....25864
15.3. User Programmable Parameters....25864
15.4. Diagnostic Trouble Codes....25864
15.5. Troubleshooting....25864
Vehicle Data Recorder Preliminary Check....25864
Vehicle Data Recorder Circuit Test....25865
VDR Brake Pressure Switch Circuit Test....25866
VDR Headlight Input Relay Circuit Test....25867
16. Theft Deterrent System....25868
16.1. System Description....25868
Overview....25868
Operation....25868
16.2. FEATURE CODE....25868
16.3. user programmable parameters....25868
16.4. diagnostic trouble codes....25868
16.5. Troubleshooting....25869
Theft Deterrent Preliminary Check....25870
Theft Deterrent System Test....25870
17. Seat Belt And Seat Sensor....25871
17.1. System Description....25871
Overview....25871
Operation....25872
17.2. Feature Code....25872
17.3. User Programmable Parameters....25872
17.4. Diagnostic Trouble Codes....25873
17.5. Troubleshooting....25873
Seat Belt Preliminary Check....25873
Seat Belt Indicator Circuit Test....25874
18. Self-Contained Air Seat....25875
18.1. System Description....25875
Overview....25875
Operation....25875
18.2. Feature Code....25875
18.3. User Programmable Parameters....25875
18.4. Diagnostic Trouble Codes....25875
18.5. Troubleshooting....25875
Driver and Passenger Self-Contained Air Seats Preliminary Check....25875
Driver and Passenger Self-Contained Air Seat Test....25876
19. Heated Seats....25877
19.1. System Description....25877
Overview....25877
Operation....25877
19.2. Feature Codes....25877
19.3. User Programmable Parameters....25877
19.4. Diagnostic Trouble CodeS....25877
19.5. Troubleshooting....25877
Driver and Passenger Heated Seats Preliminary Check....25877
Driver and Passenger Heated Seat Test....25877
CHASSIS FEATURES....25880
1. Heated Air Dryer and drain valve....25884
1.1. System Description....25884
Overview....25884
Operation....25884
1.2. Feature Codes....25884
1.3. User Programmable Parameters....25884
1.4. diagnostic trouble codes....25884
1.5. Troubleshooting....25884
Air Dryer and Heated Drain Valve Preliminary Check....25884
Heated Drain Valve Circuit Test....25885
Air Dryer Circuit Test....25886
2. Air Solenoid....25886
2.1. System Description....25886
Overview....25886
Operation....25886
2.2. Feature Codes....25887
2.3. User Programmable Parameters....25887
2.4. Diagnostic Trouble Codes....25887
2.5. Troubleshooting....25892
Air Solenoid Preliminary Check....25893
Air Solenoid Circuit Test....25893
3. Suspension Dump....25894
3.1. System Description....25894
Overview....25894
Operation....25894
3.2. Feature Code....25895
3.3. User Programmable Parameters....25895
3.4. Diagnostic Trouble Codes....25896
3.5. Troubleshooting....25897
Suspension Dump Preliminary Check....25897
Suspension Dump Test....25898
4. Differential Lock....25899
4.1. System description....25899
Overview....25899
Operation....25899
4.2. Feature Code....25900
4.3. User Programmable Parameters....25900
4.4. Diagnostic Trouble Codes....25901
4.5. Troubleshooting....25902
Differential Lock Preliminary Check....25903
Differential Lock Test....25903
5. Power Divider Lock....25904
5.1. System Description....25904
Overview....25904
Operation....25904
5.2. FEATURE CODE....25905
5.3. User Programmable Parameters....25905
5.4. Diagnostic Trouble Codes....25905
5.5. Troubleshooting....25906
Power Divider Lock Preliminary Check....25907
Power Divider Lock Test....25907
6. Power Take Off....25908
6.1. System Description....25908
Overview....25908
Operation....25908
6.2. Feature Code....25908
6.3. User Programmable Parameters....25908
6.4. Diagnostic Trouble Codes....25909
6.5. Troubleshooting....25910
Power Take Off Preliminary Check....25911
Power Take Off Circuit Test....25911
7. Anti-Lock Braking System ....25912
7.1. System Description....25912
Overview....25912
Operation....25912
Communication....25913
7.2. Feature Code....25913
7.3. User Programmable Parameters....25914
7.4. Diagnostic Trouble Codes....25914
7.5. Troubleshooting....25915
Anti-Lock Braking System Preliminary Check....25915
Bendix® ABS Circuit Tests....25916
Wabco® ABS Module Circuit Test....25919
8. Fifth Wheel Slide and jaw lock release....25920
8.1. System Description....25920
Overview....25920
Operation....25921
8.2. Feature Code....25921
8.3. User Programmable Parameters....25921
8.4. Diagnostic Trouble Codes....25922
8.5. Troubleshooting....25923
Fifth Wheel Slide Preliminary Check....25923
Fifth Wheel Slide Circuit Test....25923
Fifth Wheel Jaw Lock Release Circuit Test....25924
9. Fuel Heater....25924
9.1. System Description....25924
Overview....25925
Operation....25925
9.2. Feature Code....25925
9.3. User Programmable Parameters....25925
9.4. Diagnostic Trouble Codes....25925
9.5. Troubleshooting....25925
Fuel Heater Preliminary Check....25925
Fuel Heater Circuit Test ....25926
10. Remote Power Module....25926
10.1. System Description....25926
Overview....25927
Operation....25927
10.2. Feature Code....25927
10.3. User Programmable Parameters....25928
10.4. Diagnostic Trouble Codes....25928
10.5. Troubleshooting....25931
RPM Preliminary Check....25932
RPM Circuit Test....25932
11. remote start / stop....25934
11.1. System description....25934
Overview....25934
Operation....25935
11.2. FEATURE CODE....25935
11.3. user programmable parameters....25936
11.4. diagnostic trouble codes....25936
11.5. Troubleshooting....25936
Remote Start / Stop Preliminary Check....25937
Remote Start / Stop Test....25937
12. Two-speed axle ....25939
12.1. System description....25939
Overview....25939
Operation....25939
12.2. feature codes....25939
12.3. user programmable parameters....25939
12.4. diagnostic trouble codes....25939
12.5. troubleshooting....25940
Two-Speed Switch Preliminary Check....25940
Two-Speed Switch Test....25940
13. Customer installed lift gate power source....25941
13.1. System description....25941
Overview....25941
Operation....25941
13.2. FEATURE CODE....25941
13.3. user programmable parameters....25942
13.4. diagnostic trouble codes....25942
13.5. Troubleshooting....25943
Lift Gate Preliminary Check....25943
Lift Gate Circuit Test ....25944
14. Auto neutral ....25944
14.1. System description....25944
Overview....25944
Operation....25944
14.2. FEATURE CODE....25945
14.3. user programmable parameters....25945
14.4. diagnostic trouble codes....25945
14.5. Troubleshooting....25945
Auto Neutral Preliminary Check....25946
Auto Neutral Switch Test ....25946
Auto Neutral Circuit Test....25946
15. Axle Load Monitor....25948
15.1. System Description....25948
Overview....25948
Operation....25948
15.2. Feature Code....25948
15.3. User Programmable Parameters....25949
15.4. Diagnostic Trouble Codes....25950
15.5. Troubleshooting....25951
Axle Load Monitor Preliminary Check....25951
Axle Pressure Transducer Circuit Test....25951
16. water-in-fuel monitor ....25952
16.1. System Description....25952
Overview....25952
Operation....25952
16.2. Feature Code....25952
16.3. User Programmable Parameters....25952
16.4. Diagnostic Trouble Codes....25952
16.5. Troubleshooting....25953
Water-In-Fuel Monitor Preliminary Check....25953
Water Probe Circuit Test....25954
TRANSMISSIONS....25956
1. Transmission....25958
1.1. System Description....25958
Overview....25958
Operation....25958
1.2. Feature Code....25959
1.3. user programmable parameters....25959
1.4. Diagnostic Trouble Codes....25959
1.5. Troubleshooting....25961
Transmission Preliminary Check....25961
Eaton UltraShift®® TCM Circuit Test....25962
Eaton UltraShift® Selector Circuit Test....25965
Eaton T-Handle Shifter Circuit Test....25968
Eaton Hybrid TCM Circuit Test....25968
Allison TCU Circuit Test with IBB Engine....25970
Allison Shift Selector with IBB Engine ....25972
Allison TCU Circuit Test with I6/V8 Engine....25974
Allison Shifter with I6/V8 Engine....25975
Shifter Ignition Relay Circuit Test....25976
Park Position Unlock Solenoid Test....25978
1.6. Body Controller Signals....25978
Body Controller Signals....25979
MULTIPLEXING (DATA LINKS)....25980
1. Multiplexing (Data Links)....25982
1.1. Description....25982
Overview....25982
Operation....25982
1.2. Troubleshooting....25983
J1939 Data Link Terminating Resistors....25983
Body Controller....25984
J1939 Data Link Circuit Test....25984
J1708 Data Link Circuit Test....25985
12-VOLT POWER DISTRIBUTION AND GROUND....25986
1. 12-Volt Power Distribution and Grounds....25988
1.1. Description....25988
Overview....25988
Operation....25988
1.2. Troubleshooting....25988
Battery Power Distribution Check....25989
Accessory Power Distribution Preliminary Check....25989
Accessory Power Circuit Test....25990
Body Controller Accessory Feed Input Circuit Test....25991
Ignition Power Distribution Preliminary Check....25992
Ignition Power Circuit Test....25992
Ground Circuit Test....25994
FANS AND ENGINE ACCESSORIES....25996
1. Fan System....25998
1.1. System Description....25998
Overview....25998
Operation....25998
1.2. Feature Code....25998
1.3. User Programmable Parameters....25999
1.4. Diagnostic Trouble Codes....25999
1.5. Troubleshooting....25999
Fan System Preliminary Check....26000
Fan Override Switch Test....26000
2. Compression / Exhaust Brake....26001
2.1. System Description....26001
Overview....26001
Operation....26001
2.2. Feature Code....26001
2.3. User Programmable Parameters....26002
2.4. Diagnostic Trouble Codes....26002
2.5. Troubleshooting....26002
Compression / Exhaust Brake Preliminary Check....26003
Compression / Exhaust Brake Switch Test....26003
3. Aftertreatment ....26003
3.1. System Description....26003
Overview....26003
Operation....26004
3.2. Feature Code....26006
3.3. User Programmable Parameters....26006
3.4. Diagnostic Trouble Codes....26006
3.5. Troubleshooting....26007
Aftertreatment Preliminary Check....26008
Inhibit Regeneration Switch Test....26008
Parked Regeneration Switch Test....26009
Warning Lamp Test....26009
4. Cruise Control....26010
4.1. system description....26010
Overview....26010
Operation....26010
4.2. feature codes....26011
4.3. User Programmable Parameters....26011
4.4. diagnostic trouble codes....26011
4.5. Troubleshooting....26012
Cruise Control Preliminary Check....26013
Cruise Control Switch Test....26014
5. Snow Valve....26015
5.1. System Description....26015
Overview....26015
Operation....26015
5.2. Feature Code....26016
5.3. User Programmable Parameters....26016
5.4. Diagnostic Trouble Codes....26016
5.5. Troubleshooting....26016
Snow Valve Preliminary Check....26016
Snow Valve Module Circuit Test....26017
BATTERY, CHARGING, AND CRANKING SYSTEM....26018
1. Battery System....26020
1.1. Description....26020
Overview....26020
Operation....26020
1.2. Diagnostic Trouble Codes....26021
1.3. Troubleshooting....26021
Battery Test....26021
Battery Test Results....26022
Cable Drop Test....26022
Battery Pack Test....26022
Battery Pack Test Results....26022
2. Charging System....26023
2.1. Description....26023
Overview....26023
Operation....26023
2.2. Diagnostic Trouble Codes....26023
2.3. Troubleshooting....26024
Charging System Test....26024
Charging System Test Results....26024
3. Cranking System....26025
3.1. Description....26025
Overview....26025
Operation....26025
3.2. Troubleshooting....26026
Starting System Test....26026
Starting System Test Results....26026
4. Powerpack 3....26026
4.1. Description....26026
Overview....26027
Operation....26027
4.2. Troubleshooting....26027
VEHICLE AND DRIVER INFORMATION DISPLAY....26028
1. vehicle information display....26030
1.1. System description....26030
Overview....26030
Operation....26030
1.2. FEATURE CODE....26030
1.3. user programmable parameters....26031
1.4. diagnostic trouble codes....26031
1.5. Troubleshooting....26031
Vehicle Information Display Preliminary Check....26031
Vehicle Information Display Circuit Test....26031
2. Driver information display....26032
2.1. System description....26032
Overview....26032
Operation....26033
2.2. FEATURE CODE....26033
2.3. user programmable parameters....26033
2.4. diagnostic trouble codes....26033
2.5. Troubleshooting....26033
Driver Information Display Preliminary Check....26034
Driver Information Display Circuit Test....26034
tables....25671
Table 1Ohm's Law....25671
Table 2Relay Bench Test....25684
Table 3Gauges and Signal Paths....25689
Table 4Warning Lamp and Signal Path....25690
Table 5Audible Alarms....25692
Table 6Electronic Gauge Cluster Feature Codes....25693
Table 7Diagnostic Trouble Codes....25699
Table 8EGC Preliminary Checks....25707
Table 9Electronic Gauge Cluster Circuit Test....25709
Table 10EGC Backlighting Circuit Test....25711
Table 11EGC Gauge Test....25712
Table 12Warning Lamp Test....25713
Table 13Fuel Level Gauge Circuit Test....25714
Table 14Transmission Oil Temperature Circuit Test....25715
Table 15Rear Rear Axle Temperature Circuit Test....25716
Table 16Front Rear Axle Temperature Circuit Test....25717
Table 17Air Pressure Transducer Circuit Test....25718
Table 18Park Brake Switch Circuit Test....25720
Table 19 Air Restriction Gauge Circuit Test....25721
Table 20Low Coolant Sensor Circuit Test....25721
Table 21Diagnostic Trouble Codes....25726
Table 22Switch Pack Preliminary Check....25728
Table 23Switch Pack Circuit Test....25728
Table 24J1708 Data Link Circuit Test....25729
Table 25Feature Code....25734
Table 26Diagnostic Trouble Codes....25735
Table 27Backup Lights Preliminary Checks....25736
Table 28 Backup Light Circuit Test....25736
Table 29Backup Light Switch Test....25738
Table 30Feature Code....25740
Table 31Diagnostic Trouble Codes....25740
Table 32Dome and Courtesy Lights Preliminary Checks....25741
Table 33Door Switch Circuit Test....25742
Table 34Cab Dome Light Circuit Test....25743
Table 35Courtesy Lights Circuit Test....25745
Table 36Feature Codes....25746
Table 37Diagnostic Trouble Codes....25746
Table 38Fog Light System Preliminary Check....25747
Table 39Fog Light Switch Test....25748
Table 40Fog Light Circuit Test....25749
Table 41Feature Codes....25751
Table 42Diagnostic Trouble Codes....25752
Table 43Headlight System Preliminary Check....25754
Table 44Headlight Switch Test....25755
Table 45Turn Signal Switch Circuit Test....25756
Table 46Right Headlight Circuit Test....25757
Table 47Left Headlight Circuit Test....25759
Table 48Feature Codes....25760
Table 49Diagnostic Trouble Codes....25760
Table 50Stop, Turn, and Hazards System Preliminary Check....25763
Table 51Turn Signal Switch Circuit Test....25764
Table 52Brake Switch Circuit Test....25766
Table 53Left Front Turn Signal Circuit Test....25768
Table 54Right Front Turn Signal Circuit Test....25769
Table 55Left Rear Turn Signal Circuit Test....25769
Table 56Right Rear Turn Signal Circuit Test....25770
Table 57Feature Codes....25771
Table 58Diagnostic Trouble Codes....25771
Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....25772
Table 60Headlight Switch Test....25773
Table 61Tail Light Circuit Test....25774
Table 62Park, Marker, Clearance, and Identification Lights Circu....25774
Table 63Feature Codes....25775
Table 64Diagnostic Trouble Codes....25776
Table 65Work Light System Preliminary Check....25777
Table 66Work Light Switch Test....25777
Table 67Work Light Circuit Test....25778
Table 68Feature Codes....25779
Table 69Lighted Air Shield DTC....25780
Table 70Roof Auxiliary Load Preliminary Check....25780
Table 71Lighted Air Shield Preliminary Check....25781
Table 72Roof Auxiliary Load Switch Test....25782
Table 73Roof Auxiliary Load Circuit Test....25783
Table 74Lighted Air Shield Circuit Test....25783
Table 75Feature Codes....25784
Table 76Diagnostic Trouble Codes....25785
Table 77Trailer Lights Preliminary Check....25786
Table 78Trailer Socket Circuit Test....25786
Table 79Trailer Left Turn Relay Circuit Test....25788
Table 80Trailer Right Turn Relay Circuit Test....25789
Table 81Trailer Marker Light Relay Circuit Test....25790
Table 82Trailer Tail Light Relay Circuit Test....25791
Table 83Trailer Stop Light Relay Circuit Test....25792
Table 84Trailer ABS ECU Relay Circuit Test....25793
Table 85Feature Code....25794
Table 86Diagnostic Trouble Codes....25794
Table 87Auxiliary Snowplow Lights Preliminary Checks....25795
Table 88 Snowplow Switch Test....25796
Table 89Snowplow Lights Circuit Test....25796
Table 90Cigar Lighter and Power Feed Preliminary Check....25805
Table 91Cigar Lighter Circuit Test....25805
Table 92Two-Post Power Source Circuit Test....25805
Table 93CB Radio Power Source Preliminary Check....25807
Table 94CB Radio Circuit Test....25807
Table 95Feature Codes....25808
Table 96Diagnostic Trouble Codes....25808
Table 97Compass and Temperature Display Preliminary Check....25810
Table 98Compass Display Circuit Test....25811
Table 99Ambient Temperature Sensor Circuit Test....25814
Table 100Feature Codes....25815
Table 101Diagnostic Trouble Codes....25816
Table 102Power Locks Preliminary Check....25819
Table 103Power Windows Preliminary Check....25819
Table 104Locks and Windows Inoperative Circuit Test....25819
Table 105Power Window Circuit Test....25820
Table 106Power Door Lock Circuit Test....25821
Table 107Feature Codes....25821
Table 108Diagnostic Trouble Codes....25823
Table 109Electric Horn Preliminary Check....25823
Table 110Electric Horn Circuit Test....25824
Table 111Feature Codes....25825
Table 112Diagnostic Trouble Codes....25826
Table 113Air Horn Preliminary Checks....25826
Table 114Air Horn Circuit Test....25827
Table 115Power Mirror Preliminary Check....25829
Table 116Driver Power Mirror Circuit Test....25829
Table 117Passenger Power Mirror Circuit Test....25830
Table 118Feature Codes....25831
Table 119Diagnostic Trouble codes....25832
Table 120Heated Mirror Preliminary Check....25832
Table 121Heated Mirror Switch Test....25833
Table 122Driver Heated Mirror Circuit Test....25833
Table 123Passenger Heated Mirror Circuit Test....25834
Table 124Heated Windshield Circuit Test....25835
Table 125Radio Preliminary Check....25837
Table 126Radio Circuit Test (16 Way Connector)....25838
Table 127Radio Circuit Test (12 Way Connector)....25838
Table 128Speaker Circuit Test (16 Way Connector)....25839
Table 129Speaker Circuit Test (12 Way Connector)....25840
Table 130Two-Way Radio Circuit Test....25841
Table 131Feature Codes....25842
Table 132Diagnostic Trouble Codes....25844
Table 133Wiper and Washer Preliminary Check....25845
Table 134Washer Pump Circuit Test....25846
Table 135Wiper Switch Circuit Test....25847
Table 136Wiper Motor Circuit Test....25848
Table 137Feature Codes....25849
Table 138Diagnostic Trouble Codes....25850
Table 139Brake Switch Preliminary Check....25851
Table 140Brake Switch Circuit Test....25852
Table 141Park Brake Switch Circuit Test....25853
Table 142Feature Code....25856
Table 143Diagnostic Trouble Codes....25856
Table 144Clutch Switch Preliminary Checks....25857
Table 145Engine Crank Clutch Switch Test....25858
Table 146Cruise Control Clutch Switch Test....25860
Table 147Feature Code....25861
Table 148Diagnostic Trouble Codes....25862
Table 149Latching Relay Circuit Test....25863
Table 150Vehicle Data Recorder Preliminary Check....25864
Table 151 Vehicle Data Recorder Circuit Test....25865
Table 152VDR Brake Pressure Switch Circuit Test....25866
Table 153VDR Headlight Input Relay Circuit Test....25867
Table 154Feature Code....25868
Table 155Diagnostic Trouble Codes....25869
Table 156Theft Deterrent Preliminary Check....25870
Table 157Theft Deterrent System Test....25870
Table 158Feature Code....25872
Table 159Seat Belt Preliminary Check....25873
Table 160Seat Belt Indicator Circuit Test....25874
Table 161Driver and Passenger Self-Contained Air Seats Prelimina....25875
Table 162Driver and Passenger Self-Contained Air Seat Test....25876
Table 163Driver and Passenger Heated Seats Preliminary Check....25877
Table 164Driver and Passenger Heated Seat Test....25878
Table 165Air Dryer and Heated Drain Valve Preliminary Check....25884
Table 166Heated Drain Valve Circuit Test....25885
Table 167Air Dryer Circuit Test....25886
Table 168Feature Codes....25887
Table 169Diagnostic Trouble Codes....25887
Table 170Air Solenoid Preliminary Check....25893
Table 171Air Solenoid Circuit Test....25894
Table 172Feature Code....25895
Table 173Diagnostic Trouble Codes....25896
Table 174Suspension Dump Preliminary Check....25898
Table 175Suspension Dump Test....25898
Table 176Feature Codes....25900
Table 177Diagnostic Trouble Codes....25901
Table 178Differential Lock Preliminary Check....25903
Table 179Differential Lock Test....25903
Table 180Feature Code....25905
Table 181Diagnostic Trouble Codes....25906
Table 182Power Divider Lock Preliminary Check....25907
Table 183Power Divider Lock Test....25907
Table 184Feature Code....25908
Table 185Diagnostic Trouble Codes....25909
Table 186Power Take Off Preliminary Check....25911
Table 187Power Take Off Circuit Test....25911
Table 188Feature Code....25913
Table 189Diagnostic Trouble Codes....25915
Table 190Anti-Lock Braking System Preliminary Check....25915
Table 191Bendix® ABS Module Circuit Test....25916
Table 192Bendix® Steering Wheel Sensor Circuit Test....25918
Table 193Bendix® Yaw Sensor Circuit Test....25918
Table 194Wabco® ABS Module Circuit Test....25919
Table 195Feature Code....25921
Table 196Diagnostic Trouble Codes....25922
Table 197Fifth Wheel Slide Preliminary Check....25923
Table 198Fifth Wheel Slide Circuit Test....25923
Table 199Fifth Wheel Jaw Lock Release Circuit Test....25924
Table 200Fuel Heater Preliminary Check....25925
Table 201Fuel Heater Circuit Test ....25926
Table 202Diagnostic Trouble Codes....25928
Table 203RPM Preliminary Check....25932
Table 204RPM Circuit Test....25932
Table 205Feature Code....25935
Table 206Diagnostic Trouble Codes....25936
Table 207Remote Start / Stop Preliminary Check....25937
Table 208Remote Start / Stop Test....25937
Table 209Feature Codes....25939
Table 210Diagnostic Trouble Codes....25939
Table 211Two-Speed Switch Preliminary Check....25940
Table 212Two-Speed Switch Test....25940
Table 213Feature Code....25941
Table 214Diagnostic Trouble Codes....25942
Table 215Lift Gate Preliminary Check....25943
Table 216Lift Gate Test ....25944
Table 217Feature Code....25945
Table 218Diagnostic Trouble Codes....25945
Table 219Auto Neutral Preliminary Check....25946
Table 220Auto Neutral Switch Test ....25946
Table 221Auto Neutral Circuit Test ....25946
Table 222Feature Code....25948
Table 223Diagnostic Trouble Codes....25950
Table 224Axle Load Monitor Preliminary Check....25951
Table 225Axle Pressure Transducer Circuit Test....25951
Table 226Diagnostic Trouble Codes....25953
Table 227Water-In-Fuel Monitor Preliminary Check....25953
Table 228Water Probe Circuit Test....25954
Table 229Feature Code....25959
Table 230Diagnostic Trouble Codes....25960
Table 231Transmission Preliminary Check....25961
Table 232Eaton UltraShift® TCM Circuit Test....25963
Table 233Eaton UltraShift® Selector Circuit Test....25965
Table 234Eaton UltraShift® Selector Lighting Circuit Test ....25967
Table 235Eaton T-Handle Shifter Circuit Test....25968
Table 236Eaton T-Handle Shifter Lighting Circuit Test....25968
Table 237Eaton Hybrid TCM Circuit Test....25969
Table 238Allison TCU Circuit Test with IBB Engine....25971
Table 239Allison Shift Selector Circuit Test....25972
Table 240Allison Shift Selector Lighting Circuit Test....25974
Table 241Allison TCU Circuit Test with I6/V8 Engine....25974
Table 242Allison Column Mounted Shifter ....25975
Table 243Allison T-Handle Shifter ....25976
Table 244Shifter Ignition Relay Circuit Test....25977
Table 245Park Position Unlock Solenoid Test....25978
Table 246Body Controller Signals....25979
Table 247J1939 Data Link Circuit Test....25985
Table 248J1708 Data Link Circuit Test....25985
Table 249Battery Power Distribution Preliminary Check....25989
Table 250Accessory Power Distribution Check....25989
Table 251Accessory Power Circuit Test....25990
Table 252Body Controller Accessory Feed Input Circuit Test....25991
Table 253Ignition Power Distribution Check....25992
Table 254Ignition Power Circuit Test....25992
Table 255Ground Circuit Test....25994
Table 256Feature Code....25999
Table 257Diagnostic Trouble Codes....25999
Table 258Fan System Preliminary Check....26000
Table 259Fan Override Switch Test....26000
Table 260Feature Code....26001
Table 261Diagnostic Trouble Codes....26002
Table 262Compression / Exhaust Brake Preliminary Check....26003
Table 263Compression Brake Switch Test....26003
Table 264Soot Accumulation Level Indications....26005
Table 265Feature Code....26006
Table 266Diagnostic Trouble Codes....26006
Table 267Aftertreatment Preliminary Check....26008
Table 268Inhibit Regeneration Switch Test....26008
Table 269Parked Regeneration Switch Test....26009
Table 270Warning Lamp Test....26009
Table 271Feature Code....26011
Table 272Diagnostic Trouble Codes....26012
Table 273Cruise Control Preliminary Check....26013
Table 274Cruise Control Switch Test....26014
Table 275Feature Code....26016
Table 276Snow Valve Preliminary Check....26016
Table 277Snow Valve Module Circuit Test....26017
Table 278Diagnostic Trouble Codes....26021
Table 279Diagnostic Trouble Codes....26023
Table 280Feature Code....26031
Table 281Vehicle Information Display Preliminary Check....26031
Table 282Vehicle Information Display Circuit Test....26031
Table 283Feature Code....26033
Table 284Driver Information Display Preliminary Check....26034
Table 285Driver Information Display Circuit Test....26034
S09002 - Hood, Grille, and Fenders - 2000, 4000, 8000 (Supersedes CTS-5269) (Feb 1999) Service Manual....26038
toc....26040
Table of Contents....26040
1. DESCRIPTION....26044
1.1. HOOD....26044
1.2. SPLASH PANELS....26047
1.3. MUD GUARDS....26049
1.4. HOOD SEALS....26052
1.5. GRILLE....26053
1.6. AIR INTAKES....26056
1.7. FENDERS....26057
1.8. SPLASH SHIELDS....26058
2. REMOVE AND INSTALL....26058
2.1. 2000 SERIES HOOD....26058
2500 and 2600 Model Original Hood — Remove....26058
2500 and 2600 Model Original Hood — Install....26060
2600 Model Aerodynamic Hood (After March, 1996) — Remove....26061
2600 Model Aerodynamic Hood (After March, 1996) — Install....26063
2.2. 4000 SERIES HOOD....26064
4700 Thru 4900 Model Hood — Remove....26064
4700 Thru 4900 Model Hood — Install....26066
2.3. 8000 SERIES HOOD....26067
8100 Model Hood (Before June 1994) — Remove....26067
8100 Model Hood (Before June 1994) — Install....26069
8100 Model Hood (After June 1994) — Remove....26070
8100 Model Hood (After June 1994) — Install....26071
8200 Model Hood — Remove....26072
8200 Model Hood — Install....26074
2.4. 2000 SERIES SPLASH PANELS....26075
2500 and 2600 Model Splash Panels (Original Hood) — Remove....26075
2500 and 2600 Model Splash Panels (Original Hood) — Install....26078
2600 Model Splash Panels (Aerodynamic Hood After March 1996) — R....26079
2600 Model Splash Panels (Aerodynamic Hood After March 1996) — I....26081
2.5. 4000 SERIES SPLASH PANELS....26082
4700 Thru 4900 Model Splash Panels — Remove....26082
4700 Thru 4900 Model Splash Panels — Install....26082
2.6. 8000 SERIES SPLASH PANELS....26083
8100 Model Splash Panels — Remove....26083
8100 Model Splash Panels — Install....26083
8200 Model Splash Panels — Remove....26083
8200 Model Splash Panels — Install....26086
2.7. 2000 SERIES MUD GUARDS....26086
2500 and 2600 Model Rear Mud Guard (Original Hood) — Remove....26086
2500 and 2600 Model Rear Mud Guard (Original Hood) — Install....26087
2600 Model Only-Outer Edge Fender and Fender Extension Mud Guard....26087
2600 Model Only-Outer Edge Fender and Fender Extension Mud Guard....26089
2600 Model Rear Mud Guard (Aerodynamic Hood After March 1996) — ....26089
2600 Model Rear Mud Guard (Aerodynamic Hood After March 1996) — ....26090
2.8. 4000 SERIES MUD GUARDS....26090
4700 Thru 4900 Model Mud Guard — Remove....26090
4700 Thru 4900 Model Mud Guard — Install....26091
2.9. 8000 SERIES MUD GUARDS....26091
8100 Model Mud Guard — Remove....26091
8100 Model Mud Guard — Install....26092
8200 Model Mud Guard — Remove....26092
8200 Model Mud Guard — Install....26093
2.10. 2000 SERIES HOOD SEALS....26093
2500 and 2600 Model with Original Hood, Cab Cowl Hood Seal — Rem....26093
2500 and 2600 Model with Original Hood, Cab Cowl Hood Seal — Ins....26093
2600 Model with Aerodynamic Hood After March 1996, Cab Cowl Hood....26093
2600 Model with Aerodynamic Hood After March 1996, Cab Cowl Hood....26094
2600 Model with Original Hood, Fender Extension Hood Seal — Remo....26094
2600 Model with Original Hood, Fender Extension Hood Seal — Inst....26095
2600 Model with Aerodynamic Hood After March 1996, Fender Extens....26095
2600 Model with Aerodynamic Hood After March 1996, Fender Extens....26095
2.11. 4000 SERIES HOOD SEALS....26096
4700 Thru 4900 Model Hood Seal — Remove....26096
4700 Thru 4900 Model Hood Seal — Install....26097
2.12. 8000 SERIES HOOD SEALS....26097
8100 Model Hood Seal — Remove....26097
8100 Model Hood Seal — Install....26098
8200 Model Hood Seal — Remove....26098
8200 Model Hood Seal — Install....26098
2.13. 2000 SERIES GRILLE....26098
2500 and 2600 Model Grille (Original Hood) — Remove....26098
2500 and 2600 Model Grille (Original Hood) — Install....26099
2500 and 2600 Model Stationary Grille (Original Hood), Grille Tr....26100
2500 and 2600 Model Stationary Grille (Original Hood), Grille Tr....26101
2500 and 2600 Model Stationary Grille (Original Hood), Vertical ....26101
2500 and 2600 Model Stationary Grille (Original Hood), Vertical ....26101
2600 Model Grille (Aerodynamic Hood After March 1996), Upper Gri....26102
2600 Model Grille (Aerodynamic Hood After March 1996), Upper Gri....26103
2600 Model Grille (Aerodynamic Hood After March 1996), Lower Gri....26103
2600 Model Grille (Aerodynamic Hood After March 1996), Lower Gri....26104
2.14. 4000 SERIES GRILLE....26104
4700 thru 4900 Model Standard Grille....26104
4700 thru 4900 Model Stationary Grille — Remove....26104
4700 thru 4900 Model Stationary Grille — Install....26105
2.15. 8000 SERIES GRILLE....26105
8100 Model Grille....26105
8200 Model Grille, Upper Grille — Remove....26106
8200 Model Grille, Upper Grille — Install....26107
8200 Model Grille, Lower Grille — Remove....26107
8200 Model Grille, Lower Grille — Install....26107
3. ADJUSTMENTS....26108
3.1. RADIATOR....26108
2000 Series....26108
4000 Series — Forward Radiator Adjustment....26108
4000 Series — Rearward Radiator Adjustment....26110
8000 Series, 8100 Model (Before June 1994) — Forward Radiator Ad....26110
8000 Series, 8100 Model (Before June 1994) — Rearward Radiator A....26112
8000 Series, 8100 Model (After June 1994)....26112
8000 Series, 8200 Model....26112
3.2. HOOD....26112
2000 Series — 2500 and 2600 Hood Adjustment Forward or Back at t....26113
2000 Series — 2500 and 2600 Hood Adjustment Up or Down at the Lo....26115
2000 Series — 2500 and 2600 Hood Adjustment Side-to-Side at the ....26116
2000 Series — 2600 Hood Adjustment Forward or Back at the Lower ....26117
2000 Series — 2600 Hood Adjustment Side-to-Side at the Lower Hin....26119
4000 Series — 4700, 4800 and 4900 Hood Adjustment Forward or Bac....26120
4000 Series — 4700, 4800 and 4900 Hood Adjustment Up or Down at ....26121
4000 Series — 4700, 4800 and 4900 Hood Adjustment Side-to-Side a....26122
8000 Series — 8100 Hood Adjustment Forward or Back at the Lower ....26124
8000 Series — 8100 Hood Adjustment Up or Down at the Lower Hinge....26125
8000 Series — 8100 Hood Adjustment Side-to-Side at the Upper Hin....26126
8000 Series — 8100 Hood Adjustment Forward or Back and Up or Dow....26127
8000 Series — 8100 Hood Adjustment Side-to-Side at the Upper Hin....26128
8000 Series — 8200 Hood Adjustment Forward or Back at the Lower ....26129
8000 Series — 8200 Hood Adjustment Side-to-Side at the Lower Hin....26130
8000 Series — 8200 Hood Adjustment Up or Down at the Upper Hinge....26131
tables....26132
Table 1Torque Chart....26132
S09003 - 2001 Hood Grille Fender Bumper Service Manual....26135
S09003 - Hood, Grille, and Fenders (March 2001) Service Manual....26175
S09007 - Hood, Grille, Fenders and Bumper - 7000 (Oct 2002) Service Manual....26215
S09014 - Hood Grille Fenders Bumper Service Manual (Dec 2011)....26277
S09016 - 2010 Hood Grille Fenders Bumper WorkStar, TranStar Service Manual....26361
toc....26363
Table of Contents....26363
1. Description....26365
1.1. Bumper....26365
1.2. Grille....26365
1.3. Hood Assembly....26366
1.4. Hood Tilt Assist....26366
1.5. Hood Seal....26366
1.6. Splash Shields....26366
1.7. Air Intake Grilles....26366
1.8. Fender....26366
1.9. Fender Extensions....26367
1.10. Headlight Assembly....26367
2. Removal and Installation Procedures....26368
2.1. Bumper....26369
Bumper – Removal....26369
Bumper – Installation....26369
2.2. Grille and Bug Screen....26370
WorkStar® Grille and Bud Screen – Removal....26370
WorkStar® Grille and Bug Screen – Installation....26371
WorkStar® Grille Shroud – Removal....26371
WorkStar® Grille Shroud – Installation....26372
TranStar® Grille and Bug Screen – Removal....26373
TranStar® Grille and Bug Screen – Installation....26374
2.3. Splash Panels....26375
WorkStar® Splash Panel – Removal....26375
WorkStar® Splash Panel – Installation....26375
WorkStar® Upper Splash Panel – Removal....26376
WorkStar® Upper Splash Panel – Installation....26376
TranStar® Splash Panels – Removal....26377
TranStar® Splash Panel – Installation....26378
2.4. Hood....26379
WorkStar® – Removal....26379
WorkStar® Hood – Installation....26385
TranStar® Hood – Removal....26387
TranStar® Hood – Installation....26392
Hood – Adjustment....26393
Hood Stop – Adjustment....26396
Hood Hatch – Removal (if equipped)....26397
Hood Hatch – Installation (if equipped)....26397
2.5. Hood Tilt Assist....26398
Hood Tilt Assist – Removal....26398
Hood Tilt Assist – Installation....26399
2.6. Torsion Bars....26400
WorkStar® Torsion Bar – Removal....26400
WorkStar® Torsion Bar – Installation....26402
TranStar® Torsion Bar – Removal....26403
TranStar® Torsion Bar – Installation....26405
2.7. Hood Latch....26406
WorkStar® Hood Latch – Removal....26406
WorkStar® Hood Latch – Installation....26407
TranStar® Hood Latch – Removal....26408
TranStar® Hood Latch – Installation....26408
2.8. Hood Seal....26409
WorkStar® Hood Seal – Removal....26409
WorkStar® Hood Seal – Installation....26409
TranStar® Hood Seal – Removal....26410
TranStar® Hood Seal – Installation....26410
2.9. Air Intake Grille....26411
Air Intake Grille – Removal....26411
Air Intake Grille – Installation....26411
2.10. Fender Extensions....26412
WorkStar® Fender Extensions – Removal....26412
WorkStar® Fender Extensions – Installation....26412
TranStar® Fender Extensions – Removal....26413
TranStar® Fender Extensions – Installation....26413
2.11. Fenderettes....26414
Fenderette – Removal (if equipped)....26414
Fenderette – Installation (if equipped)....26414
2.12. High Beam Headlight Assembly....26415
WorkStar® High Beam Headlight Assembly – Removal....26415
WorkStar® High Beam Headlight Assembly – Installation....26416
WorkStar® High Beam Headlight Bulb – Removal....26417
WorkStar® High Beam Headlight Bulb – Installation....26417
WorkStar® High Beam Headlight Adjustment....26417
WorkStar® Turn Signal Bulb – Removal....26419
WorkStar® Turn Signal Bulb – Installation....26419
TranStar® High Beam Headlight Assembly – Removal....26420
TranStar® High Beam Headlight Assembly – Installation....26421
TranStar® High Beam Bulb Replacement....26421
TranStar® High Beam Headlight Adjustment ....26422
2.13. Low Beam Headlight Assembly....26423
WorkStar® Low Beam Headlight Assembly – Removal....26423
WorkStar® Low Beam Headlight Assembly – Installation....26423
TranStar® Low Beam Headlight Assembly – Removal....26424
TranStar® Low Beam Headlight Assembly – Installation....26425
Low Beam Bulb Replacement ....26425
tables....26426
Table 1Torque Chart....26426
S09018 - 2011 Hood Grille Fenders Bumper Service Manual....26427
S10020 - USPS International 4400 Master Index (June 2005) Service Manual....26461
S10024 - Eaton Hybrid System Service Manual (Oct 2009)....26469
S11002 - Spicer 13-Inch (310 mm) and 14-Inch (350 mm) Angle-Ring Single Plate Push-Type Clutch Supersedes CTS-5057 Service Manual....26540
S11003 - Spicer 14-Inch (355.6 mm) Stamped Angle-Spring Clutch Supersedes CTS-5140 (March 1996) Service Manual....26551
S11004 - Spicer 14 Inch (350 mm) Solo Clutch Supersedes CTS-5256 (March 1996) Service Manual....26597
S11006R - Clutch Control Linkage Supersedes CTS-5053R (Oct 2002) Service Manual....26631
S11014 - Hydraulic Clutch Service Manual (2010) Service Manual....26647
S12008 - Radiator, Removal and Replacement (2012) Service Manual....26676
cover....26676
S12008....26678
RADIATOR, REMOVE AND REPLACE....26678
DESCRIPTION....26678
RADIATOR AND COMPONENT REMOVAL....26678
CROSS-MEMBER....26678
SURGE TANK....26681
CHARGE AIR COOLER PIPES....26684
COOLING SYSTEM RADIATOR HOSE....26686
RADIATOR....26689
RADIATOR SHROUD AND FRAME....26690
CHARGE AIR COOLER....26693
RADIATOR CORE....26693
RADIATOR AND COMPONENT INSTALLATION....26693
RADIATOR CORE....26693
RADIATOR HOSE....26693
CHARGE AIR COOLER PIPES....26696
SURGE TANK....26696
FRONT CROSS-MEMBER....26697
S12010 - Radiator, Removal and Replacement (April 2003) Service Manual....26698
S12022 - Radiator _ Cooling System (Aug 2010) Service Manual....26739
toc....26741
Table of Contents....26741
1. DESCRIPTION....26743
1.1. Overflow Tank....26744
1.2. Deaeration Tank....26744
1.3. Fan Shroud....26745
1.4. A/C Condenser....26745
1.5. Radiator....26745
1.6. Charge Air Cooler....26745
1.7. Low Temperature Radiator....26745
1.8. Transmission Oil Cooler....26745
2. COOLING PACKAGE COMPONENTS....26746
2.1. Coolant Drain, Pressure Test, and Fill Procedures....26747
Coolant Drain Procedure (Recommended)....26750
Pressure Test Procedure (Recommended)....26752
Coolant Fill Procedure (Recommended)....26753
Coolant Drain Procedure (Optional)....26755
Coolant Fill Procedure (MaxxForce® DT, 9, and 10 Engines) (Optional)....26756
Coolant Fill Procedure (MaxxForce® 11 and 13 Engines) (Optional)....26757
2.2. Grille....26759
Grille – Removal....26759
Grille – Installation....26759
2.3. Splash Panels....26760
Splash Panel – Removal....26760
Splash Panel – Installation....26760
2.4. Overflow Tank....26761
Overflow Tank – Removal....26761
Overflow Tank – Installation....26762
2.5. Deaeration Tank....26763
Deaeration Tank – Removal....26763
Deaeration Tank – Installation....26764
2.6. Expansion Tank....26765
Expansion Tank - Removal....26765
Expansion Tank - Installation....26765
2.7. A/C Condenser....26766
A/C Condenser with Charge Air Cooler – Removal....26766
A/C Condenser with Charge Air Cooler – Installation....26768
A/C Condenser with Dual Radiators – Removal....26769
A/C Condenser with Dual Radiators – Installation....26771
2.8. Fan Shroud....26772
Fan Shroud with Charge Air Cooler – Removal....26772
Fan Shroud with Charge Air Cooler – Installation....26776
Fan Shroud with Dual Radiators – Removal....26778
Fan Shroud with Dual Radiators – Installation....26780
2.9. Radiator Fan....26781
Radiator Fan with Charge Air Cooler – Removal....26781
Radiator Fan with Charge Air Cooler – Installation....26781
Radiator Fan with Dual Radiators – Removal....26782
Radiator Fan with Dual Radiators – Installation....26782
2.10. Radiator Hose....26783
Heat Shrink Clamp – Removal....26783
Heat Shrink Clamp – Installation....26784
Radiator Hose with Charge Air Cooler – Removal....26788
Radiator Hose with Charge Air Cooler – Installation....26790
Radiator Hose with Dual Radiators – Removal....26791
Radiator Hose with Dual Radiators – Installation....26793
2.11. Charge Air Cooler....26794
Charge Air Cooler – Removal....26794
Charge Air Cooler – Installation....26796
2.12. Low Temperature Radiator....26798
Low Temperature Radiator – Removal....26798
Low Temperature Radiator – Installation....26801
2.13. Radiator Core....26803
Radiator Core with Charge Air Cooler – Removal....26803
Radiator Core with Charge Air Cooler – Installation....26809
Radiator Core with Dual Radiators – Removal....26812
Radiator Core with Dual Radiators – Installation....26819
2.14. Transmission Oil Cooler....26822
Transmission Oil Cooler (13WAN) – Removal....26822
Transmission Oil Cooler (13WAN) – Installation....26823
Transmission Oil Cooler (13WCT) – Removal....26824
Transmission Oil Cooler (13WCT) – Installation....26825
Transmission Oil Cooler (13WAW) – Removal....26826
Transmission Oil Cooler (13WAW) – Installation....26827
tables....26828
Table 1Torque Chart....26828
S12036 - Radiator_Cooling System 2010 Service Manual....26830
S12038 - 2011 Cooling System Service Manual....26907
S13006H - 6 Speed Transmissions International Model ES52-7A and ESO65-7A 6-Plus Service Manual....26954
S13008 - 6 Speed Transmissions Eaton Series FS-5106 and FS-6206 Supersedes CTS-5179 (June 1996) Service Manual....27038
S13009 - 5 Speed Transmissions Spicer ES43-5 and ES53-5 Supersedes CTS-5181 (March 1996) Service Manual....27118
S13016 7 - Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual....27178
S13037 - OMSI PFT-PCV_3000 Split Shaft PTO Service Manual....27241
S14019 - LIFT AXLE SYSTEMS (7400, 7500 7600 Models) Service Manual....27262
toc....27262
Table of Contents....27264
1. INTRODUCTION....27268
1.1. PRECAUTIONS....27268
2. SYSTEM DESCRIPTION....27269
2.1. AXLE TYPES....27270
FIXED AXLES....27270
SELF STEERING AXLES....27270
2.2. AXLE MOUNTING LOCATIONS....27271
PUSHER AXLES....27271
TAG AXLES....27272
AXLE SPACING....27272
2.3. LIFT AXLE STATIC LOADED RADIUS....27272
2.4. SYSTEM CONTROLS....27273
IN CAB CONTROLS ONLY....27274
MIXED CONTROLS PRESSURE GAUGE AND SWITCHES IN CAB/PRESSURE GAUGE....27275
3. SYSTEM OPERATION....27275
3.1. Enabling the Lift Axle System....27276
3.2. Operating the Lift Axles....27276
3.3. Disabling the Lift Axle System....27277
3.4. Auto Lift in Reverse Feature (Self-Steering Systems Only)....27277
4. TESTING AND TROUBLESHOOTING....27277
4.1. Operational Test....27278
4.2. DIAGNOSIS AND TROUBLESHOOTING....27282
5. FIXED (RIGID) AXLE ASSEMBLIES....27296
5.1. DESCRIPTION....27296
5.2. IDENTIFICATION....27296
5.3. OPERATION....27297
AIR SUPPLY....27301
ENABLING THE LIFT AXLE SYSTEM....27301
LOWERING THE LIFT AXLE....27302
RAISING THE LIFT AXLE....27302
DISABLING THE LIFT AXLE SYSTEM....27302
5.4. ADJUSTMENTS....27303
AXLE ALIGNMENT....27303
5.5. MAINTENANCE....27305
MAINTENANCE SCHEDULE....27305
AIR TANK MAINTENANCE....27305
TORQUE SETTINGS....27305
5.6. TESTING/TROUBLESHOOTING....27305
5.7. REMOVAL....27306
AIR LINES GENERAL....27306
LIFT AXLE ASSEMBLY....27306
LOAD BAG ....27307
LIFT BAG/LIFT BAG QRV....27308
QUICK RELEASE VALVE FOR LOAD BAGS....27309
FULL FUNCTION RELAY VALVE (BRAKES)....27311
PRESSURE PROTECTION VALVE....27311
FIVE PORT VALVE/SOLENOID....27311
AXLE MOUNTED TANK....27312
BRAKE MECHANISM....27312
AXLE SEAT BUSHINGS....27312
ARM PIVOT BUSHINGS....27313
5.8. CLEAN AND INSPECT....27313
AIR TANK INSPECTION....27313
5.9. INSTALL....27313
AIR LINES GENERAL....27313
LIFT AXLE ASSEMBLY....27314
LOAD BAG ....27314
LIFT BAG/LIFT BAG QRV....27315
QUICK RELEASE VALVE FOR LOAD BAGS....27316
FULL FUNCTION RELAY VALVE (BRAKES)....27316
PRESSURE PROTECTION VALVE....27317
FIVE PORT VALVE/SOLENOID....27317
AXLE MOUNTED TANK....27317
BRAKE MECHANISM....27318
AXLE SEAT BUSHINGS....27318
ARM PIVOT BUSHINGS....27319
6. SELF-STEERING AXLE ASSEMBLIES....27319
6.1. DESCRIPTION....27319
6.2. IDENTIFICATION....27320
6.3. OPERATION....27321
AIR SUPPLY....27325
ENABLING THE LIFT AXLE SYSTEM....27325
LOWERING THE LIFT AXLE....27326
RAISING THE LIFT AXLE....27327
DISABLING THE LIFT AXLE SYSTEM....27327
AUTO LIFT IN REVERSE FEATURE (SELF-STEERING SYSTEMS ONLY)....27327
6.4. ADJUSTMENTS....27328
AXLE ALIGNMENT....27328
WHEEL ALIGNMENT....27328
6.5. MAINTENANCE....27329
MAINTENANCE SCHEDULE....27329
AIR TANK MAINTENANCE....27330
TORQUE SETTINGS....27330
6.6. TESTING/TROUBLESHOOTING....27330
6.7. REMOVAL....27330
AIR LINES GENERAL....27330
LIFT AXLE ASSEMBLY....27330
LOAD BAG ....27331
LIFT BAG/LIFT BAG QRV....27332
QUICK RELEASE VALVE FOR LOAD BAGS....27333
FULL FUNCTION RELAY VALVE (BRAKES) ....27336
PRESSURE PROTECTION VALVE....27336
FIVE PORT VALVE/SOLENOID....27336
AXLE MOUNTED TANK....27337
BRAKE MECHANISM....27337
UPPER ARM BUSHINGS....27337
LOWER ARM BUSHINGS....27338
6.8. CLEAN AND INSPECT....27339
AIR TANK INSPECTION....27339
6.9. INSTALL....27339
AIR LINES GENERAL....27339
LIFT AXLE ASSEMBLY....27339
LOAD BAG ....27340
LIFT BAG/LIFT BAG QRV....27341
QUICK RELEASE VALVE FOR LOAD BAGS....27342
FULL FUNCTION RELAY VALVE (BRAKES)....27342
PRESSURE PROTECTION VALVE....27342
FIVE PORT VALVE/SOLENOID....27343
AXLE MOUNTED TANK....27343
BRAKE MECHANISM....27344
UPPER ARM BUSHINGS....27344
LOWER ARM BUSHINGS....27345
7. CONTROLS....27346
7.1. DESCRIPTION....27346
7.2. IN-CAB CONTROLS....27347
7.3. MIXED CONTROLS....27347
7.4. PNEUMATIC CONTROL SYSTEM....27348
7.5. ELECTRICAL CONTROL SYSTEM....27367
7.6. OPERATION....27379
ENABLING THE LIFT AXLE SYSTEM....27380
LOWERING THE LIFT AXLE....27380
RAISING THE LIFT AXLE....27381
DISABLING THE LIFT AXLE SYSTEM....27381
AUTO LIFT IN REVERSE FEATURE (SELF-STEERING AXLE SYSTEMS ONLY)....27382
7.7. REMOVAL....27383
LIFT AXLE PRESSURE GAUGE....27383
PRESSURE REGULATOR....27383
CONTROL SWITCHES (PEDESTAL MOUNTED)....27383
CONTROL RELAYS (PEDESTAL MOUNTED)....27383
7.8. INSTALL....27383
LIFT AXLE PRESSURE GAUGE....27383
PRESSURE REGULATOR....27384
CONTROL SWITCHES (PEDESTAL MOUNTED)....27384
CONTROL RELAYS (PEDESTAL MOUNTED)....27384
7.9. TESTING/TROUBLESHOOTING....27384
8. SPECIFICATIONS....27384
8.1. LIFT AXLE SYSTEM SPECIFICATIONS....27384
8.2. TORQUE SETTINGS....27385
tables....27262
Operational Test....27278
Lift Axle Symptom List....27282
Troubleshooting Table....27283
Troubleshooting Table....27283
Troubleshooting Table....27285
Troubleshooting Table....27285
Troubleshooting Table....27288
Troubleshooting Table....27290
Troubleshooting Table....27291
Troubleshooting Table....27292
Troubleshooting Table....27294
Troubleshooting Table....27295
Troubleshooting Table....27295
Troubleshooting Table Mechanical Problems....27295
Load Pressure Chart for 20,000 Pound Fixed Lift Axle....27302
Periodic Maintenance on Fixed Lift Axles....27305
Load Pressure Chart for 13,200 Pound Self-Steering Lift Axle....27326
Periodic Maintenance on Self-Steering Lift Axles ....27329
Lift Axle System Specifications 20,000 Pound Capacity Rigid Axle....27384
Lift Axle System Specifications 13,200 Pound Capacity Self-Steer....27385
Torque Chart for Specific Fasteners....27385
U-Bolt Torque Values (Clean, Non-Plated, Lubricated Threads)....27388
General Capscrew/Bolt Torque Values (Clean, Non-Plated, Lubricat....27388
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual....27389
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual....27399
S16016 - Air Conditioning - Heater System_ 2000, 4000, and 8000 - 12_06_1994 and After Formerly (CTS-5227) Service Manual....27445
S16017X - Air Conditioning Compressor and Clutch, Two Cylinder Reciprocating Type - After 01_01_1993 (R-134A) (Formerly CTS-5241) Service Manual....27484
S16025 - HEAT VENTILATION AIR CONDITIONING (HVAC), Orifice Tube System, Pre-March 2007 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Service Manual....27511
S160263 - CAB 4100, 4200, 4300, 4400, DuraStar, TerraStar 4100, 4200, 4300, 4400, DuraStar, TerraStar Service Manual....27757
S16027 - SERVICE CAB 4100, 4200, 4300, 4400 SERVICE MANUAL ....28074
S16034 - HEAT VENTILATION AIR CONDITIONING (HVAC), TXV System, March 2007 - 2009 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Models, CXT, DuraStar, TranStar, WorkStar and RXT....28104
S16038 - CAB_ 7300, 7400, 7500, 7600, 7700, 8500, 8600, TranStar, and WorkStar Models Service Manual....28251
S16046 - 3200 Bus, DuraStar, TerraStar, TranStar, WorkStar Models Heat Ventilation Air Conditioning (HVAC) for 2010 Service Manual....28452
S16053 - Heat Ventilation Air Conditioning (HVAC) for 2010 - South Africa _ 7000 RHD AND 8000 RHD Service Manual....28602
S16054 - SERVICE MANUAL CAB MANUALModel DuraStar Vehicle....28753
S16055 - HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 HVAC DuraStar Vehicle Service Manual....28930
s04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual....29086
s12005 - Radiator Shutters, Supersedes CTS-5084 (March 1996) Service Manual....29117
International/Navistar Trucks DuraStar and WorkStar Series Repair Service Manual
