International/Navistar TranStar, ProStar Series Trucks Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for International/Navistar 8000-Series TranStar, ProStar Series Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
International Navistar 8000-Series TranStar, ProStar Series Trucks workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 31,720 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0000001601 - ProStar + Radiator, Cooling System with SCR Service Manual.pdf
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10.pdf
0000002122 - ProStar and LoneStar Series Built June 14, 2010 and After Electrical Circuit Diagrams (Supersedes S08344 and S08371).pdf
0000002122 - ProStar, Lone Star (2010 & Newer) Wiring Diagram.pdf
0000002221 - ProStar +, LoneStar HVAC System Service Manual.pdf
0000002222 - 2013 Cooling System Service Manual.pdf
0000002323 - Day Cab And Sleeper Cab LoneStar, ProStar Service Manual.pdf
0000002324 - TranStar and WorkStar Cab Service Manual (Supersedes S16052) Service Manual.pdf
0000002601 - 3200RXT DuraStar - 4100, 4300, 4400 TranStar Natural Gas (NG), TranStar - 8500, 8600 WorkStar - 7300, 7400, 7500, 7600, 7700 Wiring Diagrams.pdf
0000002601 - 3200, RXT, DuraStar, TranStar, TranStar Natural Gas, WorkStar Series Built May 17, 2010 and Later Electrical Circuit Diagrams (Supersedes S08343).pdf
0000002842 - 3200, DuraStar, TranStar, WorkStar, and RXT Models Built March, 2008 to May 16, 2010 Electrical Circuit Diagrams (Supersedes S08337).pdf
0000002842 - Electrical Circuit Diagrams (2008 to 2010).pdf
00000003161 - 2013 Hood Grille Fenders Bumper Service Manual.pdf
0000003922 - DuraStar - 4300, 4400 WorkStar - 7300, 7400, 7500, 7600, 7700 TranStar - 8500, 8600 Electrical Circuit Diagrams - Models Built From November 22, 2010.pdf
0000003922 - DuraStar, WorkStar, TranStar Series Models Built From November 22, 2010 Electrical Circuit Diagrams (Supersedes S08353) (Latin America _ Mexico).pdf
0000004041 - 2018-2020 MV Technician Manual (Service and Diagnostic).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
0000019282 - Australian ProStar Technician Manual (Service and Diagnostic).pdf
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Revision 1 (Supersedes 0000001601, 0000001843 and 0000002222) Service Manual.pdf
0000857080 - ProStar Model NF2AD00 Built December 2015 and After (Euro V) Electrical Circuit Diagrams Australian Market.pdf
0000863170 - 2010-2016 ProStar _ TranStar Technician Manual (Service and Diagnostic), Revision 18.pdf
1087481R1 - 1000 Through 4000, 7000, 8000 Series Electrical Circuit Diagrams CTS-4417.pdf
4328434 - New Truck Processing Manual.pdf
CTS-5122K - 2000 , 4000 and 8000 Series September 1993 and Later Electrical Circuit Diagrams.pdf
CTS-5122T - 2000, 4000, 8000 Series Built After February 1, 1996 Electrical Circuit Diagrams.pdf
s04010 - Air Compressor_ Bendix TU-FLO 501, Supersedes CTS-5145 (March 1996) Service Manual.pdf
s09002 - Hood, Grille, and Fenders - 2000, 4000, 8000 (Supersedes CTS-5269) (Feb 1999) Service Manual.pdf
S02005R - Rockwell Front Non-Drive Steering Axle, Supersedes CTS-5046R (April 1996) Service Manual.pdf
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual.pdf
S03002R - Neway Air Suspension, Supersedes CTS-5028R (March 1996) Service Manual.pdf
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual.pdf
S03011 - Hendrickson HN-460 Suspension, Supersedes CTS-5221 (March 1996) Service Manual.pdf
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual.pdf
S03015 - 2007 MY ProStar _ LoneStar MAXXPOWER Front Air Suspension (Oct 2009) Service Manual.pdf
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual.pdf
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual.pdf
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual.pdf
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual.pdf
S04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual.pdf
S04014 - Air Compressor_ Holset SS 296 and QE 296_338, Supersedes CTS-5197 (March 1996) Service Manual.pdf
S04019 - Double Diaphragm Anchorlok Spring Brake, Supersedes CTS-5074 (March 1996) Service Manual.pdf
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual.pdf
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual.pdf
S04033 - Antilock Brakes_Traction Control_ Bendix - Troubleshooting, Supersedes CTS-5250 (June 1996) Service Manual.pdf
S04038 EC-17 - Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Service Manual.pdf
S04053 - ECE-13 Brake System (2010) Service Manual.pdf
S04055 - MCAC 465 Air Compressor (Dec 2010) Service Manual.pdf
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual.pdf
S05012 - Steering Column Assembly, Tilt_Telescoping Supersedes CTS-5167 (May 1996) Service Manual.pdf
S05013 - Steering Column Assembly, Standard and Tilt, Supersedes CTS-5168 (April 1996) Service Manual.pdf
S05015Y - Power Steering Gear_ Sheppard M-Series, Supersedes CTS-5262 (Sept 2000) Service Manual.pdf
S05016 - Steering Wheel Removal and Installation (Sept 2010) Service Manual.pdf
S05018 - LoneStar Steering Column Assembly, Tilt _ Telescoping (Oct 2011) Service Manual.pdf
S05021 - Steering Wheel and Steering Column Assembly (July 2012)Manual - Truck3_10_2016 12_00_00 AM.pdf
S05025 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual.pdf
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual.pdf
S08003 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual.pdf
S08018 - 9100, 9200, 9300, 9400, 9600, 9700, and 9800 Model Alternator (Delco-Remy 26-SI Series), Supersedes CTS-5077 (March 1996) Service Manual.pdf
S08034X - Instruments, Supersedes CTS-5088K (Oct 1999) Service Manual.pdf
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual.pdf
S08154X - Speedometer _ Tachometer Diagnostics and Service, Supersedes CTS-5257 (Oct 1999) Service Manual.pdf
S08155X - Instruments (New Data Link Driven Instrument Cluster), Supersedes CTS-5228 (Oct 1999) Service Manual.pdf
S08186 - 2000, 4000, 8000 Models Built October 1, 1998 To September 30, 1999 Electrical Circuit Diagrams.pdf
S08186X - 2000, 4000, 8000 Models Built October 1, 1999 and After Electrical Circuit Diagrams.pdf
S08230- Electrical System Troubleshooting Guide, Supersedes CTS-5300 (July 1999) Service Manual.pdf
S08287 - 1000-4000, 7000, 8000 Fuses and Circuit Breakers Supersedes CTS-4410 (June 2001) Service Manual.pdf
S08300 - Body Builder Electrical Data Book for Models Built January 2001 to February 28, 2007 Supersedes PBB-73000B (Aug 2008) Service Manual.pdf
S08300, Formerly PBB-73000B - 3200 4000 7000 8000 - Body Builder Data Book.pdf
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes (June 2005) Service Manual.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
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
S08322 - 3200, 4100, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, RXTModels Built March 1, 2007 to March 18, 2008 Wiring Diagrams.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 GuideDiagnostic Trouble Codes.pdf
S08327 - 2007 - 2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual.pdf
S08339 - 2007 MY ProStar _ LoneStar Chassis Built January, 2007 and After Electrical Circuit Diagrams Manual.pdf
S08354 - 2007 MY ProStar _ LoneStar Models Built After January 2007 Electrical System Troubleshooting Guide Manual.pdf
S08358 - 2011 Auto Start Stop Service Manual.pdf
S08360 - ProStar _ LoneStar Models Built After June 2010 Electrical System Troubleshooting Guide Manual.pdf
S08361 - 2010 Electrical Troubleshooting.pdf
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Service Manual.pdf
S09006 - Hood, Grille, Fenders and Bumper - 8500 (June 2002) Service Manual.pdf
S09008 - Hood, Grille, Fenders and Bumper - 8600 (Nov 2002) Service Manual.pdf
S09016 - Hood, Grille, Fenders and Bumper (Dec 2009) Service Manual.pdf
S11001S - Spicer 14-Inch (356 mm) and 15 1_2-Inch (394 mm) Two-Plate, Pull-Type Clutch Supersedes CTS-5043S (March 1996) Service Manual.pdf
S11003 - Spicer 14-Inch (355.6 mm) Stamped Angle-Spring Clutch Supersedes CTS-5140 (March 1996) Service Manual.pdf
S11004 - Spicer 14 Inch (350 mm) Solo Clutch Supersedes CTS-5256 (March 1996) Service Manual.pdf
S11006R - Clutch Control Linkage Supersedes CTS-5053R (Oct 2002) Service Manual.pdf
S11014 - Hydraulic Clutch Service Manual 2010 Service Manual.pdf
S11018 - 2011 Hydraulic Clutch Service Manual.pdf
S12001J - Fan Drive Clutch_ Kysor 1090 Supersedes CTS-5015J (March 1996) Service Manual.pdf
S12004R - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual.pdf
S12005 - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual.pdf
S12008 - Radiator, Removal and Replacement (2012) Service Manual.pdf
S12011 - Radiator _ Cooling System (Aug 2012) Service Manual.pdf
S12021 - 2007 MY ProStar _ LoneStar Radiator _ Cooling System (Aug 2012) Service Manual.pdf
S12036 - Radiator_Cooling System (2010) Service Manual.pdf
S13006H - 6 Speed Transmissions International Model ES52-7A and ESO65-7A 6-Plus Service Manual.pdf
S13007 - 13 Speed & 18 Speed Transmissions Eaton RTLO-713 _ 18 Series Supersedes CTS-5176 (June 1996) Service Manual.pdf
S13008 - 6 Speed Transmissions Eaton Series FS-5106 and FS-6206 Supersedes CTS-5179 (June 1996) Service Manual.pdf
S13016 - 7 Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual.pdf
S13017 - 10 Speed Transmissions Eaton RTLO Series Supersedes CTS-5196 (March 1996) Service Manual.pdf
S13018 - 8 Speed, 9 Speed, And 13 Speed Transmissions Eaton Series Supersedes CTS-5205 (June 1996) Service Manual.pdf
S14002 - 2 SPEED AXLE SHIFT UNIT_ EATON (Supersedes CTS-5166) Service Manual.pdf
S14004 - SINGLE REDUCTION, TANDEM AXLES_ SPICER J400-S, W460-S (Supersedes CTS-5259) Service Manual.pdf
S14006T - SINGLE REDUCTION CARRIERS_ ROCKWELL (Supersedes CTS-5080T) Service Manual.pdf
S14008T - SINGLE SPEED REAR AXLE_ INTERNATIONAL (Supersedes CTS-5108T) Service Manual - Truck8_21_2012 12_00_00 AM.pdf
S14013 - SINGLE REDUCTION, TANDEM DRIVE AXLES_ EATON (Supersedes CTS-5213) Service Manual.pdf
S14016 - 2 SPEED AND DOUBLE REDUCTION SINGLE DRIVE AXLES_ EATON (Supersedes CTS-5195) Service Manual.pdf
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual.pdf
S16003 - Repair Instructions for Fiberglass and Plastic (ABS) Material (Formerly CTS-5173) Service Manual.pdf
S16007S - Cab_ 2000, 4000, AND 8000 (Formerly CTS-5130S) Service Manual.pdf
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual.pdf
S16016 - Air Conditioning - Heater System_ 2000, 4000, and 8000 - 12_06_1994 and After Formerly (CTS-5227) 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
S16022Y - Air Conditioning Protection and Diagnostic System (APAds) Description, Operation, Troubleshooting, Remove, Install, and Electrical Circuit Diagrams Maintenance 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, 8600Manual - Truck2_16_2011 12_00_00 AM.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 Service Manual.pdf
S16038 - CAB_ 7300, 7400, 7500, 7600, 7700, 8500, 8600, TranStar, and WorkStar Models Service Manual.pdf
S16039 - Heat Ventilation Air Conditioning (HVAC) System and TXV System For 2007 Service Manual.pdf
S16043 - 2009 12V DC No Idle HVAC Service Manual.pdf
S16046 - 3200 Bus, DuraStar, TerraStar, TranStar, WorkStar Models Heat Ventilation Air Conditioning (HVAC) for 2010 Service Manual.pdf
S16053 - Heat Ventilation Air Conditioning (HVAC) for 2010 - South Africa _ 7000 RHD AND 8000 RHD Service Manual.pdf
S082503A - Electrical System Troubleshooting Guide Models Built After 05_20_2003 (Apr 2004) Service Manual.pdf
S082503 - Electrical System Troubleshooting Guide Models Built 10_16_2000 to 05_20_2003 (Jan 2008) Service Manual.pdf
S082503 - TRUCK SERVICE MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Before 05_20_2003.pdf
S082504 - 3200, 4100, 4200,4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models (May 2003 to Feb 2007) Electrical Troubleshooting.pdf
S082504 - Electrical System Troubleshooting Guide Models Built 05_20_2003 to 02_28_2007 (Jan 2008) Service Manual.pdf
S082852 - 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600 Models Built January 1, 2002 To September 30, 2002 Electrical Circuit Diagrams (Jan 2002)Circuit Diagrams3_30_2016 12_00_00 AM.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)Circuit Diagrams3_30_2016 12_00_00 AM.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
S082854 - Wiring Diagrams (2004 to 2005).pdf
TABLE OF CONTENTS
00000003161 - 2013 Hood Grille Fenders Bumper Service Manual....1
toc....3
Table of Contents....3
1. DESCRIPTION....5
1.1. BUMPER....5
Two Piece Tilt-Away Bumper....5
One Piece Stationary Bumper....5
Three Piece Tilt-Away Bumper....6
Three Piece Stationary Bumper....6
1.2. GRILLE AND BUG SCREEN....7
1.3. Hood Assembly....7
1.4. Hood Tilt Assist....7
1.5. HOOD SEAL....7
1.6. SPLASH SHIELDS....7
1.7. AIR INTAKE....7
1.8. FENDER....7
1.9. FENDER EXTENSIONS....7
1.10. Headlight Assembly....7
2. REMOVE AND INSTALL PROCEDURES....8
2.1. TILT-AWAY BUMPER....9
Two Piece Tilt-Away Bumper – Removal....9
Two Piece Tilt-Away Bumper – Installation....12
2.2. two piece TILT-AWAY BUMPER PANELS....13
Two Piece Tilt-Away Bumper Panel – Removal....13
Two Piece Tilt-Away Bumper Panel – Installation....18
2.3. BUMPER LATCH....19
Bumper Latch – Removal....19
Bumper Latch – Installation....19
2.4. TILT BRACKET....20
Tilt Bracket – Removal....20
Tilt Bracket – Installation....22
2.5. one piece STATIONARY BUMPER....23
One Piece Stationary Bumper-Removal....23
One Piece Stationary Bumper-Installation....24
2.6. one piece stationary Bumper filler panels....25
One Piece Stationary Bumper Filler Panel – Removal....25
One Piece Stationary Bumper Filler Panel – Installation....25
2.7. three piece BUMPER....26
Three Piece Bumper Seal-Removal....26
Three Piece Bumper Upper Reinforcement Tubes-Removal....27
Three Piece Bumper Lower Reinforcement Tubes-Removal....28
Three Piece Bumper Left and Right Bumper Panel-Removal....29
Three Piece Bumper Fixed Assembly-Removal....30
Three Piece Bumper Air Intake Grill-Removal....31
Three Piece Bumper Air Intake Grill-Installation....32
Three Piece Bumper Fixed Assembly-Installation....33
Three Piece Bumper Left and Right Bumper Panel-Installation....34
Three Piece Bumper Lower Reinforcement Tubes-Installation....35
Three Piece Bumper Upper Reinforcement Tubes-Installation....36
Three Piece Bumper Seal-Installation....37
2.8. GRILLE AND BUG SCREEN....38
Grille and Bug Screen – Removal....38
Grille and Bug Screen – Installation....39
2.9. SPLASH SHIELDS....40
Splash Shields – Removal....40
Splash Shields – Installation....42
2.10. HOOD....43
Hood – Removal....43
Hood – Installation....48
Hood – Adjustment....50
2.11. Hood Tilt assist....52
Hood Tilt Assist – Removal....52
Hood Tilt Assist – Installation....54
2.12. Torsion Bars....55
Torsion Bar – Removal....55
Torsion Bar – Installation....56
2.13. Hood Latch....57
Hood Latch – Removal....57
Hood Latch – Installation....58
2.14. Hood Mirror....59
Hood Mirror – Removal....59
Hood Mirror – Installation....60
2.15. Hood Seal....61
Hood Seal – Removal....61
Hood Seal – Installation....61
2.16. Hood and fender panels....62
Hood and Fender Panel – Removal....64
Hood and Fender Panel – Installation....72
2.17. FENDER EXTENSIONS....76
Fender Extensions – Removal....76
Fender Extensions – Installation....77
2.18. Headlight Assembly....78
Headlight Assembly – Removal....78
Headlight Assembly – Installation....79
Headlight Bulb Replacement....79
Headlight Adjustment....80
tables....81
Table 1Torque Chart....81
0000001601 - ProStar + Radiator, Cooling System with SCR Service Manual....82
toc....84
Summary of Changes....84
1. General Description....90
1.1. Deaeration Tank....92
1.2. Fan Shroud....92
1.3. A/C Condenser....92
1.4. Transmission Oil Cooler....92
1.5. Radiator....92
1.6. Charge Air Cooler....92
1.7. Low-Temperature Radiator....92
1.8. Fan Drive....93
1.9. Power Steering Oil Cooler....93
2. Removal and Installation....94
2.1. Coolant Drain, Pressure Test, and Fill Procedures....95
Coolant Drain Procedure – Navistar ® 11, 13, 15 and Cummins® ISX15 (Recommended)....97
Pressure Test Procedure – Navistar ® 11, 13, 15, and Cummins® ISX15 (Recommended)....99
Coolant Fill Procedure – Navistar ® 11, 13, 15 and Cummins® ISX15 (Recommended)....100
Coolant Drain Procedure – Navistar ® 11, 13, 15, Cummins® ISX15 (Optional)....102
Coolant Fill Procedure – Navistar ® 11, 13, 15 (Optional)....103
Coolant Fill Procedure – Cummins® ISX Engines (Optional)....105
2.2. Grille....106
Grille – Removal....106
Grille – Installation....106
2.3. Deaeration Tank – Navistar ® Engines....108
Deaeration Tank Removal – Navistar ® 11, 13, 15....108
Deaeration Tank – Installation Navistar ® 11, 13, 15....109
2.4. Deaeration Tank – Cummins® isx engines....109
Deaeration Tank Removal – Cummins® ISX15....110
Deaeration Tank Installation – Cummins® ISX15....110
2.5. A/C Condenser....112
A/C Condenser Removal – Navistar ® 11, 13 ....112
A/C Condenser Installation – Navistar ® 11 or 13 ....114
A/C Condenser Removal – Navistar ® 15 Liter ....115
A/C Condenser Installation – Navistar® 15 Liter ....116
A/C Condenser Removal – Cummins® ISX15 ....117
A/C Condenser Installation – Cummins® ISX15....118
2.6. Fan Shroud....119
Fan Shroud Removal – Navistar ® 11, 13....119
Fan Shroud Installation – Navistar® 11, 13 Liter ....124
Fan Shroud Removal – (Three-Piece Upper) Navistar® 15 ....125
Fan Shroud Installation – (Three-Piece Upper) Navistar® 15 ....127
Fan Shroud Removal – (Three-Piece Lower) Navistar® 15 ....128
Fan Shroud Installation – (Three-Piece Lower) Navistar ® 15....128
Fan Shroud (One-Piece) Removal – Navistar ® 15....129
Fan Shroud Installation – (One-Piece) Navistar ® 15....131
Fan Shroud Removal – (Two-Piece) Cummins® ISX15....131
Fan Shroud Installation – (Two-Piece) Cummins® ISX15....136
2.7. Radiator Fan....138
Radiator Fan Removal – Navistar ® 11, 13....138
Radiator Fan Installation – Navistar® 11, 13 ....139
Radiator Fan Removal (With Three-Piece Fan Shroud) – Navistar® 15....140
Radiator Fan Installation (With Three-Piece Fan Shroud) – Navistar® 15....140
Radiator Fan Removal (With One-Piece Fan Shroud) – Navistar® 15....141
Radiator Fan Installation (With One-Piece Fan Shroud) – Navistar ® 15....142
Radiator Fan Removal – Cummins® ISX15....142
Radiator Fan Installation – Cummins® ISX15....142
2.8. Fan Drive....144
Fan Drive Removal – Navistar ® 11, 13....144
Fan Drive Installation – Navistar ® 11, 13....145
Fan Drive Removal – Navistar® 15....146
Fan Drive Installation – Navistar® 15....147
Fan Drive Assembly Removal – Cummins® ISX15 (Horton)....147
Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ....148
2.9. Fan Belt....150
Fan Belt Removal – Navistar ® 11, 13....150
Fan Belt Installation – Navistar ® 11, 13....151
Fan Belt Removal – Navistar® 15 ....152
Fan Belt Installation – Navistar ® 15....153
Alternator Fan Belt Removal – Navistar ® 15 ....154
Alternator Fan Belt Installation – Navistar ® 15 ....155
Fan Belt Removal – Cummins® ISX15 ....156
Fan Belt Installation – Cummins® ISX15....157
2.10. Radiator Hoses....158
Heat Shrink Clamp – Removal....158
Heat Shrink Clamp – Installation....159
Radiator Hose Removal – Navistar® 11, 13 ....162
Radiator Hose Installation – Navistar® 11, 13....163
Radiator Hose Removal – Navistar ® 15 ....164
Radiator Hose Installation – Navistar ® 15....165
Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Removal – Navistar ® 15 ....166
Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Installation – Navistar® 15....167
Radiator Hose Removal – Cummins® ISX15....169
Radiator Hose Installation – Cummins® ISX15 ....171
2.11. Recirculation Seals....173
Recirculation Seals Removal – Navistar ® 11, 13....173
Recirculation Seals Installation – Navistar ® 11, 13 ....173
Recirculation Seals Removal – Navistar® 15 ....174
Recirculation Seals Installation – Navistar ® 15....176
2.12. Charge Air Cooler....177
Charge Air Cooler Removal – Navistar® 11, 13, 15....177
Charge Air Cooler Installation – Navistar ® 11, 13, 15....178
Charge Air Cooler Removal – Cummins® ISX15....178
Charge Air Cooler Installation – Cummins® ISX15....182
2.13. Hood-Tilt Assist Cylinder....185
Hood-Tilt Assist Cylinder – Removal....185
Hood-Tilt Assist Cylinder – Installation....187
2.14. Low-Temperature Radiator (Navistar® Engines Only)....188
Low-Temperature Radiator Removal – Navistar® 11, 13....188
Low-Temperature Radiator Installation – Navistar® 11, 13....190
Low-Temperature Radiator Removal – Navistar® 15....191
Low-Temperature Radiator Installation – Navistar® 15....194
2.15. Radiator Assembly....197
Radiator Assembly Removal – Navistar® 11, 13....197
Radiator Assembly Installation – Navistar® 11, 13....199
Radiator Assembly Removal – Navistar® 15....199
Radiator Assembly Installation – Navistar® 15....201
Radiator Assembly Removal – Cummins® ISX15....202
Radiator Assembly Installation – Cummins® ISX15....209
2.16. Radiator Core....211
Radiator Core Removal – Navistar® 11, 13....212
Radiator Core Installation – Navistar® 11, 13....214
Radiator Core Removal – Navistar® 15....216
Radiator Core Installation – Navistar® 15....217
Radiator Core- Removal – Cummins® ISX15 ....218
Radiator Core Installation – Cummins® ISX15 ....222
2.17. Power Steering Oil Cooler....224
Power Steering Oil Cooler – Removal....224
Power Steering Oil Cooler – Installation....225
2.18. Transmission Oil Cooler (Cummins® ISX15 ONLY)....226
Transmission Oil Cooler – Removal....226
Transmission Oil Cooler – Installation....229
tables....229
Table 2Torque Chart Navistar® Engines....229
Table 3 Torque Chart Cummins® ISX15 Engine....231
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10....234
toc....236
Summary of Changes....236
1. Description....242
1.1. Theory of Operation....248
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.....248
1.2. Switchback / Horizontal....249
1.3. Vertical / Vertical....250
1.4. In-Line....251
2. General Service Information....252
2.1. Exhaust Aftertreatment System Modifications....253
2.2. Gaskets and Fasteners....254
2.3. Diesel Particulate Filter (DPF) Indexing....254
2.4. DPF and DOC Cleaning....254
2.5. DPF General Inspection....255
DPF Inspection Points....256
2.6. DOC General Inspection....259
DOC Inspection Points....259
2.7. DPF / DOC Thread Repair....263
12 MM Thread Replacement....263
14 MM Thread Replacement....267
2.8. DOC and DPF Reuse Guidelines....271
General Information....271
Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted....272
Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged....273
Diesel Particulate Filter (DPF) Inlet / Outlet – New....274
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1)....275
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2)....276
Diesel Particulate Filter (DPF) Inlet – Clean....277
Diesel Particulate Filter (DPF) Inlet – Gouged....278
Diesel Particulate Filter (DPF) Inlet – Ash....279
Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings....280
Diesel Particulate Filter (DPF) Outlet – Soot Stains....281
Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process....282
Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains ....283
Diesel Particulate Filter (DPF) Outlet – Face Cracked....284
Diesel Particulate Filter (DPF) Outlet – Coolant Staining....285
Diesel Particulate Filter (DPF) Outlet – Melted....286
2.9. Decomposition Reactor Tube Cleaning....287
2.10. Diesel Exhaust Fluid (DEF) Dosing Valve cleaning....288
2.11. DEF Supply Module Filter Inspection....290
2.12. Diesel Exhaust Fluid (DEF) System Contamination....292
2.13. DEF System Decontamination Procedure....295
2.14. Diesel Exhaust Fluid (DEF) Refractometer Tool....296
Using the DEF Refractometer....296
DEF Refractometer Maintenance....298
2.15. Diesel Exhaust Fluid (DEF) Dosing System Reuse Guidelines....299
2.16. Diesel Exhaust Fluid (DEF) Tank Draining....302
3. Switchback / Horizontal....303
3.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....303
Switchback / Horizontal – Removal....303
Switchback / Horizontal – Installation....305
Diesel Exhaust Fluid (DEF) Dosing Valve – Removal....306
Diesel Exhaust Fluid (DEF) Dosing Valve – Installation....307
Decomposition Reactor Tube – Removal....308
Decomposition Reactor Tube – Installation....309
Aftertreatment Assembly Mounting Bracket – Removal....310
Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly Mounting Bracket – Installation....311
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal....312
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation....312
Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal....314
Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation....314
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal (If Equipped)....315
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If Equipped)....315
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped)....316
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped)....316
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal....317
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation....317
(DPF) Temperature Sensors and Module – Removal....319
Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation....319
Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal....321
Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation....322
Diesel Particulate Filter (DPF) High Pressure Tube – Removal....323
Diesel Particulate Filter (DPF) High Pressure Tube – Installation....323
Diesel Particulate Filter (DPF) Low Pressure Tube – Removal....324
Diesel Particulate Filter (DPF) Low Pressure Tube – Installation....324
4. Vertical / Vertical ....325
4.1. Navistar® N13 Engine....325
Vertical / Vertical....325
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal....326
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Installation....326
Power Distribution Module (PDM) – Removal....327
Power Distribution Module (PDM) – Installation....327
Aftertreatment Control Module (ACM) – Removal....328
Aftertreatment Control Module (ACM) – Installation....328
5. In–Line....329
5.1. Cummins ISB6.7 or Navistar® N9 and N10 Engines....329
In-Line....329
6. Diesel Exhaust Fluid (DEF) System....330
6.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....330
Diesel Exhaust Fluid (DEF) Tank – Removal....330
Diesel Exhaust Fluid (DEF) Tank – Installation....333
Power Distribution Module (PDM) – Removal....334
Power Distribution Module (PDM) – Installation....334
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal....335
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation....338
Diesel Exhaust Fluid (DEF) Tank Lines – Removal....339
Diesel Exhaust Fluid (DEF) Tank Lines – Installation....341
Diesel Exhaust Fluid (DEF) Supply Module – Removal....342
Diesel Exhaust Fluid (DEF) Supply Module – Installation....343
Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal....344
Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation....344
Aftertreatment Control Module (ACM) – Removal....345
Aftertreatment Control Module (ACM) – Installation....346
Diesel Exhaust Fluid (DEF) Tank Bracket – Removal....347
Diesel Exhaust Fluid (DEF) Tank Bracket – Installation....348
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal....349
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation....350
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal....351
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation....352
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal....353
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation....355
Diesel Exhaust Fluid (DEF) System....356
7. Acronym List....357
tables....253
Table 2Minimum Clearance Between Exhaust System Components and Other Chassis Components.....253
Table 32Acronym List.....357
Table 33Torque Chart.....358
0000002122 - ProStar and LoneStar Series Built June 14, 2010 and After Electrical Circuit Diagrams (Supersedes S08344 and S08371)....359
0000002122 - ProStar, Lone Star (2010 & Newer) Wiring Diagram....1021
0000002221 - ProStar +, LoneStar HVAC System Service Manual....1568
toc....1570
Summary of Changes....1570
1. SAFETY PRECAUTIONS....1578
2. GENERAL DESCRIPTION....1583
2.1. SYSTEM OPERATIONAL DESCRIPTION....1585
Air Distribution (General)....1585
Air Distribution (Air Conditioning)....1587
Air Distribution (Heat and Ventilation)....1588
Air Distribution (Defrost)....1588
A/C Refrigerant Flow....1589
Rear HVAC System....1591
Rear Air Distribution (General)....1594
Rear Air Distribution (Air Conditioning)....1595
Rear Air Distribution (Heat)....1595
A/C Refrigerant Flow – Sleeper A/C System....1596
2.2. COMPONENTS....1597
Thermostatic Expansion Valve (TXV)....1598
Freeze Probe....1598
Low Pressure Switch....1598
Linear Power Module....1598
Recirculation Filter....1598
HVAC Control Panel....1598
Rear HVAC Components....1598
Rear Thermostatic Expansion Valve (TXV)....1599
Rear Evaporator....1599
Rear HVAC Plumbing....1599
Rear Heater Core....1599
Rear Blower Assembly....1600
Rear Linear Power Module....1600
Rear Temperature Blend Air Door Actuator....1600
Rear HVAC Controller....1600
Rear HVAC Control Panel....1601
Rear HVAC Control Switches (Located in Instrument Panel)....1601
2.3. INTERNAL COMPONENTS....1602
Filter-Drier....1602
Heater Core....1602
Blower Assembly....1603
Evaporator Core....1603
HVAC Filter....1603
2.4. UNDER HOOD COMPONENTS....1603
Pressure Transducer....1603
Compressor and Clutch....1603
Condenser....1603
A/C Plumbing....1603
2.5. HVAC ELECTRICAL SYSTEM OVERVIEW....1604
General Operation Of The HVAC Electrical System....1604
General Operation of the Rear HVAC Electrical System....1604
3. SYSTEM OPERATION....1605
3.1. CONTROL ASSEMBLY....1605
3.2. BLOWER FAN SPEED CONTROL....1605
3.3. TEMPERATURE CONTROL....1605
3.4. MODE CONTROL....1605
MAX Air Conditioning Mode....1606
NORM Air Conditioning Mode....1606
Bi-Level Air Conditioning Mode....1607
Vent Mode....1607
Floor Mode....1607
Mix Mode....1607
Defrost....1607
3.5. DEHUMIDIFYING....1607
4. SERVICE PROCEDURES FOR R-134A....1608
4.1. r-134a service precautions....1609
4.2. Recommended service tools....1612
4.3. sealant detection....1612
4.4. Refrigerant identification....1613
4.5. Leak detection....1614
RHS980C-NAV Leak Detection....1614
D440A-NAV and D400A Leak Detectors....1615
Ultrasonic Leak Detectors....1615
Refrigerant Leak Testing with Nitrogen....1616
4.6. AUTOMATIC MODE....1618
4.7. DISCHARGING THE SYSTEM (RECYCLE MODE)....1620
4.8. Evacuating the System (vacuum mode)....1622
4.9. Charging the Air Conditioning System (Charge Mode)....1623
4.10. FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM....1624
Flushing Using the RHS980C-NAV (Recommended Method)....1625
Alternate Method for Flushing (and Purging) the A/C System....1627
4.11. OIL FILL GUIDELINES....1628
Oil Separation During Refrigerant Recovery....1629
Excessive Oil Loss Due to Refrigerant Leaks....1630
4.12. CHECKING COMPRESSOR OIL LEVEL....1632
5. REMOVE AND INSTALL PROCEDURES....1635
5.1. PRESSURE TRANSDUCER....1636
Pressure Transducer – Removal....1636
Pressure Transducer – Installation....1637
5.2. LOW PRESSURE SWITCH....1637
Low Pressure Switch – Removal....1637
Low Pressure Switch – Installation....1638
5.3. FREEZE PROBE....1638
Freeze Probe – Removal....1638
Freeze Probe – Installation....1639
5.4. HVAC AIR FILTER....1640
HVAC Air Filter – Removal....1640
HVAC Air Filter – Installation....1640
5.5. REFRIGERANT LINE....1641
Refrigerant Line – Removal....1641
Refrigerant Line – Installation....1642
5.6. FILTER-DRIER....1644
Filter-Drier – Removal....1644
Filter-Drier – Installation....1645
5.7. THERMOSTATIC EXPANSION VALVE (TXV)....1646
Thermostatic Expansion Valve (TXV) – Removal....1646
Thermostatic Expansion Valve (TXV) – Installation....1647
5.8. FRESH AIR MODULE....1647
Fresh Air Module – Removal....1647
Fresh Air Module – Installation....1649
5.9. INTERIOR MODULE TRIM COVER....1649
Interior Module Trim Cover – Removal....1650
Interior Module Trim Cover – Installation....1650
5.10. FRESH / RECIRCULATE DOOR ACTUATOR....1650
Fresh/Recirculate Door Actuator – Removal....1651
Fresh/Recirculate Door Actuator – Installation....1651
5.11. BLEND DOOR ACTUATOR....1652
Blend Door Actuator – Removal....1652
Blend Door Actuator – Installation....1653
5.12. MODE DOOR ACTUATOR....1654
Mode Door Actuator – Removal....1654
Mode Door Actuator – Installation....1655
5.13. FRESH/RECIRCULATE DOOR GEAR TRAIN....1655
Fresh/Recirculate Door Gear Train – Removal....1655
Fresh/Recirculate Door Gear Train – Installation....1657
5.14. BLEND DOOR GEAR TRAIN....1658
Blend Door Gear Train – Removal....1658
Blend Door Gear Train – Installation....1661
5.15. MODE DOOR GEAR TRAIN....1662
Mode Door Gear Train – Removal....1662
Mode Door Gear Train – Installation....1665
5.16. RECIRCULATION FILTERS....1667
Recirculation Filters – Removal....1667
Recirculation Filters – Installation....1668
5.17. LINEAR POWER MODULE (LPM)....1669
Linear Power Module (LPM) – Removal....1669
Linear Power Module (LPM) – Installation....1670
5.18. BLOWER ASSEMBLY....1670
Blower Assembly – Removal....1670
Blower Assembly – Installation....1671
5.19. HEATER CORE....1671
Heater Core – Removal....1672
Heater Core – Installation....1673
5.20. HVAC CONTROL PANEL ASSEMBLY....1674
HVAC Control Panel Assembly – Removal....1674
HVAC Control Panel Assembly – Installation....1674
5.21. COMPRESSOR/CLUTCH....1675
Compressor/Clutch – Removal....1675
Compressor/Clutch – Installation....1676
5.22. A/C CONDENSER....1676
5.23. HEATER HOSES/LINES....1676
5.24. EVAPORATOR....1677
Evaporator – Removal....1677
Evaporator – Installation....1678
5.25. BLOWER SCROLL HOUSING....1679
Blower Scroll Housing – Removal....1679
Blower Scroll Housing – Installation....1680
5.26. SPLITTING/SEPARATING BLOWER SCROLL HOUSING....1680
Splitting/Separating Blower Scroll Housing – Removal....1680
Splitting/Separating Blower Scroll Housing – Installation....1682
5.27. INTERIOR MODULE....1683
Interior Module – Removal....1683
Interior Module – Installation....1688
5.28. SPLITTING/SEPARATING INTERIOR MODULE....1689
Splitting/Separating Interior Module – Removal....1689
Splitting/Separating Interior Module – Installation....1693
5.29. FRESH/RECIRCULATE, MODE, AND BLEND AIR DOORS....1694
5.30. HVAC CONTROLS (SLEEPER)....1695
HVAC Controls – Removal....1695
Digital Controls – Installation....1695
Analog Controls – Installation....1696
5.31. HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT....1696
Heater Hose Assembly – Removal....1696
Heater Hose Assembly – Installation....1697
5.32. A/C HOSE ASSEMBLY – TO REAR HVAC UNIT....1698
A/C Hose Assembly – Removal....1698
A/C Hose Assembly – Installation....1698
5.33. THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT....1700
Thermostatic Expansion Valve – Removal....1700
Thermostatic Expansion Valve – Installation....1700
5.34. BLOWER – REAR HVAC UNIT....1702
Blower – Removal....1702
Blower – Installation....1702
5.35. FILTER ELEMENT – REAR HVAC UNIT....1703
Filter Element – Removal....1703
Filter Element – Installation....1703
5.36. OUTLET DUCT TEMPERATURE SENSOR – REAR HVAC UNIT....1704
Outlet Duct Temperature Sensor – Removal....1704
Outlet Duct Temperature Sensor – Installation....1704
5.37. LINEAR POWER MODULE – REAR HVAC UNIT....1705
Linear Power Module – Removal....1705
Linear Power Module – Installation....1705
5.38. BLEND DOOR ACTUATOR – REAR HVAC UNIT....1706
Blend Door Actuator – Removal....1706
Blend Door Actuator – Installation....1706
5.39. SLEEPER HVAC CONTROLLER – REAR HVAC UNIT....1707
Sleeper HVAC Controller – Removal....1707
Sleeper HVAC Controller – Installation....1707
5.40. HEATER CORE – REAR HVAC UNIT....1708
Heater Core – Removal....1708
Heater Core – Installation....1709
5.41. TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT....1711
Temperature Blend Air Door – Removal....1711
Temperature Blend Air Door – Installation....1713
5.42. EVAPORATOR CORE – REAR HVAC UNIT....1715
Evaporator Core – Removal....1715
Evaporator Core – Installation....1717
5.43. REAR HVAC UNIT, COMPLETE....1719
Rear HVAC Unit – Removal....1719
Rear HVAC Unit – Installation....1720
6. DIAGNOSIS AND TROUBLESHOOTING....1722
6.1. PRELIMINARY CHECKS....1722
Check for Obvious Damage....1722
Refrigerant Identification....1722
Check for Noncondensable Gases....1722
6.2. PHYSICAL CHECKS....1723
Physical Check Procedure....1723
Refrigerant Compressor....1724
Condenser....1724
Pressure Transducer....1725
Low Pressure Switch....1725
Filter-Drier....1725
Thermostatic Expansion Valve (TXV)....1725
Evaporator....1726
Line Restrictions....1726
6.3. A/C SYSTEM TEST MODE ....1726
6.4. ABNORMAL GAUGE READINGS....1729
Diagnosis of Abnormal Gauge Readings....1729
6.5. FRONT ACTUATOR / DOOR POSITION RECALIBRATION....1731
Recalibrate Front Actuator / Door Position....1731
6.6. TROUBLESHOOTING TABLES....1731
HVAC Fault Codes....1731
HVAC Control Circuit Test....1733
Mode Door Actuator Checks....1735
Blend Door Actuator Checks ....1737
Fresh/Recirculate Door Actuator Checks....1738
Linear Power Module/Blower Motor Checks....1739
A/C Compressor Checks....1741
Pressure Transducer (IBB engine) Checks....1743
Pressure Transducer (I6, V8 engine) Checks....1745
Freeze Thermistor Checks....1747
Low Pressure Switch Checks....1748
Auxiliary HVAC Controller Test....1749
Auxiliary HVAC (Analog) Control Checks....1752
Sleeper HVAC (LED) Control Checks....1754
Rear HVAC Blend Door Actuator Checks....1756
Rear HVAC Blower Motor/LPM Checks....1757
Rear HVAC Temperature Sensor Checks....1759
7. SPECIFICATIONS....1760
7.1. TORQUE CHART....1760
7.2. AIR CONDITIONING SYSTEM....1761
8. SPECIAL TOOLS....1762
8.1. INTERNATIONAL® SERVICING SYSTEM (RHS980C-NAV)....1764
8.2. RHS980C-NAV TEMPERATURE PROBES....1766
8.3. REFRIGERANT IDENTIFIER ....1766
8.4. D-400A AND D440A-NAV REFRIGERANT LEAK DETECTORS....1767
8.5. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT....1768
8.6. FLUSH/PURGE FITTING ADAPTERS....1768
8.7. TOOLS OBTAINED LOCALLY....1769
8.8. ELECTRONIC SERVICE TOOL (EST), EZ-TECH....1770
tables....1606
Table 2Air Distribution Chart....1606
Table 3Oil Capacity by Component....1629
Table 4Check for Noncondensable Gases....1723
Table 5System Pressure Versus Ambient Temperature....1723
Table 6System Pressure Test Chart ....1729
Table 7HVAC Fault Codes....1731
Table 8HVAC Control Circuit Test....1733
Table 9Mode Door Actuator Circuit Test.....1736
Table 10Blend Actuator Circuit Test....1737
Table 11Recirc Door Actuator Circuit Test....1738
Table 12LPM / Blower Motor Circuit Test....1739
Table 13Cab LPM and Blower Speed Voltage Table....1740
Table 14A/C Compressor Clutch Circuit Test.....1741
Table 15Pressure Transducer Circuit Test (IBB engine)....1743
Table 17Pressure Transducer Circuit Test (I6, V8 engine)....1745
Table 19Pressure Transducer Voltage Table....1746
Table 20Freeze Thermistor Circuit Test....1747
Table 21Low Pressure Switch Circuit Test....1748
Table 22Thermistor Cross Reference....1749
Table 23Auxiliary HVAC Controller Circuit Test....1749
Table 25Analog Temperature and Blower Speed Control Circuit Test....1752
Table 27HVAC LED Control Circuit Test....1754
Table 29 Rear HVAC Blend Door Actuator Circuit Test....1756
Table 30Rear Blower Motor/LPM Circuit Test....1757
Table 31Auxiliary HVAC Temperature Sensor Circuit Test....1759
Table 32Torque Chart....1760
Table 33Air Conditioning System Specifications....1761
Table 34Special Service Tools....1762
Table 35Frequently Used International® A/C Servicing System Consumable Items....1762
0000002222 - 2013 Cooling System Service Manual....1771
toc....1773
Summary of Changes....1773
1. Description....1777
1.1. Deaeration Tank....1778
1.2. Fan Shroud....1778
1.3. A/C Condenser....1778
1.4. Transmission Oil Cooler....1778
1.5. Radiator....1778
1.6. Charge Air Cooler....1778
1.7. Low-Temperature Radiator....1778
1.8. Fan Drive....1778
2. Removal and Installation....1779
2.1. Coolant Drain, Pressure Test, and Fill procedures....1780
Coolant Drain Procedure (Recommended)....1782
Pressure Test Procedure (Recommended)....1784
Coolant Fill Procedure (Recommended)....1785
Coolant Drain Procedure (Optional)....1787
Coolant Fill Procedure (Optional)....1788
2.2. Grille....1791
Grille – Removal....1791
Grille – Installation....1792
2.3. Deaeration Tank....1793
Deaeration Tank – Removal....1793
Deaeration Tank – Installation....1794
2.4. A/C Condenser....1795
A/C Condenser – Removal....1795
A/C Condenser – Installation....1797
2.5. Fan Shroud....1798
Fan Shroud – Removal....1798
Fan Shroud – Installation....1802
2.6. Radiator Fan....1803
Radiator Fan – Removal....1803
Radiator Fan – Installation....1804
2.7. Fan Clutch....1805
Fan Clutch – Removal....1805
Fan Clutch – Installation....1806
2.8. Fan Belt....1807
Fan Belt – Removal....1807
Fan Belt – Installation....1808
2.9. Radiator Hose....1809
Heat Shrink Clamp – Removal....1809
Heat Shrink Clamp – Installation....1810
Radiator Hose – Removal....1813
Radiator Hose – Installation....1817
2.10. Charge Air Cooler....1818
Charge Air Cooler – Removal....1818
Charge Air Cooler – Installation....1820
2.11. Low-Temperature Radiator....1821
Low-Temperature Radiator – Removal....1821
Low-Temperature Radiator – Installation....1823
2.12. Radiator Assembly....1824
Radiator Assembly – Removal....1824
Radiator Assembly – Installation....1827
2.13. Radiator Core....1828
Radiator Core – Removal....1828
Radiator Core – Installation....1830
2.14. Transmission Oil Cooler (Crossmember mounted)....1831
Transmission Oil Cooler (Crossmember mounted) – Removal....1832
Transmission Oil Cooler (Crossmember mounted) – Installation....1832
tables....1833
Table 2Torque Chart....1833
0000002323 - Day Cab And Sleeper Cab LoneStar, ProStar Service Manual....1834
toc....1836
Summary of Changes....1836
1. DESCRIPTION....1844
1.1. day Cab and sleeper cab....1844
1.2. Cab Interior Trim Panels....1846
1.3. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION....1847
1.4. WINDSHIELD....1848
1.5. ELECTRIC WINDSHIELD WIPERS....1849
1.6. WINDSHIELD WASHER....1850
1.7. IGNITION SWITCH CYLINDER....1851
2. removal and installation....1852
2.1. Windshield....1852
Windshield – Removal....1852
Windshield – Installation....1857
2.2. Rear Window Glass....1869
Rear Window Glass – Removal....1869
Rear Window Glass – Installation....1870
2.3. Hood Seal....1880
Hood Seal – Removal....1880
Hood Seal – Installation....1880
2.4. SunShade....1881
Sunshade – Removal....1881
Sunshade – Installation....1882
2.5. Sun Visor and Clip....1883
Sun Visor and Clip – Removal....1883
Sun Visor and Clip – Installation....1883
2.6. Ignition Switch And Ignition Switch Cylinder....1884
Ignition Switch – Removal....1884
Ignition Switch – Installation....1885
Ignition Switch Cylinder – Removal....1886
Ignition Switch Cylinder – Installation....1888
2.7. Cab Doors....1889
Cab Doors – Removal....1889
Cab Doors – Installation....1892
2.8. Door Hinge....1893
Door Hinge – Removal....1893
Door Hinge – Installation....1893
2.9. Door Striker Pin....1895
Door Striker Pin – Removal....1895
Door Striker Pin – Installation....1895
2.10. Door Check Bracket....1896
Door Check Bracket – Removal....1896
Door Check Bracket – Installation....1897
2.11. Door Check Link....1898
Door Check Link – Removal....1898
Door Check Link – Installation....1899
2.12. Door Trim Panel....1900
Door Trim Panel – Removal....1900
Door Trim Panel – Installation....1902
2.13. Door Vapor Barrier....1903
Door Vapor Barrier – Removal....1903
Door Vapor Barrier – Installation....1904
2.14. Window Slide Block....1905
Window Slide Block – Removal....1905
Window Slide Block – Installation....1906
2.15. Door Glass....1907
Door Glass – Removal....1907
Door Glass – Installation....1909
2.16. Modular Door Hardware Assembly....1910
Modular Door Hardware Assembly – Removal....1910
Modular Door Hardware Assembly – Installation....1913
2.17. Vent Window, Latch, And Seal....1914
Vent Window, Latch, and Seal – Removal....1914
Vent Window, Latch, and Seal – Installation....1915
2.18. Door Lock Cylinder....1916
Door Lock Cylinder – Removal....1916
Door Lock Cylinder – Installation....1917
2.19. Window Electric Motor....1918
Window Electric Motor – Removal....1918
Window Electric Motor – Installation....1918
2.20. Regulator Arm Assembly....1920
Regulator Arm Assembly – Removal....1920
Regulator Arm Assembly – Installation....1923
2.21. Outer Door Handle....1925
Outer Door Handle – Removal....1925
Outer Door Handle – Installation....1927
2.22. Door Latch....1928
Door Latch – Removal....1928
Door Latch – Installation....1929
2.23. Inner Door Handle....1930
Inner Door Handle – Removal....1930
Inner Door Handle – Installation....1932
2.24. Weather Seals....1933
Weather Seals – Removal....1933
Weather Seals – Installation....1933
2.25. Window Run Channels....1935
Window Run Channels – Removal....1935
Window Run Channels – Installation....1936
2.26. Electric Window And Door Lock Switch....1937
Electric Window and Door Lock Switch – Removal....1937
Electric Window and Door Lock Switch – Installation....1937
2.27. Electric Mirror Switch....1939
Electric Mirror Switch – Removal....1939
Electric Mirror Switch – Installation....1940
2.28. Dash Panel....1941
Gauge Cluster – Removal....1941
Gauge Cluster – Installation....1942
Dash Panel – Removal....1942
Dash Panel – Installation....1946
2.29. front SEATS....1947
Front Seat – Removal....1947
Front Seat – Installation....1948
2.30. Scuff Plate and Seat Belt Retractor Cover....1949
Scuff Plate and Seat Belt Retractor Cover – Removal....1949
Scuff Plate and Seat Belt Retractor Cover – Installation....1949
2.31. B-Pillar Trim Panel....1950
B-Pillar Trim Panel – Removal....1950
B-Pillar Trim Panel – Installation....1950
2.32. Header Console Panel....1952
Header Console Panel – Removal....1952
Header Console Panel – Installation....1956
2.33. Headliner Trim Panel....1957
Headliner Trim Panel – Removal....1957
Headliner Trim Panel – Installation....1958
2.34. Windshield Wiper Arm and Blade Assembly....1959
Windshield Wiper Arm and Blade Assembly – Removal....1959
Windshield Wiper Arm and Blade Assembly – Installation....1959
2.35. Windshield Wiper Assembly....1961
Windshield Wiper Assembly – Removal....1961
Windshield Wiper Assembly – Installation....1961
2.36. Electric Windshield Wiper Motor....1963
Electric Windshield Wiper Motor – Removal....1963
Electric Windshield Wiper Motor – Installation....1964
2.37. Windshield Washer Bottle With Pump Motor....1966
ProStar Windshield Washer Bottle With Pump Motor – Removal....1966
ProStar Windshield Washer Bottle With Motor – Installation....1966
LoneStar Windshield Washer Bottle With Motor – Removal....1967
LoneStar Windshield Washer Bottle With Motor – Installation....1968
2.38. Cab Cowl Tray....1969
Cab Cowl Tray – Removal....1969
Cab Cowl Tray – Installation....1970
2.39. Lonestar air cleaner HOUSING....1971
Air Cleaner Housing – Removal....1971
Air Cleaner Housing – Installation....1972
2.40. Lonestar cowl trim panel....1973
Cowl Trim Panel – Removal....1973
Cowl Trim Panel – Installation....1973
2.41. KICK PANEL....1974
Kick Panel – Removal....1974
Kick Panel – Installation....1974
2.42. STEERING COLUMN TRIM PANEL....1975
Steering Column Trim Panel – Removal....1975
Steering Column Trim Panel – Installation....1975
2.43. Engine Cover And Cup Holder....1976
Cup Holder and Ashtray – Removal....1976
Cup Holder and Ashtray – Installation....1976
One-Piece Engine Cover – Removal....1977
One-Piece Engine Cover – Installation....1977
Two-Piece Engine Cover – Removal....1978
Two-Piece Engine Cover – Installation....1978
2.44. Rear Air Suspension Assembly....1979
Rear Air Suspension Assembly – Removal....1979
Rear Air Suspension Assembly – Installation....1980
2.45. Front Cab Mounting Insulators....1981
Front Cab Mounting Insulators – Removal....1981
Front Cab Mounting Insulators – Installation....1982
2.46. Cab Air Suspension System....1983
Height Control Valve – Removal....1983
Height Control Valve – Installation....1984
Shock Absorber – Removal....1985
Shock Absorber – Installation....1986
Suspension Air Spring (Bag) – Removal....1986
Suspension Air Spring (Bag) – Installation....1988
Lateral Control Rod – Removal....1989
Lateral Control Rod – Installation....1990
Jounce Bumper – Removal....1990
Jounce Bumper – Installation....1990
2.47. Cab....1991
Initial Procedures Before Cab Removal....1991
Cab – Removal....1993
Cab – Squaring....1995
Cab – Installation....1996
Final Procedures After Cab Installation....1997
2.48. Sleeper Vent Window Assembly, handle, and seal....1997
Sleeper Vent Window Assembly – Removal....1997
Sleeper Vent Window Assembly – Installation....1998
Sleeper Vent Window Assembly Handle – Removal....1999
Sleeper Vent Window Assembly Handle – Installation....1999
2.49. Sleeper interior....2000
Air Line Cabinet – Removal....2000
Air Line Cabinet – Installation....2000
Upper Tower Cabinet – Removal....2001
Upper Tower Cabinet – Installation....2001
Lower Tower Cabinet – Removal....2002
Lower Tower Cabinet – Installation....2003
Rear Wardrobe Cabinet – Removal....2003
Rear Wardrobe Cabinet – Installation....2004
Lower Bunk Assembly – Removal....2004
Lower Bunk Assembly – Installation....2004
Upper Bunk Assembly – Removal....2005
Upper Bunk Assembly – Installation....2005
Sleeper Control Panel – Removal....2006
Sleeper Control Panel – Installation....2006
Lower Side Trim Panel – Removal....2007
Lower Side Trim Panel – Installation....2008
Upper Side Trim Panel – Removal....2008
Upper Side Trim Panel – Installation....2010
Lower Rear Trim Panel – Removal....2010
Lower Rear Trim Panel – Installation....2011
Upper Rear Trim Panel – Removal....2012
Upper Rear Trim Panel – Installation....2012
T-Rail Corner Panel – Removal....2013
T-Rail Corner Panel – Installation....2013
Sleeper Headliner – Removal....2014
Sleeper Headliner – Installation....2015
Rear Wall Speaker – Removal....2015
Rear Wall Speaker – Installation....2016
2.50. Sleeper interior “Suite”....2017
Table Assembly – Removal....2017
Table Assembly – Installation....2017
Cup Holder – Removal....2018
Cup Holder – Installation....2018
Upper Tower Cabinet – Removal....2018
Upper Tower Cabinet – Installation....2020
Lower Tower Cabinet – Removal....2021
Lower Tower Cabinet – Installation....2022
Side Airline Cabinet – Removal....2022
Side Airline Cabinet – Installation....2024
Rear Airline Cabinet – Removal....2025
Rear Airline Cabinet – Installation....2026
Corner Speaker and HVAC Ductwork – Removal....2026
Corner Speaker and HVAC Ductwork – Installation....2027
Sleeper Control Panel – Removal....2028
Sleeper Control Panel – Installation....2029
Bunk Mattress – Removal....2029
Bunk Mattress – Installation....2030
Bunk Frame Assembly – Removal....2030
Bunk Frame Assembly – Installation....2031
Bunk Hinge Assembly – Removal....2032
Bunk Hinge Assembly – Installation....2032
Bunk Latch Assembly – Removal....2033
Bunk Latch Assembly – Installation....2034
Side Trim Panel – Removal....2034
Side Trim Panel – Installation....2036
Rear Trim Panel – Removal....2036
Rear Trim Panel – Installation....2037
Sleeper Headliner and Dome Lights – Removal....2037
Sleeper Headliner and Dome Lights – Installation....2039
Sleeper Floor Mat – Removal....2039
Sleeper Floor Mat – Installation....2041
2.51. Chassis skirts....2043
ProStar Chassis Skirts – Removal....2043
ProStar Chassis Skirts – Installation....2045
LoneStar Chassis Skirts – Removal....2047
LoneStar Chassis Skirts – Installation....2048
3. TROUBLESHOOTING....2049
3.1. ELECTRIC WINDSHIELD WIPER MOTOR....2049
3.2. WASHER PUMP MOTOR....2050
3.3. CAB AIR SUSPENSION SYSTEM....2051
4. LUBRICATION....2052
4.1. 4000 MILES (6000 km) OR MONTHLY....2052
4.2. AS REQUIRED....2052
5. ADJUSTMENTS....2053
5.1. CAB SQUARING....2053
5.2. CAB DOOR....2054
5.3. Door HINGE....2055
5.4. STRIKER PIN....2056
5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....2057
5.6. Daycab Ride Height....2058
5.7. Sleeper Cab Ride Height....2061
6. TORQUE....2062
6.1. Torque Chart....2062
0000002324 - TranStar and WorkStar Cab Service Manual (Supersedes S16052) Service Manual....2066
toc....2068
Summary of Changes....2068
1. DESCRIPTION....2074
1.1. Standard Cab and extended cab....2074
1.2. Cab Interior Trim Panels....2074
1.3. VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS....2075
1.4. WINDSHIELD....2076
1.5. ELECTRIC WINDSHIELD WIPERS....2077
1.6. WINDSHIELD WASHER....2077
1.7. IGNITION SWITCH CYLINDER....2078
1.8. Rear CAB AIR SUSPENSION system....2079
2. REMOVAL AND INSTALLATION....2080
2.1. Windshield....2081
Windshield - Removal....2081
Windshield - Installation....2085
2.2. Rear Window Glass....2096
Rear Window Glass (Unobstructed Access) – Removal....2096
Rear Window Glass (Unobstructed Access) – Installation....2098
Rear Window Glass (Obstructed Access) – Removal....2108
Rear Window Glass (Obstructed Access) – Installation....2113
2.3. Rear Side Window....2128
Rear Side Window – Removal....2128
Latch – Removal....2129
Latch – Installation....2129
Rear Side Window – Installation....2130
2.4. Hood Seal....2132
Hood Seal – Removal....2132
Hood Seal – Installation ....2132
2.5. Cab Cowl Tray....2133
Cab Cowl Tray – Removal....2133
Cab Cowl Tray – Installation....2133
2.6. Windshield Wiper Arm and Blade Assembly....2134
Windshield Wiper Arm and Blade Assembly – Removal....2134
Windshield Wiper Arm and Blade Assembly – Installation....2135
2.7. Windshield Wiper Assembly....2135
Windshield Wiper Assembly – Removal....2135
Windshield Wiper Assembly – Installation....2136
2.8. Windshield Washer Bottle With Pump Motor....2137
WorkStar® Windshield Washer Bottle With Pump Motor – Removal....2137
WorkStar® Windshield Washer Bottle With Pump Motor – Installation....2138
TranStar® Windshield Washer Bottle With Pump Motor – Removal....2139
TranStar® Windshield Washer Bottle With Pump Motor – Installation ....2140
2.9. Windshield Washer Pump Motor....2141
Windshield Washer Pump Motor – Removal....2141
Windshield Washer Pump Motor – Installation....2142
2.10. Electric Windshield Wiper Motor....2142
Electric Windshield Wiper Motor – Removal....2142
Electric Windshield Wiper Motor – Installation....2143
2.11. Cab Doors....2144
Cab Doors – Removal....2144
Cab Doors – Installation....2147
2.12. Door Hinge....2148
Door Hinge – Removal....2148
Door Hinge – Installation....2149
2.13. Door Striker Pin....2149
Door Striker Pin – Removal....2149
Door Striker Pin – Installation....2150
2.14. Door Check Bracket....2150
Door Check Bracket – Removal....2150
Door Check Bracket – Installation....2151
2.15. Door Check Link....2151
Door Check Link – Removal....2151
Door Check Link – Installation....2152
2.16. Door Trim Panel....2153
Door Trim Panel – Removal....2153
Door Trim Panel – Installation....2154
2.17. Door Vapor Barrier....2155
Door Vapor Barrier – Removal....2155
Door Vapor Barrier – Installation....2155
2.18. Window Slide Block....2156
Window Slide Block – Removal....2156
Window Slide Block – Installation....2157
2.19. Door Glass....2157
Door Glass – Removal....2157
Door Glass – Installation....2159
2.20. Modular Door Hardware Assembly....2160
Modular Door Hardware Assembly – Removal....2160
Modular Door Hardware Assembly – Installation....2163
2.21. Vent Window, Latch, And Seal....2165
Vent Window, Latch, And Seal – Removal....2165
Vent Window, Latch, And Seal – Installation....2166
2.22. Door Lock Cylinder....2167
Door Lock Cylinder – Removal....2167
Door Lock Cylinder – Installation....2168
2.23. Window Electric Motor....2169
Window Electric Motor – Removal....2169
Window Electric Motor – Installation....2169
2.24. Regulator Arm Assembly....2170
Regulator Arm Assembly – Removal....2170
Regulator Arm Assembly – Installation....2174
2.25. Outer Door Handle....2175
Outer Door Handle – Removal....2175
Outer Door Handle – Installation....2177
2.26. Door Latch....2178
Door Latch – Removal....2178
Door Latch – Installation....2179
2.27. Inner Door Handle....2179
Inner Door Handle – Removal....2179
Inner Door Handle – Installation....2180
2.28. Window Run Channels....2181
Window Run Channels – Removal....2181
Window Run Channels – Installation....2183
2.29. Electric Window And Door Lock Switch....2184
Electric Window And Door Lock Switch – Removal....2184
Electric Window And Door Lock Switch – Installation....2185
2.30. Electric Mirror Switch....2185
Electric Mirror Switch – Removal....2185
Electric Mirror Switch – Installation....2186
2.31. Weather Seals....2186
Weather Seals – Removal....2186
Weather Seals – Installation....2186
2.32. Scuff Plate and Seat Belt Retractor Cover....2187
Scuff Plate and Seat Belt Retractor Cover – Removal....2187
Scuff Plate and Seat Belt Retractor Cover – Installation....2187
2.33. Sunshade....2188
Sunshade – Removal....2188
Sunshade – Installation....2188
2.34. Sun Visor and Clip....2189
Sun Visor and Clip – Removal....2189
Sun Visor and Clip – Installation....2189
2.35. Ignition Switch And Ignition Switch Cylinder....2190
Ignition Switch – Removal....2190
Ignition Switch – Installation....2191
Ignition Switch Cylinder – Removal....2192
Ignition Switch Cylinder – Installation....2193
2.36. INSTRUMENT Panel....2194
Gauge Cluster – Removal....2194
Gauge Cluster – Installation....2195
Instrument Panel – Removal....2195
Instrument Panel – Installation....2198
2.37. Front Seats....2200
Front Seats – Removal....2200
Front Seats – Installation....2201
2.38. Rear Bench Seat....2202
Rear Bench Seat – Removal....2202
Rear Bench Seat – Installation....2202
2.39. Corner and Side Interior Trim Panel....2203
Corner and Side Interior Trim Panel – Removal....2203
Corner and Side Interior Trim Panel – Installation....2203
2.40. Rear Interior Trim Panel....2204
Rear Interior Trim Panel – Removal....2204
Rear Interior Trim Panel – Installation....2204
2.41. Header Console Panel....2205
Header Console Panel – Removal....2205
Header Console Panel – Installation....2209
2.42. Headliner Trim Panel (Standard Cab)....2209
Headliner Trim Panel (Standard Cab) – Removal....2209
Headliner Trim Panel (Standard Cab) – Installation....2211
2.43. Headliner Trim Panel (Extended Cab)....2211
Headliner Trim Panel (Extended Cab) Front – Removal....2211
Headliner Trim Panel (Extended Cab) Front – Installation....2213
Headliner Trim Panel (Extended Cab) Rear – Removal....2214
Headliner Trim Panel (Extended Cab) Rear – Installation....2215
2.44. Engine Cover And Cup Holder....2216
Cup Holder and Ashtray – Removal....2216
Cup Holder and Ashtray – Installation....2216
Engine Cover – Removal....2217
Engine Cover – Installation....2217
2.45. Cab....2217
Initial Procedures Before Cab Removal....2217
Cab – Removal....2220
Cab – Installation....2221
Final Procedures After Cab Installation....2222
2.46. Rear Cab Air Suspension Assembly....2223
Rear Cab Air Suspension Assembly – Removal....2223
Rear Cab Air Suspension Assembly – Installation....2224
2.47. Front Cab Mounting Bushings....2225
Front Cab Mounting Bushings – Removal....2225
Front Cab Mounting Bushings – Installation....2226
2.48. Rear Cab Air Suspension System....2227
Height Control Valve – Removal....2227
Height Control Valve – Installation....2228
Shock Absorber – Removal....2229
Shock Absorber – Installation....2230
Suspension Air Spring (Bag) – Removal....2230
Suspension Air Spring (Bag) – Installation....2232
Lateral Control Rod – Removal....2232
Lateral Control Rod – Installation....2233
Jounce Bumper – Removal....2234
Jounce Bumper – Installation....2234
3. TROUBLESHOOTING....2235
3.1. ELECTRIC WINDSHIELD WIPER MOTOR....2235
3.2. WASHER PUMP MOTOR....2236
3.3. Rear CAB AIR SUSPENSION SYSTEM....2236
4. LUBRICATION....2237
4.1. 4,000 MILES (6,000 km) OR MONTHLY....2237
4.2. AS REQUIRED....2237
5. ADJUSTMENTS....2238
5.1. CAB SQUARING....2238
5.2. CAB DOOR....2239
5.3. Door HINGE....2239
5.4. STRIKER PIN....2240
5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....2241
5.6. Rear Cab Air Suspension....2242
Ride Height....2242
tables....2244
Table 5Torque....2244
0000002601 - 3200, RXT, DuraStar, TranStar, TranStar Natural Gas, WorkStar Series Built May 17, 2010 and Later Electrical Circuit Diagrams (Supersedes S08343)....2246
0000002601 - 3200RXT DuraStar - 4100, 4300, 4400 TranStar Natural Gas (NG), TranStar - 8500, 8600 WorkStar - 7300, 7400, 7500, 7600, 7700 Wiring Diagrams....3283
0000002842 - 3200, DuraStar, TranStar, WorkStar, and RXT Models Built March, 2008 to May 16, 2010 Electrical Circuit Diagrams (Supersedes S08337)....4003
0000002842 - Electrical Circuit Diagrams (2008 to 2010)....4411
0000003922 - DuraStar - 4300, 4400 WorkStar - 7300, 7400, 7500, 7600, 7700 TranStar - 8500, 8600 Electrical Circuit Diagrams - Models Built From November 22, 2010....4811
0000003922 - DuraStar, WorkStar, TranStar Series Models Built From November 22, 2010 Electrical Circuit Diagrams (Supersedes S08353) (Latin America _ Mexico)....5293
0000004041 - 2018-2020 MV Technician Manual (Service and Diagnostic)....5785
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)....6337
toc....6339
Table of Contents....6339
INSTRUCTIONS AND CHARTS (Chapter 1)....6345
2.1. Circuit Number Identification and Location Chart, p. 1....6345
2.2. Circuit Number Identification and Location Chart, p. 2....6346
2.3. Circuit Number Identification and Location Chart, p. 3....6347
2.4. Circuit Number Identification and Location Chart, p. 4....6348
2.5. Circuit Number Identification and Location Chart, p. 5....6349
2.6. NAVPAK/ECM I6 Engine Controller Connector Pin Number Identi....6350
2.7. Circuit Diagram Instructions, p. 7....6351
2.8. Circuit Diagram Instructions, p. 8....6352
2.9. Schematic Symbol Chart, p. 9....6353
2.10. Relay Functions, p. 10....6354
2.11. Lamp Bulb Chart, p. 11....6355
2.12. International V8 and I6 ECM Controller Connectors Pin Numb....6356
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....6357
3.1. Accessory, p. 1....6357
3.2. Battery Feeds, Cab, p. 2....6358
3.3. Battery, p. 3....6359
3.4. 1708 Data Link Chassis, p. 4....6360
3.5. Switch Data Link, p. 5....6361
3.6. Drivetrain 1939 Data Link (Cab), p. 6....6362
3.7. Drivetrain 1939 Data Link (Chassis), p. 7....6363
3.8. Grounds Chassis, p. 8....6364
3.9. Grounds Chassis, p. 9....6365
3.10. Grounds IP, p. 10....6366
3.11. Grounds IP, p. 11....6367
3.12. Ignition Cab, p. 12....6368
3.13. Ignition Cab, p. 13....6369
3.14. Ignition Feeds, Chassis, p. 14....6370
3.15. Start, p. 15....6371
CAB ACCESSORIES (Chapter 3)....6372
4.1. Cigar Lighter and Power Feeds, p. 1....6372
4.2. CB Power, p. 2....6373
4.3. Compass and Temperature Display, p. 3....6374
4.4. Front Doors Windows and Locks (Power), p. 4....6375
4.5. Crew Doors Windows and Locks (Power), p. 5....6376
4.6. Horn, Dual Electric, p. 6....6377
4.7. Mirrors (Heated, Lighted and Power), p. 7....6378
4.8. Radio (Entertainment), Speakers, p. 8....6379
4.9. Windshield Wiper and Washer Pump, p. 9....6380
4.10. 2–Way Radio, p. 10....6381
4.11. Switch Pack, Optional Gauge Pack, p. 11....6382
4.12. Lighted Air Shield, p. 12....6383
4.13. Roof Aux. Load, p. 13....6384
4.14. Satellite Communication Qualcomm-MCT and IMCT Systems, p. ....6385
4.15. Self Contained Air Seat, p. 15....6386
4.16. Digital Clock PTC, p. 16....6387
4.17. Transmission Allison LCT Column Shifter, p. 17....6388
4.18. Heated Seats for 7700 Models Only, p. 18....6389
4.19. Backup Camera, p. 19....6390
4.20. XATA Computer, p. 20....6391
4.21. Keyless Ignition System, p. 21....6392
12V CHARGING + CRANKING SYSTEM (Chapter 4)....6393
5.1. I6 EGR Engines, p. 1....6393
5.2. V8 AVNT Engines, p. 2....6394
5.3. Caterpillar, Cummins ISM Engines, p. 3....6395
5.4. I6 HEUI Engines, p. 4....6396
5.5. Caterpillar Engines, Cummins ISM and with Eaton Ultrashift/....6397
5.6. I6 EGR Engines with Air Start, p. 6....6398
FANS AND ENGINE ACCESSORIES (Chapter 5)....6399
6.1. Fan Wiring, p. 1....6399
6.2. Ether Start, p. 2....6400
6.3. Snow Valve, p. 3....6401
6.4. Fan Wiring, Caterpillar and Cummins, p. 4....6402
ELECTRONIC ENGINES (Chapter 6)....6403
7.1. Electronic Engine Controls, I6–EGR Engines, p. 1....6403
7.2. Electronic Engine Controls, I6-EGR Engine Cruise Control an....6404
7.3. Electronic Engine Controls, (V8–AVNT) Engines, p. 3....6405
7.4. Electronic Engine Controls, V8–AVNT Engine Cruise Control a....6406
7.5. Caterpillar C10, C11, C12, and C13 Engines, p. 5....6407
7.6. Cummins ISM Engine, p. 6....6408
7.7. I6 HEUI Engine, p. 7....6409
7.8. I6 HEUI Engine Cruise Control and Body Builder Connections ....6410
GAUGES WITH AND WITHOUT INTEGRAL WARNING LIGHT (Chapter 7)....6411
8.1. IP/Gauge List, p. 1....6411
8.2. Warning Light List, p. 2....6412
8.3. Warning Lights Controlled by Engine, Transmission, ABS Cont....6413
8.4. Engine Oil Pressure and Temp, Speedometer, Tach, Voltmeter ....6414
8.5. IP/Gauges and Warning Lights — Gauge Cluster, p. 5....6415
8.6. Air Pressure Input Circuit, p. 6....6416
8.7. Axle Temperature, FWD Rear and Rear Axles, Gauge Input Circ....6417
8.8. Fuel Gauge Input Circuit (Single Tank) Differential Lock Wa....6418
8.9. Gauges and Warning Lights — Fuel Filter Restriction and Wat....6419
8.10. Gauges and Warning Lights — Park Brake Light and Transmiss....6420
8.11. Gauges and Warning Lights — Ammeter, p. 11....6421
8.12. Engine Oil Temperature Gauge With Caterpillar, p. 12....6422
8.13. Front Axle Engagement Lamp, p. 13....6423
LIGHTS (Chapter 8)....6424
9.1. Back Up Lights, p. 1....6424
9.2. Light Systems — Clearance, Marker, Park, Tail, Turn and Sto....6425
9.3. Light Systems — Clearance, Marker, Park, Tail, Turn and Sto....6426
9.4. Light Systems — Turn Signal and Stop Switches, p. 4....6427
9.5. Dome Light, Map Light, p. 5....6428
9.6. Dome Light, Map Light (Cont.), p. 6....6429
9.7. Fog Light and Work Light, p. 7....6430
9.8. Headlights, p. 8....6431
9.9. Aux. Headlights, Aux. Park, Aux. Turn, p. 9....6432
9.10. Panel Lights, p. 10....6433
CHASSIS ACCESSORIES (Chapter 9)....6434
10.1. Air Dryer and Heated Drain Valve, p. 1....6434
10.2. Antilock Brake System (ABS), Air, p. 2....6435
10.3. Antilock Brake System (ABS), Air, Traction Control, p. 3....6436
10.4. Antilock Brake System (ABS), Hydraulic, p. 4....6437
10.5. Antilock Brake System (ABS), Hydraulic (Cont.), p. 5....6438
10.6. Antilock Brake System (ABS), Hydraulic (Cont.), p. 6....6439
10.7. Two Speed Axle Switch With Manual Transmission and I6 HEUI....6440
10.8. Brake System, Hydraulic, p. 8....6441
10.9. Fuel Transfer Pump, p. 9....6442
10.10. Back of Cab Body Builder and Trailer Stop, Tail, Marker, ....6443
10.11. Body Builder and Trailer Turns, Center Pin ABS, Center Pi....6444
10.12. Body Builder and Trailer Socket Back of Cab Sockets, p. 1....6445
10.13. Body Builder and Trailer Socket End of Frame (EOF) Socket....6446
10.14. Air Solenoid 4–Way Pack, p. 14....6447
10.15. Remote Power Units, Solenoid Packs, Remote Engine Speed C....6448
10.16. HYD Power Park, p. 16....6449
10.17. Air Suspension, p. 17....6450
10.18. Aux. Trailer, Acc Controlled, p. 18....6451
10.19. Aux. Trailer, Battery Controlled, p. 19....6452
10.20. Lift Axles (Non-Steerable), p. 20....6453
10.21. Lift Axles (Steerable), p. 21....6454
10.22. Air Actuated Park Brake, p. 22....6455
10.23. Antilock Brake System, WABCO Air, p. 23....6456
10.24. Antilock Brake System, WABCO Air, p. 24....6457
10.25. Lift Axles, With Non-Steerable for SS Models, p. 25....6458
10.26. Fuel / Water Separator With 12VDC Fuel Preheater, p. 26....6459
10.27. Electronic Trailer Brake Accommodation, p. 27....6460
10.28. Lectrashift Accommodation, p. 28....6461
10.29. Auxiliary 40 Amp Circuit, p. 29....6462
10.30. Hourmeter, Customer Mounted PTO, p. 30....6463
10.31. Remote Start/ Stop, p. 31....6464
10.32. Lift Axle with 14RAR, p. 32....6465
10.33. Lift Gate, p. 33....6466
10.34. Lift Axle Multiplex, p. 34....6467
TRANSMISSIONS (Chapter 10)....6468
11.1. Allison LCT Transmission or Allison 1000, 2000, 2400, p. 1....6468
11.2. Allison MD Transmission, p. 2....6469
11.3. Allison MD Transmission (WTEC), p. 3....6470
11.4. Allison MD Transmission (Cont.), p. 4....6471
11.5. Transmission, WTEC MD W/Auto Neutral, p. 5....6472
11.6. Eaton Autoshift Transmission, p. 6....6473
11.7. Eaton Autoshift Transmission (Cont.), p. 7....6474
11.8. Eaton Lightning Transmission, p. 8....6475
11.9. Allison HD Transmission, p. 9....6476
11.10. Allison HD Transmission, p. 10....6477
11.11. Allison HD Transmission, p. 11....6478
11.12. Allison HD Transmission With Auto Neutral, p. 12....6479
11.13. Allison HD Transmission With Auto Neutral and with 0013WU....6480
11.14. Allison LCT Transmission (Allison 1000, 2000, 2400) with ....6481
11.15. Transmission Retarder Control Wiring with MD Xmsn, Hard W....6482
11.16. Transmission Retarder Control Wiring with MD Xmsn, Hard W....6483
AIR CONDITIONING (Chapter 11)....6484
12.1. HVAC Systems, p. 1....6484
12.2. Air Conditioning (Only), p. 2....6485
12.3. Autotherm Systems, p. 3....6486
CONNECTOR COMPOSITES (Chapter 12)....6487
13.1. Connector Composites (10M), (71), (72), (345F), p. 1....6487
13.2. Connector Composites (420F), (420M), (520), (521), (522), ....6488
13.3. Connector Composites (1002), (1003), (1010), p. 3....6489
13.4. Connector Composite (1011), p. 4....6490
13.5. Connector Composite (1012), p. 5....6491
13.6. Connector Composite (1013), p. 6....6492
13.7. Connector Composite (1014), p. 7....6493
13.8. Connector Composites (1018), (1019M), (1020M), (1021M), (1....6494
13.9. Connector Composites (1027M, F), (1100), (1101A), (1101), ....6495
13.10. Connector Composites (1104), (1106), (1200), (1210), p. 1....6496
13.11. Connector Composites (1300), (1301), (1400), (1402), (141....6497
13.12. Connector Composites (1553), (1554F), (1555), (1600), (16....6498
13.13. Connector Composites (1652), (1657M), (1658), (1659), (18....6499
13.14. Connector Composites (1804), (1807), (1808), (1809), (181....6500
13.15. Connector Composites (1820), (1822), (1823), (1824), (182....6501
13.16. Connector Composites (1918), (1935), (1920), (2000), (200....6502
13.17. Connector Composites (2006M), (2007F), (2021F), (2021M), ....6503
13.18. Connector Composites (2304M), (2305M), (2306M), (2307F), ....6504
13.19. Connector Composites (2601M, F), (2602M, F), (3000M), (30....6505
13.20. Connector Composites (3204M, F), (3209), (3210M), (3211M)....6506
13.21. Connector Composite (4001), p. 21....6507
13.22. Connector Composite (4002), p. 22....6508
13.23. Connector Composite (4003), p. 23....6509
13.24. Connector Composites (4004), (4007), (4008), p. 24....6510
13.25. Connector Composite (4014), p. 25....6511
13.26. Connector Composite (4014/1700), p. 26....6512
13.27. Connector Composites (4015), (4017), (4018), (4019), (402....6513
13.28. Connector Composites (4024), (4030), (4031), (4032), (403....6514
13.29. Connector Composites (4070), (4071), (4087), (4098), (410....6515
13.30. Connector Composite (4103), p. 30....6516
13.31. Connector Composites (4105), (4111), (4120), (4301), p. 3....6517
13.32. Connector Composites (4305), (4410), (4410B), (4410C), (4....6518
13.33. Connector Composites (4411A), (4411B), (4412), (4415), (4....6519
13.34. Connector Composite (4705), p. 34....6520
13.35. Connector Composites (4810), (4712F), (4820), (4713F), (4....6521
13.36. Connector Composites (4900), (4910), (4950), (4951), p. 3....6522
13.37. Connector Composites (6007), (6011), p. 37....6523
13.38. Connector Composites (6013M), (6014), p. 38....6524
13.39. Connector Composites (6015), (6020), (6021), p. 39....6525
13.40. Connector Composites (6200), (6316), (6323), (6332), (633....6526
13.41. Connector Composites (6550), (6703), (6704), (6708), (710....6527
13.42. Connector Composites (7200), (7202), (7203), p. 42....6528
13.43. Connector Composites (7204), (7205), (7206), (7211), (72....6529
13.44. Connector Composites (7214), (7300), (7301), p. 44....6530
13.45. Connector Composites (7302), (7304), (7305), (7306), (750....6531
13.46. Connector Composites (7603), (7604), (7605), (7606), (760....6532
13.47. Connector Composites (7800), (7801M), (7803), (7900), (79....6533
13.48. Connector Composites (7905), (7906), (8000), (8001), (810....6534
13.49. Connector Composites (8201), (8301), (8310), (8311), (831....6535
13.50. Connector Composites (8503), (8503A), (8505), (8506), (85....6536
13.51. Connector Composites (8700), (8701), (8800), (8801), (880....6537
13.52. Connector Composites (9001), (9002), (9100), (9101), (910....6538
13.53. Connector Composites (9260), (9261), (9262), (9263), (926....6539
13.54. Connector Composites (9405), (9501), (9502), (9503), (950....6540
13.55. Connector Composites (9507), (9508), (9509), (9510), (951....6541
13.56. Connector Composites (9516), (9517), (9518), (9519), p. 5....6542
13.57. Connector Composite (9700), p. 57....6543
13.58. Connector Composite (9700), p. 58....6544
13.59. Connector Composites (9715), (9715A), (9715B), p. 59....6545
13.60. Connector Composites (9716), (9716A), (9716B), p. 60....6546
13.61. Connector Composites (9717A), (9717B), p. 61....6547
13.62. Connector Composites (9718), (9719), (9720), (9733), (973....6548
13.63. Connector Composites (9777), (9778), (9800), p. 63....6549
13.64. Connector Composites (9870), (9871), (9811), (9812), (981....6550
13.65. Connector Composites (9913B), (9914), (4100), (4109), (41....6551
0000019282 - Australian ProStar Technician Manual (Service and Diagnostic)....6552
toc....6554
Table of Contents....6554
Safety Terminology....6557
Safety Instructions....6557
Work Area....6557
Safety Equipment....6557
Protective Measures....6557
Vehicle....6557
Engine....6558
Fire Prevention....6558
Batteries....6558
Compressed Air....6558
Tools....6558
Fluids Under Pressure....6559
Fuel....6559
Removal of Tools, Parts, and Equipment....6559
Frame....6560
1. GENERAL FRAME RECOMMENDATIONS....6562
DRILLING OR NOTCHING....6562
WELDING OR FLAME CUTTING....6562
REINFORCEMENT TO INCREASE CAPACITY....6562
INCREASE IN LOCAL STRESS....6562
2. 2. IDENTIFICATION OF FRAME RAIL MATERIAL....6563
3. 3. FRAME DAMAGE....6563
4. WELDING AND REINFORCEMENT....6564
WELDING PRECAUTIONS....6564
REINFORCEMENT....6565
REINFORCEMENT ATTACHMENT....6565
5. 5. CORROSION....6566
6. FRAME ALIGNMENT....6566
PRE-ALIGNMENT INSPECTION....6566
METHOD OF CHECKING FRAME ALIGNMENT....6566
Method of Checking....6567
Side Elevation Dimensions....6567
AXLE ALIGNMENT WITH FRAME....6568
FRAME STRAIGHTENING....6568
7. REPAIR AND REINFORCEMENT....6568
PREPARATION OF FRAME FOR REPAIR....6568
Bevel Crack to Weld....6568
Clean Surface to Weld....6569
WELDING....6569
General Recommendations....6569
All Steel Sidemembers....6569
Mild Steel Frames (36,000 PSI Yield Strength)....6570
High Strength Low Alloy Steel Frames (50,000, 60,000 and 80,000 PSI Yield Strength....6571
Heat Treated Frames (120,000 PSI Yield Strength)....6572
REINFORCEMENT....6573
GENERAL WELD REPAIR REINFORCEMENT PROCEDURES....6575
FULL LENGTH CHANNEL WELD REPAIR REINFORCEMENTS....6575
Recommended Applications....6575
FULL LENGTH "L" WELD REPAIR REINFORCEMENTS....6576
Recommended Applications....6576
Application Procedures....6576
LOCAL CHANNEL WELD REPAIR REINFORCEMENTS....6576
Recommended Applications....6576
Application Procedures....6576
LOCAL "L" OR INVERTED "L" WELD REPAIR REINFORCEMENTS....6576
Recommended Applications....6576
Application Procedures....6577
FLAT PLATE WELD REPAIR REINFORCEMENTS....6577
Recommended Applications....6577
Application Procedures....6577
8. BOLT AND TORQUE INFORMATION....6577
HUCKBOLT FASTENERS (HP 8)....6578
Removal....6579
Installation....6579
HUCK-SPIN® fasteners....6581
Description....6581
Removal....6582
Installation....6585
Huck-spin® 2 fasteners....6585
Description....6585
Removal....6586
Installation....6589
9. DRILLING....6589
HOLE LOCATION GUIDELINES....6589
10. AFTERMARKET MODIFICATIONS....6595
ALUMINUM SIDEMEMBERS OR CROSSMEMBERS....6595
11. 11. WHEELBASE ALTERATIONS....6595
Front Axle....6600
1. Non-Driving Axle....6602
Meritor....6602
Overview....6602
Front Suspension....6604
1. Suspension....6606
Parabolic Taper Leaf Spring....6606
Overview....6606
Tech Tips....6608
Brakes....6610
1. Description....6612
Air Pressure Gauges....6613
Low-Pressure Indicator....6613
Stop Light Switch....6613
Foot VALVE....6613
Quick Release Valve....6613
MANIFOLD Valve (MV-3)....6613
Tractor Protection Valve....6613
Relay Valve AND ANTILOCK TRACTION RELAY VALVE (R-12™ AND ATR-6™)....6613
Antilock modulator Valve (M-32™ AND M-32QR™)....6614
Spring Brake Modulating Valve....6614
Hand Control Valve....6614
Air Dryer ....6615
SOLENOID PACK....6615
RESERVOIR....6615
AIR LINES....6615
Test valves....6615
Valve Silencer....6615
2. 4-Channel with Automatic Traction Control....6617
Overview....6617
Reservoir....6619
Reservoir – Removal....6619
Reservoir – Installation....6620
Foot Valve....6621
Foot Valve – Removal....6621
Foot Valve – Installation....6622
Quick Release Valve ....6623
Quick Release Valve – Removal....6623
Quick Release Valve – Installation....6623
Manifold Valve ....6624
Manifold Valve – Removal....6624
Manifold Valve – Installation....6624
Tractor Protection Valve ....6625
Tractor Protection Valve – Removal....6625
Tractor Protection Valve – Installation....6625
Relay Valve(R-12™ AND ATR-6™)....6626
ATR-6™ Antilock Traction Relay Valve – Removal....6626
ATR-6™ Antilock Traction Relay Valve – Installation....6628
Antilock modulator Valve (M-32™ AND M-32QR™)....6629
M-32™ Antilock Modulator Valve – Removal....6629
M-32™ Antilock Modulator Valve – Installation....6630
Hand Control Valve ....6631
Hand Control Valve – Removal....6631
Hand Control Valve – Installation....6632
Air Dryer ....6633
Overview....6633
Air Dryer – Removal....6634
Air Dryer – Installation....6635
Slack Adjusters....6636
Front Axle....6636
Overview....6636
Service Information....6637
Rear Axle....6637
Overview....6637
Service Information....6638
Spring Brake Modulating Valve ....6639
Spring Brake Modulating Valve – Removal....6639
Spring Brake Modulating Valve – Installation....6639
Solenoid Pack....6640
Solenoid Pack – Removal....6640
Solenoid Pack – Installation....6640
Pressure Switches....6641
Pressure Switches – Removal....6641
Pressure Switches – Installation....6641
Air Tank....6641
Overview....6641
3. Air Compressor....6643
Cummins® 18.7 CFM....6643
Overview....6643
Steering....6646
1. Description....6648
Steering Wheel....6648
Clock Spring....6648
Steering Column....6649
2. Removal and Installation....6650
Steering Wheel....6651
Steering Wheel – Removal....6651
Steering Wheel – Installation....6654
Clock Spring....6655
Clock Spring – Removal....6655
Clock Spring – Installation....6659
Steering Column....6660
Steering Column – Removal....6660
Steering Column – Installation....6662
3. Checks and Adjustments....6663
Steering Wheel....6663
Steering Wheel – Check....6663
Steering Wheel – Adjust....6663
4. Power Steering Gear: Sheppard M-Series....6664
Identification....6664
Operation....6667
OIL FLOW THROUGH THE GEAR....6668
Steering System Diagnostics....6670
Diagnostic Overview....6670
Define the Concern....6670
Perform Visual Inspection....6670
Inspect Mechanical Components....6670
Hydraulic Diagnosis....6670
Oil Flow and Pressure Recommendations....6673
Common Complaints....6673
Troubleshooting....6676
Symptoms Table....6676
Re-phasing Column....6679
Troubleshooting Checklist....6680
Preventative Maintenance....6681
Fluid and Filter Change....6681
Input Shaft Seal Replacement — Disassembly....6683
Input Shaft Seal Replacement — Assembly....6687
Bleeding....6690
Single Gear System....6690
Dual Steering Gears....6692
Set Relief Plungers....6695
Pitman Arm....6696
Remove....6696
Install....6698
Steering Gear Disassembly....6705
Sub-assembly Repair....6720
M-SERIES - OPTIONAL INTEGRAL RELIEF VALVE....6720
Clean....6722
Inspect....6723
Parts Discolored (Blue)....6723
Broken Housing....6723
Housing or Piston Scoring....6723
Sector Shaft Roller (Bearing Wear)....6723
Actuating Shaft....6724
Thrust Bearings....6724
Actuating Shaft Thread Wear....6724
Piston Rings Cut, Pinched, Sheered or Worn....6724
Reassemble....6725
Dual Steering System....6741
Description....6741
Operation....6741
Integral Slave Gear....6744
Adjustments....6746
Final....6746
Axle Stop....6746
Specifications....6747
Torque....6748
Special Tools....6749
Glossary of Terms and Definitions....6750
Drivelines....6754
1. Propeller Shaft....6756
Overview....6757
Universal Joints....6758
Overview....6758
Slip Joint....6759
Overview....6759
Center (Carrier) Bearing....6760
Overview....6760
Maintenance....6761
Service Checks....6761
Remove....6764
Equipment Conditions....6764
Full Round End Yokes....6764
Half Round End Yokes....6766
Center (Carrier) Bearing....6766
Disassemble....6767
Slip Joint....6767
Outside / Inside Snap Ring Yoke Universal Joint....6767
Full Round Yoke Universal Joint....6769
Center (Carrier) Bearing....6770
Clean and Inspect....6771
Inspect Cross Bearing and End Surfaces....6771
Inspect Full Round Yoke....6772
Inspect Half Round Yoke....6773
Assembly....6774
Overview....6774
Slip Joint....6774
Snap Ring Yoke Universal Joint....6774
Full Round Yoke Universal Joint....6777
Center (Carrier) Bearing....6779
Installation....6780
Full Round End Yokes....6780
Half Round End Yokes....6783
Center (Carrier) Bearing....6785
Vibration....6786
Overview....6786
Possible Causes....6786
Types of Vibration....6787
Overview....6787
Possible Causes....6787
Transverse Vibration....6788
Overview....6788
Torsional Vibration....6789
Overview....6789
Checking Propeller Shaft Runout (Propeller Shaft Installed)....6790
Overview....6790
Equipment Conditions....6790
Propeller Shaft Phasing....6791
Overview....6791
Balancing Propeller Shaft....6792
Overview....6792
Rephasing Propeller Shaft....6793
Equipment Conditions....6793
Adding Weight to Propeller Shaft....6794
Checking Driveline Angles....6796
Overview....6796
Driveline Angle Measurement....6796
Equipment Conditions....6796
Joint Working Angle Cancellation....6801
Overview....6801
How JWA's Change with Load....6801
Overview....6801
Troubleshooting....6803
Troubleshooting Chart....6803
Lubrication....6805
Universal Joint....6805
Overview....6805
Slip Joint....6806
Overview....6806
Torque....6807
Special Tools....6808
Exhaust....6810
1. Horizontal with Vertical Tips....6812
Overview....6812
2. Engine Compression Brake....6813
Cummins Engine Compression Brake....6813
Overview....6813
Electrical / Software....6814
1. Electronic Service Tools (EST)....6824
Diamond Logic® Builder....6824
Overview....6824
Selecting an Interface Cable....6826
Overview....6826
Special Tools....6826
Equipment Conditions....6826
Selection Procedure....6826
Follow-On Procedure....6827
Connecting to a Vehicle....6828
Overview....6828
Special Tools....6828
Equipment Conditions....6828
Connection Procedure....6828
Follow-On Procedure....6829
Activating Diagnostic Mode....6830
Overview....6830
Special Tools....6830
Equipment Conditions....6830
Activation Procedure....6830
Follow-On Procedure....6831
Starting a Session....6832
Overview....6832
Special Tools....6832
Equipment Conditions....6832
Starting Procedure....6832
Follow-On Procedure....6833
Viewing Fault Codes....6834
Overview....6834
Special Tools....6834
Equipment Conditions....6834
Viewing Procedure....6834
Follow-On Procedure....6834
Clearing Fault Codes....6835
Overview....6835
Special Tools....6835
Equipment Conditions....6835
Clearing Procedure....6835
Follow-On Procedure....6835
Modifying Signals Tab....6836
Overview....6836
Special Tools....6836
Equipment Conditions....6836
Modify Watched Signal Columns....6836
Modify Watched Signals....6837
Follow-On Procedure....6837
Programming Modules....6838
Overview....6838
Special Tools....6838
Equipment Conditions....6838
Programming Procedure....6839
Follow-On Procedure....6842
Input Not Recognized by Body Control Module....6843
Overview....6843
Special Tools....6843
Equipment Conditions....6843
Troubleshooting Procedure....6843
Follow-On Procedure....6844
Output Not Commanded by Body Control Module....6845
Overview....6845
Special Tools....6845
Equipment Conditions....6845
Troubleshooting Procedure....6845
Follow-On Procedure....6846
2. General Electrical Repair....6847
Electrical Connector Cleaning....6847
Overview....6847
Special Tools....6847
Specifications....6847
Equipment Conditions....6847
Cleaning Procedure....6847
Follow-On Procedure....6847
3. 12 Volt Electrical System....6848
Battery Box....6848
Overview....6848
Battery Disconnect....6851
Overview....6851
Special Tools....6851
Equipment Conditions....6851
Disconnect Procedure....6851
Follow-On Procedure....6852
Battery Reconnect....6853
Overview....6853
Special Tools....6853
Equipment Conditions....6853
Reconnect Procedure....6854
Follow-On Procedure....6854
Battery Terminal Cleaning....6855
Overview....6855
Special Tools....6855
Equipment Conditions....6855
Cleaning Procedure....6856
Follow-On Procedure....6856
Starting and Charging....6857
Overview....6857
Operational Checkout Procedure....6858
Electrical System Operational Checkout Procedure....6858
Starting System....6859
Overview....6859
Battery Pack....6859
Starter....6859
Control....6859
No Click No Crank....6860
Overview....6860
Possible Causes....6860
Click No Crank....6862
Overview....6862
Possible Causes....6862
Low Cranking Speed....6864
Overview....6864
Possible Causes....6864
250K Input Diagnostics....6865
Overview....6865
Manual Transmission Starter Input Diagnostics....6866
Manual Transmission Start Input Pinpoint Tests....6869
Tools Required....6869
Automatic Transmission Starter Input Diagnostics....6877
Automatic Transmission Starter Input Pinpoint Tests....6879
Tools Required....6879
500K Input Diagnostics....6882
Overview....6882
Key Switch and Grid Control....6882
Crank Inhibit....6882
GridCtrl_CrankInhibit....6882
Crank_Inhibit_Reason....6883
Lower_Clutch_Signal....6883
Neutral_Status_TCM....6883
Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal)....6883
Hood_Switch....6883
500K Input Operational Checkout Procedure....6885
Overview....6885
Charging System....6889
Overview....6889
Battery Pack....6889
Alternator....6889
Red Battery Warning Light....6890
Overview....6890
Possible Causes....6890
Repeated Jump Starts....6892
Overview....6892
Possible Causes....6892
Battery Gauge Reading High....6894
Overview....6894
Possible Causes....6894
Battery Gauge Reading Low / Fluctuating....6895
Overview....6895
Possible Causes....6895
Tests and Inspections....6897
Battery Test....6897
Overview....6897
Tools Required....6897
Equipment Condition....6897
Test Setup....6897
Test Procedure....6897
Expected Outcome....6898
Follow-On Procedure....6899
Electrical System Test....6900
Overview....6900
Tools Required....6900
Equipment Condition....6900
Test Setup....6900
Test Procedure....6900
Starter System Test Procedure....6903
Charging System Test Procedure....6904
Expected Outcome....6905
Follow-On Procedure....6905
Cable Drop Test....6906
Overview....6906
Tools Required....6906
Equipment Condition....6906
Test Setup....6906
Test Procedure....6906
Expected Outcome....6907
Follow-On Procedure....6907
Parasitic Draw Test....6908
Overview....6908
Tools Required....6908
Equipment Condition....6908
Test Setup....6908
Test Procedure....6909
Expected Outcome....6911
Follow-On Procedure....6911
Manual Engine Bar Test....6912
Overview....6912
Tools Required....6912
Equipment Condition....6912
Test Setup....6912
Test Procedure....6912
Expected Outcome....6912
Follow-On Procedure....6912
Starter Control Circuit Test....6913
Overview....6913
Tools Required....6913
Equipment Condition....6913
Test Setup....6913
Test Procedure....6913
Expected Outcome....6913
Follow-On Procedure....6914
Ring Gear Inspection....6915
Overview....6915
Tools Required....6915
Equipment Condition....6915
Inspection Procedure....6915
Expected Outcome....6916
Follow-On Procedure....6916
Electrical System Inspection....6917
Overview....6917
Tools Required....6917
Equipment Condition....6917
Inspection Procedure....6917
Expected Outcome....6917
Follow-On Procedure....6917
Auto Start Stop....6918
With Switch Control....6918
Overview....6918
Operational Checkout Procedure....6920
Overview....6920
Remote Start Stop....6922
Overview....6922
500K....6924
Overview....6924
Operational Checkout Procedure....6925
Overview....6925
Not Operating with 500K....6926
Fault Overview....6926
Fault Facts....6926
Possible Causes....6926
Pin-Point Test - Remote Start / Stop Not Operating with 500K....6932
Tools Required....6932
250K....6933
Overview....6933
Operational Checkout Procedure....6935
Cooper Bussmann Inverter....6936
Overview....6936
Overview....6936
Inverter Diagnostics....6936
Operational Checkout Procedure....6938
Diagnostic Steps....6938
Inverter Inoperative....6940
Symptom Overview....6940
Symptom Facts....6940
Possible Causes....6940
Diagnostic Steps....6941
Pin-Point Test - Inverter Inoperative....6942
Tools Required....6942
E01 – DC Input Under-Voltage Shutdown....6944
Fault Code Overview....6944
Fault Facts....6944
Possible Causes....6944
Diagnostic Steps....6945
Pin-Point Test - E01....6946
Tools Required....6946
E02 – DC Input Over-Voltage Shutdown....6948
Fault Code Overview....6948
Fault Facts....6948
Possible Causes....6948
Diagnostic Steps....6949
Pin-Point Test - E02....6950
Tools Required....6950
E03 – Inverter Output Overload....6951
Fault Code Overview....6951
Fault Facts....6951
Possible Causes....6951
Diagnostic Steps....6952
E04 – Inverter Over-Temperature Shutdown....6953
Fault Code Overview....6953
Fault Facts....6953
Possible Causes....6953
Diagnostic Steps....6954
E05 – DC Input Under-Voltage Warning....6955
Fault Code Overview....6955
Fault Facts....6955
Possible Causes....6955
Diagnostic Steps....6956
Pin-Point Test - E05....6957
Tools Required....6957
E06 – Inverter Output Overload Warning....6959
Fault Code Overview....6959
Fault Facts....6959
Possible Causes....6959
Diagnostic Steps....6960
E07 – Inverter Over-Temperature Warning....6961
Fault Code Overview....6961
Fault Facts....6961
Possible Causes....6961
Diagnostic Steps....6962
E10 – Charger Output Over-Voltage Shutdown....6963
Fault Code Overview....6963
Fault Facts....6963
Possible Causes....6963
Diagnostic Steps....6964
E11 – Battery Not Accepting Charge....6965
Fault Code Overview....6965
Fault Facts....6965
Possible Causes....6965
Diagnostic Steps....6966
Pin-Point Test - E11....6967
Tools Required....6967
E12 – Transfer Relay Over-Temperature Shutdown....6969
Fault Code Overview....6969
Fault Facts....6969
Possible Causes....6969
Diagnostic Steps....6970
4. Accessories....6971
Steering Wheel Switches....6971
Overview....6971
Tests....6974
Cruise Control Steering Wheel Switch Circuit Test....6974
Pin-Point Tests - Cruise Control Steering Wheel Switch....6976
Tools Required....6976
Multiplexed Steering Wheel Switch Circuit Test....6980
Pin-Point Tests - Multiplexed Steering Wheel Switch....6982
Tools Required....6982
Radio Control Steering Wheel Switch Circuit Test....6986
Pin-Point Tests - Radio Control Steering Wheel Switch....6988
Tools Required....6988
5. Data Links....6992
500k....6992
Overview....6992
500K Diagnostic Connector Overview....6992
J1939 Public Bus....6994
Overview....6994
J1939 Bus Faults....6994
Bus open on the backbone....6995
Bus open or loss of power to an individual module....6995
Bus short....6996
J1939 Public communication bus....6996
J1939 Communication Faults with Navistar Launcher....7000
Overview....7000
Associated Symptoms....7000
Fault Facts....7000
J1939 Public Bus Operational Check....7002
Overview....7002
J1939 Bus Integrity Checks....7003
Overview....7003
J1939 Diagnostics – Bus Open....7004
Overview....7004
J1939 Public bus diagnostics - Open in IP Harness....7009
J1939 Public bus diagnostics - Open in Forward Chassis Harness....7014
J1939 Diagnostics- Bus inactive....7019
J1939 Center IP diagnostics – SP1024....7022
J1939 Center IP Diagnostics - SP1025....7026
J1939 Center IP diagnostics — SP1026....7030
J1939 Right IP Harness diagnostics....7033
J1939 Left IP Harness Module Diagnostics....7035
J1939 Forward / Center Chassis Module Diagnostics....7037
J1939 Powertrain harness diagnostics — Navistar engine....7039
J1939 Powertrain harness diagnostics — Cummins engine....7041
6. HVAC....7042
On-Highway HVAC System....7042
Front HVAC System (Day Cab)....7042
Overview....7042
Air Distribution (General)....7044
Air Distribution (Air Conditioning)....7046
Air Distribution (Heat and Ventilation)....7047
Air Distribution (Defrost)....7047
A/C Refrigerant Flow....7048
General Operation of the HVAC Electrical System....7050
Operational Checkout Procedure....7051
1.0 – Front HVAC System Operational Checkout Procedure....7051
Symptoms....7054
1.1 – A/C Blows Warm All the Time (Incorrect System Pressure)....7054
Overview....7054
Possible Causes....7054
1.2 – Heater Does Not Blow Warm....7058
1.3 – Compressor Does Not Cycle....7059
Overview....7059
Possible Causes....7059
1.4 – Operator Not Able to Control Air Flow Outlet....7062
Overview....7062
Rear HVAC System (Sleeper)....7066
Overview....7066
Rear Air Distribution (General)....7069
Rear Air Distribution (Air Conditioning)....7070
Rear Air Distribution (Heat)....7070
A/C Refrigerant Flow – Sleeper A/C System....7071
Electrical Overview....7073
General Operation of the Rear HVAC Electrical System....7073
Operational Checkout Procedure....7074
2.0 – Rear A/C System Operational Checkout Procedure....7074
Symptoms....7076
2.1 – A/C Blows Warm All the Time....7076
2.2 – Heater Does Not Blow Warm....7077
2.3 – Dash Switches Don’t Control Rear A/C....7078
Overview....7078
Possible Causes....7078
2.4 – Operator Not Able to Control Air Flow Outlet....7081
2.5 – Operator Not Able to Control Rear HVAC from Rear Controls....7082
Overview....7082
Possible Causes....7082
Special Tools....7085
A/C System Flush Tool 19-000-01....7085
Servicing System RHS980C-NAV....7086
RHS980C-NAV TEMPERATURE PROBES....7087
REFRIGERANT IDENTIFIER ....7087
Air Conditioning Oil and Dye Injection Equipment 12401-NAV....7088
D-400A AND D440A-NAV REFRIGERANT LEAK DETECTORS....7089
TOOLS OBTAINED LOCALLY....7090
Fault Codes....7091
SPN 876 FMI 5 – Compressor Clutch Circuit....7091
Fault Overview....7091
Associated Faults....7091
Fault Facts....7091
Possible Causes....7091
SPN 1552 FMI 2 – A/C Control Head Temperature Mix DM1....7092
Fault Overview....7092
Associated Faults....7092
Fault Facts....7092
Possible Causes....7092
Pin-Point Test SPN 1552 FMI 2....7093
Tools Required....7093
SPN 2058 FMI 9 – Rear A/C Data Link Communication Failure....7094
Fault Overview....7094
Associated Faults....7094
Fault Facts....7094
Possible Causes....7094
Pin-Point Test SPN 2058 FMI 9....7096
Tools Required....7096
SPN 2058 FMI 14 – Rear A/C Data Link Communication Failure....7101
Fault Overview....7101
Associated Faults....7101
Fault Facts....7101
Possible Causes....7101
Pin-Point Test SPN 2058 FMI 14....7103
Tools Required....7103
SPN 2609 FMI 15 – Low Charge Protection....7108
Fault Overview....7108
Associated Faults....7108
Fault Facts....7108
Possible Causes....7108
SPN 2609 FMI 16 – A/C High Pressure Protection....7110
Fault Overview....7110
Associated Faults....7110
Fault Facts....7110
Possible Causes....7110
SPN 3981 FMI 2 – A/C Control Head Mode Fault DM1....7113
Fault Overview....7113
Associated Faults....7113
Fault Facts....7113
Possible Causes....7113
Pin-Point Test SPN 3981 FMI 2....7114
Tools Required....7114
SPN 3982 FMI 2 – A/C Rear Blower Speed Control Switch Error....7115
Fault Overview....7115
Associated Faults....7115
Fault Facts....7115
Possible Causes....7115
SPN 3983 FMI 2 – Rear A/C Temperature Control Switch Error....7116
Fault Overview....7116
Associated Faults....7116
Fault Facts....7116
Possible Causes....7116
SPN 3984 FMI 2 – A/C Control Head Air Inlet DM1....7117
Fault Overview....7117
Associated Faults....7117
Fault Facts....7117
Possible Causes....7117
Pin-Point Test SPN 3984 FMI 2....7118
Tools Required....7118
SPN 3985 FMI 9 – A/C Control Head Circuit Failed To Communicate With Body Controller....7119
Fault Overview....7119
Associated Faults....7119
Fault Facts....7119
Possible Causes....7119
Pin-Point Test SPN 3985 FMI 9....7120
Tools Required....7120
SPN 520465 FMI 2 – A/C Control Head Multiple Motor Faults....7122
Fault Overview....7122
Associated Faults....7122
Fault Facts....7122
Possible Causes....7122
Pin-Point Test SPN 520465 FMI 2....7125
Tools Required....7125
Tests and Inspections....7128
A/C Compressor Clutch Electrical Tests....7128
Overview....7128
Tools Required....7128
Equipment Condition....7128
Test Setup....7128
Test Procedure....7128
Expected Outcome....7131
Follow On Procedure....7131
A/C Request Electrical Tests....7132
Overview....7132
Tools Required....7132
Equipment Condition....7132
Test Setup....7132
Test Procedure....7132
Expected Outcome....7133
Follow-On Procedure....7133
A/C System Internal Damage Inspection....7134
Overview....7134
Tools Required....7134
Equipment Condition....7134
Inspection Procedure....7134
Expected Outcome....7137
A/C System Inspection....7138
Overview....7138
Tools Required....7138
Equipment Condition....7138
Inspection Procedure....7139
Expected Outcome....7146
A/C System Restriction Test....7147
Overview....7147
Tools Required....7147
Equipment Condition....7147
Test Setup....7147
Test Procedure....7147
Expected Outcome....7148
Blend Door Tests....7149
Overview....7149
Tools Required....7149
Equipment Condition....7149
Test Setup....7149
Test Procedure....7150
Expected Outcome....7153
Follow On Procedure....7153
Blower Switch Electrical Tests....7154
Overview....7154
Tools Required....7154
Equipment Condition....7154
Test Setup....7154
Test Procedure....7154
Expected Outcome....7155
Blower Motor Electrical Tests....7156
Overview....7156
Tools Required....7156
Equipment Condition....7156
Test Setup....7156
Test Procedure....7156
Expected Outcome....7159
Follow On Procedure....7159
Body Controller Power and GND Tests....7160
Overview....7160
Tools Required....7160
Equipment Condition....7160
Test Setup....7160
Test Procedure....7160
Expected Outcome....7160
Follow On Procedure....7161
Charge Quantity Measurement Test....7162
Overview....7162
Tools Required....7162
Equipment Condition....7162
Test Setup....7162
Test Procedure....7162
Expected Outcome....7162
Compressor Clutch Signal Check....7163
Overview....7163
Tools Required....7163
Equipment Condition....7163
Test Setup....7163
Test Procedure....7164
Expected Outcome....7166
Follow On Procedure....7166
Control Head Electrical Tests....7167
Overview....7167
Tools Required....7167
Equipment Condition....7167
Test Setup....7167
Test Procedure....7167
Expected Outcome....7169
Follow On Procedure....7169
Freeze Probe Electrical Tests....7170
Overview....7170
Tools Required....7170
Equipment Condition....7170
Test Setup....7170
Test Procedure....7170
Expected Outcome....7172
Follow On Procedure....7172
Front A/C System Functional Test....7173
Overview....7173
Tools Required....7173
Equipment Condition....7173
Test Setup....7173
Test Procedure....7173
Expected Outcome....7173
Follow On Procedure....7173
Heater Core Seal Leak Test....7174
Overview....7174
Tools Required....7174
Equipment Condition....7174
Test Setup....7174
Test Procedure....7175
Expected Outcome....7176
Follow On Procedure....7176
HVAC Actuator Calibration Procedure....7177
Overview....7177
Tools Required....7177
Equipment Condition....7177
Test Setup....7177
Test Procedure....7177
Expected Outcome....7177
HVAC Module Inspection....7178
Overview....7178
Tools Required....7178
Equipment Condition....7178
Test Setup....7178
Inspection Procedure....7178
Expected Outcome....7180
Leak Detection Test....7181
Overview....7181
Tools Required....7181
Equipment Condition....7181
Test Procedure Refrigerant Present....7181
Test Procedure No Refrigerant Present....7182
Test Procedure No Refrigerant Present - High Pressure Nitrogen....7183
Expected Outcome....7184
Low-Pressure Switch Electrical Tests....7185
Overview....7185
Tools Required....7185
Equipment Condition....7185
Test Setup....7185
Test Procedure....7185
Expected Outcome....7187
Follow On Procedure....7187
Mode Door Tests....7188
Overview....7188
Tools Required....7188
Equipment Condition....7188
Test Setup....7188
Test Procedure....7189
Expected Outcome....7192
Follow On Procedure....7192
Pressure Transducer Electrical Tests....7193
Overview....7193
Tools Required....7193
Equipment Condition....7193
Four-wire Pressure Reading Test Procedure....7194
Four-wire Temperature Reading Test Procedure....7197
Three-wire Pressure Transducer Test Procedure....7198
Expected Outcome....7200
Pressure Transducer Functional Test....7201
Overview....7201
Tools Required....7201
Equipment Condition....7201
Test Setup....7201
Pressure Test Procedure....7201
Temperature Test Procedure....7201
Expected Outcome....7202
Rear A/C Electrical System Inspection....7203
Overview....7203
Tools Required....7203
Equipment Condition....7203
Inspection Procedure....7203
Expected Outcome....7204
Rear A/C Input Check....7205
Overview....7205
Tools Required....7205
Equipment Condition....7205
Test Setup....7205
Test Procedure....7205
Expected Outcome....7207
Follow On Procedure....7207
Rear A/C System Functional Test....7208
Overview....7208
Tools Required....7208
Equipment Condition....7208
Test Setup....7208
Test Procedure....7208
Expected Outcome....7209
Follow-On Procedure....7209
Rear Blend Door Electrical Checks....7210
Overview....7210
Tools Required....7210
Equipment Condition....7210
Test Setup....7210
Test Procuedure....7210
Expected Outcome....7212
Rear Blend Door Movement Test....7213
Overview....7213
Tools Required....7213
Equipment Condition....7213
Test Setup....7213
Test Procedure....7213
Expected Outcome....7213
Rear Blower Motor Electrical Test....7214
Overview....7214
Tools Required....7214
Equipment Condition....7214
Test Setup....7214
Test Procedure....7214
Expected Outcome....7217
Rear HVAC Controller Electrical Test....7218
Overview....7218
Tools Required....7218
Equipment Condition....7218
Test Setup....7218
Test Procedure....7218
Expected Outcome....7220
Recirculation Door Tests....7221
Overview....7221
Tools Required....7221
Equipment Condition....7221
Test Setup....7221
Test Procedure....7222
Expected Outcome....7225
Follow On Procedure....7225
Refrigerant Identification....7226
Overview....7226
Tools Required....7226
Equipment Condition....7226
Test Setup....7226
Test Procedure....7226
Expected Outcome....7226
Follow-On Procedure....7226
Static Pressure Test....7227
Overview....7227
Tools Required....7227
Equipment Condition....7227
Test Setup....7227
Test Procedure....7227
Expected Outcome....7228
Follow On Procedure....7228
Switch Pack Electrical Tests....7229
Overview....7229
Tools Required....7229
Equipment Condition....7229
Test Setup....7229
Test Procedure....7229
Expected Outcome....7232
Follow On Procedure....7232
System Performance Test....7233
Overview....7233
Tools Required....7233
Equipment Condition....7233
Test Setup....7233
Test Procedure....7233
Expected Outcome....7234
Follow-On Procedure....7234
Temperature Switch Electrical Tests....7235
Overview....7235
Tools Required....7235
Equipment Condition....7235
Test Setup....7235
Test Procedure....7235
Expected Outcome....7238
Flush HVAC System....7239
Overview....7239
Tools Required....7244
Equipment Conditions....7248
Flush Procedure....7249
Refrigerant Line Flush....7256
Purge HVAC System....7257
Overview....7257
Purge Procedure....7258
Service Procedures....7259
Automatic Mode....7259
Charging the System (Charge Mode)....7261
Equipment Conditions....7261
Checking Compressor Oil Level....7262
Discharging the System (Recycle Mode)....7265
Evacuating the System (Vacuum Mode)....7267
Oil Fill Guidelines....7269
Oil Separation During Refrigerant Recovery....7270
Excessive Oil Loss Due to Refrigerant Leaks....7271
Removal and Installation....7273
A/C Condenser – Removal....7273
A/C Hose Assembly — Rear HVAC – Removal....7274
A/C Hose Assembly – Rear HVAC Installation....7275
Analog Controls – Installation....7276
Blend Door Actuator – Removal....7277
Blend Door Actuator – Installation....7278
Blend Door Actuator — Rear HVAC – Removal....7279
Blend Door Actuator — Rear HVAC – Removal....7282
Blend Door Gear Train – Removal....7283
Blend Door Gear Train – Installation....7286
Blower — Rear HVAC – Removal....7287
Blower – Rear HVAC Installation....7288
Blower Assembly – Removal....7289
Blower Assembly – Installation....7290
Blower Scroll Housing – Removal....7291
Blower Scroll Housing – Installation....7292
Compressor / Clutch – Removal....7293
Compressor / Clutch – Installation....7294
Digital Controls – Installation....7295
Evaporator – Removal....7296
Evaporator – Installation....7297
Evaporator Core — Rear HVAC – Removal....7298
Evaporator Core – Rear HVAC Installation....7301
Filter-Drier – Removal....7303
Filter-Drier – Installation....7305
Filter Element — Rear HVAC – Removal....7306
Filter Element – Rear HVAC Installation....7307
Freeze Probe – Removal....7308
Freeze Probe – Installation....7309
Fresh Air Module – Removal....7310
Fresh Air Module – Installation....7312
Front HVAC Module – Removal....7313
Heater Core – Removal....7319
Heater Core – Installation....7321
Heater Core — Rear HVAC – Removal....7322
Heater Core – Rear HVAC Installation....7324
Heater Hoses / Lines....7325
Heater Hose Assembly — Rear HVAC – Removal....7326
Heater Hose Assembly – Rear HVAC Installation....7327
HVAC Air Filter – Removal....7328
HVAC Air Filter – Installation....7329
HVAC Control Panel Assembly – Removal....7330
HVAC Control Panel Assembly – Installation....7331
Interior Module – Installation....7332
Interior Module Trim Cover – Removal....7334
Interior Module Trim Cover – Installation....7335
Linear Power Module (LPM) – Removal....7336
Linear Power Module (LPM) – Installation....7338
Linear Power Module (LPM) — Rear HVAC – Removal....7339
Linear Power Module (LPM) – Rear HVAC - Installation....7340
Low Pressure Switch – Removal....7341
Low Pressure Switch – Installation....7342
Mode Door Actuator – Removal....7343
Mode Door Actuator – Installation....7344
Mode Door Gear Train – Removal....7345
Mode Door Gear Train – Installation....7348
Outlet Duct Temperature Sensor — Rear HVAC – Removal....7349
Outlet Duct Temperature Sensor – Rear HVAC Installation....7350
Pressure Transducer – Removal....7351
Pressure Transducer – Installation....7352
Rear HVAC Controls – Removal....7353
Rear HVAC Module – Removal....7354
Rear HVAC Module – Installation....7356
Recirculation Door Actuator – Removal....7358
Recirculation Door Actuator – Installation....7359
Recirculation Door Gear Train – Removal....7360
Recirculation Door Gear Train – Installation....7362
Recirculation Filters – Removal....7363
Recirculation Filters – Installation....7365
Recirculation, Mode, and Blend Doors – Removal....7366
Refrigerant Line – Removal....7367
Refrigerant Line – Installation....7369
Separating Blower Scroll Housing – Removal....7370
Separating Front HVAC Module – Removal....7372
Sleeper HVAC Controller – Removal....7376
Sleeper HVAC Controller – Installation....7377
Splitting / Separating Blower Scroll Housing – Installation....7378
Splitting / Separating Interior Module – Installation....7379
Temperature Blend Air Door – Installation....7380
Thermostatic Expansion Valve (TXV) – Removal....7381
Thermostatic Expansion Valve (TXV) – Installation....7382
Thermostatic Expansion Valve (TXV) — Rear HVAC – Removal....7383
Thermostatic Expansion Valve (TXV) — Rear HVAC – Installation....7384
MaxxPower No-Idle System....7385
Overview....7385
Component Locations....7386
System Operation....7389
Blower Motor....7391
Linear Power Module (LPM)....7391
Discharge Temperature Sensor....7391
Inlet Temperature Sensor....7391
System Controller....7391
Compressor Controller....7391
Blend Door Actuator....7391
Flow Control Valve....7392
HVAC Control Panel....7392
Engine Preheat Switch....7392
HVAC Filter....7392
No Idle Condenser....7392
No Idle Condenser Fan....7392
Evaporator (Shared)....7392
No Idle A/C Compressor....7393
No Idle Receiver-Drier....7393
No Idle High Pressure Switch....7393
Heater Coil (Shared)....7393
HVAC Plumbing....7394
Expansion Valve....7394
HVAC Drain Tube....7395
No Idle Coolant Heater....7395
Coolant Shutoff Valves....7395
Operational Checkout Procedures....7396
1.0 – Maxxpower No-Idle System Operational Checkout Procedure....7396
Symptoms....7398
1.1 – System INOP....7398
Overview....7398
Possible Causes....7398
Pin-Point Test – 1.1 System INOP....7403
Tools Required....7403
1.2 – Short Run Time....7414
Overview....7414
Equipment Conditions....7414
Possible Causes....7414
1.3 – No Air Flow From Vents....7416
Overview....7416
Possible Causes....7416
Pin-Point Test – 1.3 No Air Flow From Vents....7420
Tools Required....7420
1.4 – Blows Warm When Cold Requested....7427
Overview....7427
Possible Causes....7427
Pin-Point Test – 1.4 Blows Warm When Cold Requested....7435
Tools Required....7435
1.5 – Blows Cold When Warm is Requested....7456
Overview....7456
Possible Causes....7456
Pin-Point Test – 1.5 Blows Cold When Warm Requested....7460
Tools Required....7460
1.6 – Excessive System Cycling....7468
Overview....7468
Possible Causes....7468
Pin-Point Test – 1.6 Excessive System Cycling....7472
Tools Required....7472
1.7 – Noisy or Vibrates....7481
Overview....7481
Possible Causes....7481
Fault Codes....7483
SPN 109 FMI 14 – Pressure Switch Circuit Open....7483
SPN 168 FMI 3 – Battery Voltage High....7484
Fault Overview....7484
Associated Faults....7484
Fault Facts....7484
Possible Causes....7484
SPN 168 FMI 4 – Voltage Low....7485
Fault Overview....7485
Associated Faults....7485
Fault Facts....7485
Possible Causes....7485
SPN 1547 FMI 0 – Inlet Temp Sensor High....7487
SPN 1548 FMI 3 – Discharge Temp Sensor High....7488
SPN 1548 FMI 4 – Discharge Temp Sensor Low....7489
SPN 2058 FMI 9 – Rear A/C Data Link Communication Failure....7490
Fault Overview....7490
Associated Faults....7490
Fault Facts....7490
Possible Causes....7490
Pin-Point Test SPN 2058 FMI 9....7492
Tools Required....7492
SPN 2058 FMI 14 – Rear A/C Data Link Communication Failure....7497
Fault Overview....7497
Associated Faults....7497
Fault Facts....7497
Possible Causes....7497
Pin-Point Test SPN 2058 FMI 14....7499
Tools Required....7499
SPN 520210 FMI 6 – Blower Output Short Circuit....7504
Fault Overview....7504
Associated Faults....7504
Fault Facts....7504
Possible Causes....7504
Pin-Point Test - SPN 520210 FMI 6....7507
Tools Required....7507
SPN 520808 FMI 14 – No-Idle Compressor Relay Open / Short....7512
SPN 520810 FMI 14 – Condenser Fan Relay Short / Open....7513
Tests and Inspections....7514
Amperage Draw Test....7514
Overview....7514
Tools Required....7514
Equipment Condition....7514
Test Setup....7514
Test Procedure....7514
Expected Outcome....7516
Follow-On Procedure....7516
Blend Door Calibration Procedure....7517
Overview....7517
Tools Required....7517
Equipment Condition....7517
1.Bunk raised to gain access to No-Idle system.....7517
Test Setup....7517
Test Procedure....7517
Expected Outcome....7518
Follow-On Procedure....7518
Discharge Temperature Sensor Electrical Test....7519
Overview....7519
Tools Required....7519
Equipment Condition....7519
Test Setup....7519
Test Procedure....7519
Expected Outcome....7521
Follow-On Procedure....7521
Inlet air Temperature Sensor Electrical Test....7522
Overview....7522
Tools Required....7522
Equipment Condition....7522
Test Setup....7522
Test Procedure....7522
Expected Outcome....7524
Follow-On Procedure....7524
Maxxpower No-Idle Electrical System Inspection....7525
Overview....7525
Tools Required....7525
Equipment Condition....7525
Inspection Procedure....7525
Expected Outcome....7527
Removal and Installation....7528
Blend Door Removal....7528
Blend Door Installation....7533
Blend Door Actuator Removal....7534
Blend Door Actuator Installation....7535
Blower Motor Removal....7536
Blower Motor Installation....7537
Compressor Controller Removal....7538
Compressor Controller Installation....7540
Condenser Fan Removal....7541
Condenser Fan Installation....7543
Discharge Temperature Sensor Removal....7544
Discharge Temperature Sensor Installation....7545
Evaporator Inlet Filter Removal....7546
Evaporator Inlet Filter Installation....7547
Flow Control Valve Removal....7548
Flow Control Valve Installation....7549
Heater Coil Removal....7550
Heater Coil Installation....7554
HVAC Drain Tube Removal....7555
HVAC Drain Tube Installation....7556
Inlet Temperature Sensor Removal....7557
Inlet Temperature Sensor Installation....7558
Linear Power Module (LPM) Removal....7559
Linear Power Module (LPM) Installation....7560
No-Idle HVAC Unit Removal....7561
No-Idle HVAC Unit Installation....7570
Refrigerant Circuit Removal....7572
Refrigerant Circuit Installation....7574
System Controller Removal....7575
System Controller Installation....7576
Air Conditioning System Specifications....7577
Circuit Diagrams....7579
Eberspaecher Auxiliary Heater....7582
Overview....7582
Regular Maintenance....7583
Monthly....7583
Every 1000 operating hours....7583
Connecting EDiTH to heater....7584
Starting and using EDiTH software....7584
Reading fault codes....7590
Clearing fault codes....7590
Removing controller lock....7591
Fault Code Diagnostics....7592
Overview....7592
10 – Overvoltage / Shutdown....7594
Fault Code Overview....7594
11 – Undervoltage / Shutdown....7595
Fault Code Overview....7595
Pin-Point Tests....7597
Tools Required....7597
12 – Overheating....7598
Fault Code Overview....7598
14 – Possible Overheating Detected (Differential Evaluation)....7599
Fault Code Overview....7599
15 – Operation Lock – Heater has Overheated More than 10 Times....7600
Fault Code Overview....7600
17 – Overheating — Emergency Off....7601
Fault Code Overview....7601
20 – Glow Plug – Interruption....7602
Fault Code Overview....7602
Pin-Point Tests....7603
Tools Required....7603
21 – Glow Plug Output: Short Circuit, Overload or Accidental Ground....7604
Fault Code Overview....7604
30 – Speed of Combustion Fan motor Outside Tolerance Range....7605
Fault Code Overview....7605
31 – Combustion Fan Motor Open Circuit....7606
Fault Code Overview....7606
Pin-Point Tests....7607
Tools Required....7607
32 – Combustion Fan Motor Short Circuit, Overload or Accidental Ground....7608
Fault Code Overview....7608
39 – Vehicle Blower Relay Control – Short Circuit, Overload or Earth Short....7609
Fault Code Overview....7609
41 – Water Pump – Interruption....7610
Fault Code Overview....7610
Pin-Point Tests....7611
Tools Required....7611
42 – Water Pump – Short Circuit, Overload or Earth Short....7612
Fault Code Overview....7612
Pin-Point Tests....7613
Tools Required....7613
47 – Metering Pump – Short Circuit, Overload or Earth Short....7614
Fault Code Overview....7614
Pin-Point Tests....7616
Tools Required....7616
48 – Metering Pump – Interruption....7617
Fault Code Overview....7617
50 – Operation Lock Because of Too Many Failed Starting Attempts....7618
Fault Code Overview....7618
51 – Time Exceeded – Blowing Cold....7619
Fault Code Overview....7619
52 – Safety Time Exceeded....7620
Fault Code Overview....7620
53 – Flame Aborted from Control Stage “Large”....7622
Fault Code Overview....7622
54 – Flame Aborted from Control Stage “Boost”....7623
Fault Code Overview....7623
56 – Flame Aborted from Control Stage “Small”....7624
Fault Code Overview....7624
60 – Temperature Sensor – Interruption....7625
Fault Code Overview....7625
61 – Temperature Sensor – Short-Circuit, Overload or Accidental Ground....7626
Fault Code Overview....7626
64 – Flame Sensor – Interruption....7627
Fault Code Overview....7627
65 – Flame Sensor – Short-Circuit, Overload or Accidental Ground....7628
Fault Code Overview....7628
71 – Overheating Sensor – Interruption....7629
Fault Code Overview....7629
72 – Overheating Sensor – Short-Circuit, Overload or Accidental Ground....7630
Fault Code Overview....7630
90 – Controller Defect....7631
Fault Code Overview....7631
91 – External Interference Voltage....7632
Fault Code Overview....7632
92 – Controller Defect....7633
Fault Code Overview....7633
93 – Controller Defect....7634
Fault Code Overview....7634
94 – Controller Defect....7635
Fault Code Overview....7635
95 – Controller Defect....7636
Fault Code Overview....7636
96 – Controller Defect....7637
Fault Code Overview....7637
97 – Controller Defect....7638
Fault Code Overview....7638
98 – Controller Defect....7639
Fault Code Overview....7639
99 – Controller Defect....7640
Fault Code Overview....7640
100 – Controller Defect....7641
Fault Code Overview....7641
101 – Controller Defect....7642
Fault Code Overview....7642
Symptom Diagnostics....7643
Overview....7643
Tests and Inspections....7645
Blower Motor Test....7645
Tools Required....7645
Test Setup....7645
Test Procedure....7645
Expected Outcome....7645
Coolant Circuit Inspection....7646
Inspection Setup....7646
Inspection Procedure....7646
Expected Outcome....7646
Connector Inspection....7647
Inspection Setup....7647
Inspection Procedure....7647
Expected Outcome....7647
Flame Sensor Test....7648
Tools Required....7648
Test Setup....7648
Test Procedure....7648
Expected Outcome....7648
Fuel Intake Inspection....7650
Inspection Setup....7650
Inspection Procedure....7650
Expected Outcome....7650
Fuel Pump Quantity Test....7651
Tools Required....7651
Test Setup....7651
Test Procedure....7651
Expected Outcome....7652
Glow Pin Test....7653
Tools Required....7653
Test Setup....7653
Test Procedure....7653
Expected Outcome....7653
Glow Plug Filter Inspection....7654
Inspection Setup....7654
Inspection Procedure....7654
Expected Outcome....7654
Follow-on Procedure....7654
Intake and exhaust air Inspection....7655
Inspection Setup....7655
Inspection Procedure....7655
Expected Outcome....7655
Integrated Fuel Filter Inspection....7656
Inspection Setup....7656
Inspection Procedure....7656
Expected Outcome....7656
Overheat Sensor Test....7657
Tools Required....7657
Test Setup....7657
Test Procedure....7657
Expected Outcome....7658
Temperature Sensor Test....7659
Tools Required....7659
Test Setup....7659
Test Procedure....7659
Expected Outcome....7659
Removal and Installation....7661
Blower motor....7661
Removal....7661
Installation....7662
Blower Motor Cover....7663
Removal....7663
Installation....7663
Controller....7664
Removal....7664
Installation....7665
Flame Sensor....7666
Removal....7666
Installation....7666
Fuel Pump....7667
Removal....7667
Installation....7668
Glow Pin Screen....7670
Removal....7670
Installation....7670
Glow Plug....7671
Removal....7671
Installation....7671
Heat Exchanger Cover....7672
Removal....7672
Installation....7672
Overheat / Temperature Sensor Assembly....7673
Removal....7673
Installation....7673
Water Pump....7674
Removal....7674
Installation....7674
Diagnostic Tools and Accessories....7675
ESP2029007050280Z - Y Adapter....7675
ESP2215241890000Z - ISO Adapter....7675
TXT126870334 – Terminal release tool....7676
TXT126870335 – Terminal release tool....7676
ZTSE4357 – Digital Multimeter (DMM)....7677
ZTSE4435C - International® Electronic Engine Terminal Test Kit....7678
ZTSE44983 - Banana Plug Harness....7678
ZTSE4871 – Breakout Harness 4871....7679
Auxiliary Battery Box....7680
Overview....7680
Torque Chart....7681
7. Instrumentation / Gauges....7682
Overview....7682
Operational Checkout Procedure....7683
Overview....7683
EGC Programming....7685
Overview....7685
Voltage....7686
Overview....7686
Possible Causes....7686
Special Tools....7686
Fuel Level ....7688
Overview....7688
Possible Causes....7688
DEF Level....7695
Overview....7695
Possible Causes....7695
Transmission Temperature....7697
Overview....7697
Possible Causes....7697
Pin-point Tests....7702
Air Gauges....7703
Diagnostics....7703
Overview....7703
Symptoms - Air 1 Gauge....7704
Overview....7704
Possible Causes....7704
Pin-Point Tests - Air 1 Gauge....7708
Tools Required....7708
Symptoms - Air 2 Gauge....7711
Overview....7711
Possible Causes....7711
Pin-Point Tests - Air 2 Gauge....7715
Tools Required....7715
Engine Coolant Temperature....7719
Overview....7719
Engine Oil Pressure....7720
Overview....7720
Engine Oil Temperature....7721
Overview....7721
Engine Speed (Tachometer)....7722
Overview....7722
Vehicle Speed (Speedometer)....7723
Overview....7723
Outside Air Temperature....7724
Overview....7724
8. Lighting Systems....7727
Fog Lights....7727
Overview....7727
Operational Checkout Procedure....7730
Overview....7730
Fog Light Input Diagnostics....7733
Fault Overview....7733
Fault Facts....7733
Possible Causes....7733
Fog Light Output - Not Illuminating....7735
Fault Overview....7735
Fault Facts....7735
Possible Causes....7735
Pin-Point Test - Fog Light Output - Not Illuminating....7740
Tools Required....7740
Fog Light Output Diagnostics - Illuminating When Not Requested....7744
Fault Overview....7744
Fault Facts....7744
Possible Causes....7744
Pin-Point Test -Fog Light Output - Illuminating When Not Requested....7747
Tools Required....7747
SPN 2388 FMI 5 - Left Fog Light Open Circuit....7749
Fault Overview....7749
Associated Faults....7749
Fault Facts....7749
Possible Causes....7749
Pin-Point Test - SPN 2388 FMI 5....7751
Tools Required....7751
SPN 2388 FMI 6 - Left Fog Light Short to GND....7753
Fault Overview....7753
Associated Faults....7753
Fault Facts....7753
Possible Causes....7753
Pin-Point Test - SPN 2388 FMI 6....7755
Tools Required....7755
SPN 4008 FMI 5 - Right Fog Light Open Circuit....7757
Fault Overview....7757
Associated Faults....7757
Fault Facts....7757
Possible Causes....7757
Pin-Point Test - SPN 4008 FMI 5....7759
Tools Required....7759
SPN 4008 FMI 6 - Right Fog Light Short to GND....7761
Fault Overview....7761
Associated Faults....7761
Fault Facts....7761
Possible Causes....7761
Pin-Point Test - SPN 4008 FMI 6....7763
Tools Required....7763
Headlights and Daytime Running Lights....7765
Overview....7765
The headlamp system has multiple different input manipulators that effect output operations. There are multiple input feature codes that effect low beam and high beam headlamp operation. Use Diamond Logic® Builder (DLB) to view all active feature codes an....7765
Operational Checkout Procedure....7770
Overview....7770
Low Beam Input Diagnostics....7775
Fault Overview....7775
Fault Facts....7775
Possible Causes....7775
Low Beam Output Diagnostics - Not illuminating....7777
Fault Overview....7777
Fault Facts....7777
Possible Causes....7777
Pin-Point Test - Low Beam Head Lamp Output - Not Illuminating....7782
Tools Required....7782
Low Beam Output Diagnostics - Illuminating When Not Requested....7786
Fault Overview....7786
Fault Facts....7786
Possible Causes....7786
Pin-Point Test - Low Beam Head Lamp Output - Illuminating When Not Requested....7789
Tools Required....7789
SPN 2653 FMI 5 - Left Low Beam Open Circuit....7791
Fault Overview....7791
Associated Faults....7791
Fault Facts....7791
Possible Causes....7791
Pin-Point Test - SPN 2653 FMI 5....7793
Tools Required....7793
Pin-Point Test - SPN 2653 FMI 5....7794
SPN 2653 FMI 6 - Left Low Beam Short to GND....7795
Fault Overview....7795
Associated Faults....7795
Fault Facts....7795
Possible Causes....7795
Pin-Point Test - SPN 2653 FMI 6....7797
Tools Required....7797
SPN 2655 FMI 5 - Right Low Beam Open Circuit....7799
Fault Overview....7799
Associated Faults....7799
Fault Facts....7799
Possible Causes....7799
Pin-Point Test - SPN 2655 FMI 5....7801
Tools Required....7801
SPN 2655 FMI 6 - Right Low Beam Short to GND....7803
Fault Overview....7803
Associated Faults....7803
Fault Facts....7803
Possible Causes....7803
Pin-Point Test - SPN 2655 FMI 6....7805
Tools Required....7805
High Beam Input Diagnostics....7807
Fault Overview....7807
Fault Facts....7807
Possible Causes....7807
Pin-Point Test - High Beam Lamps Input....7810
Tools Required....7810
High Beam Output Diagnostics - Not Illuminating....7815
Fault Overview....7815
Fault Facts....7815
Possible Causes....7815
Pin-Point Test - High Beam Head Lamp Output - Not Illuminating....7820
Tools Required....7820
High Beam Output Diagnostics - Illuminating When Not Requested....7824
Fault Overview....7824
Fault Facts....7824
Possible Causes....7824
Pin-Point Test - High Beam Head Lamp Output - Illuminating When Not Requested....7827
Tools Required....7827
SPN 4011 FMI 5 - Left High Beam Open Circuit....7829
Fault Overview....7829
Associated Faults....7829
Fault Facts....7829
Possible Causes....7829
Pin-Point Test - SPN 4011 FMI 5....7831
Tools Required....7831
SPN 4011 FMI 6 - Left High Beam Short to Ground....7833
Fault Overview....7833
Associated Faults....7833
Fault Facts....7833
Possible Causes....7833
Pin-Point Test - SPN 4011 FMI 6....7835
Tools Required....7835
SPN 4012 FMI 5 - Right High beam Open Circuit....7837
Fault Overview....7837
Associated Faults....7837
Fault Facts....7837
Possible Causes....7837
Pin-Point Test - SPN 4012 FMI 5....7839
Tools Required....7839
SPN 4012 FMI 6 - Right High Beam Short to Ground....7841
Fault Overview....7841
Associated Faults....7841
Fault Facts....7841
Possible Causes....7841
Pin-Point Test - SPN 4012 FMI 6....7843
Tools Required....7843
Brake Switch....7845
Overview....7845
Overview....7845
Operational Checkout Procedure....7846
Air Brakes - Feature Code 4091 / 4092 ....7849
Overview....7849
Brake Switch is Not Working....7852
Feature Code Overview....7852
Fault Facts....7852
Possible Causes....7852
Pin-Point Test - Feature Code 4091 / 4092....7855
Tools Required....7855
SPN 597 FMI 0 - Brake Switch Input short to PWR with Air Brakes 4091 / 4092....7859
Fault Overview....7859
Associated Faults....7859
Fault Facts....7859
Possible Causes....7859
Pin-Point Test - SPN 597 FMI 0 with AIr Brakes (4091 / 4092)....7861
Tools Required....7861
SPN 597 FMI 1 - Brake Switch Reading Below Normal Range with Air Brakes 4091 / 4092....7865
Fault Overview....7865
Associated Faults....7865
Fault Facts....7865
Possible Causes....7865
SPN 597 FMI 2 - Analog Brake Switch signal does not agree with Digital brake switch signal....7867
Fault Overview....7867
Associated Faults....7867
Fault Facts....7867
Possible Causes....7867
Stop, Turn, and Hazard Lights....7869
Overview....7869
Operational Checkout Procedure....7870
Overview....7870
Turn Signal, Hazard, and Front Turn Lamp Diagnostics....7878
Overview....7878
Hazard Input Diagnostics....7881
Overview....7881
Fault Facts....7881
Possible Causes....7881
Pin-Point Test - Hazard Input Diagnostics....7884
Tools Required....7884
Turn Signal Input Diagnostics....7890
Overview....7890
Fault Facts....7890
Possible Causes....7890
Pin-Point Test - Turn Signal Input Diagnostics....7893
Tools Required....7893
Front Turn Lamp Not Illuminating....7899
Overview....7899
Fault Facts....7899
Possible Causes....7899
Pin-Point Test- Front Turn Lamp Output Not Illuminating....7903
Tools Required....7903
Front Turn Lamps Illuminating When Not Requested....7907
Overview....7907
Fault Facts....7907
Possible Causes....7907
Pin-Point Test - Front Turn Lamps Illuminating When Not Requested....7909
Tools Required....7909
SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7911
Fault Overview....7911
Associated Faults....7911
Fault Facts....7911
Possible Causes....7911
Pin-Point Test SPN 2368 FMI 5....7913
Tools Required....7913
SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7915
Fault Overview....7915
Associated Faults....7915
Fault Facts....7915
Possible Causes....7915
Pin-Point Test SPN 2368 FMI 6....7917
Tools Required....7917
SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7919
Fault Overview....7919
Associated Faults....7919
Fault Facts....7919
Possible Causes....7919
Pin-Point Test SPN 2370 FMI 5....7921
Tools Required....7921
SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7923
Fault Overview....7923
Associated Faults....7923
Fault Facts....7923
Possible Causes....7923
Pin-Point Test SPN 2370 FMI 6....7925
Tools Required....7925
Combined Stop and Turn Lamps Diagnostics....7927
Overview....7927
Combined Stop and Turn Lamps - Rear Turn Lamp Not Illuminating....7929
Overview....7929
Fault Facts....7929
Possible Causes....7929
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7933
Tools Required....7933
Combined Stop and Turn Lamps - Rear Turn Lamps Illuminating When Not Requested....7937
Overview....7937
Fault Facts....7937
Possible Causes....7937
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7939
Tools Required....7939
SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7941
Fault Overview....7941
Associated Fault....7941
Fault Facts....7941
Possible Causes....7941
Pin-Point Test SPN 2372 FMI 5....7943
Tools Required....7943
SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7945
Fault Overview....7945
Associated Faults....7945
Fault Facts....7945
Possible Causes....7945
Pin-Point Test SPN 2372 FMI 6....7947
Tools Required....7947
SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....7949
Fault Overview....7949
Associated Faults....7949
Fault Facts....7949
Possible Causes....7949
Pin-Point Test SPN 2374 FMI 5....7951
Tools Required....7951
SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....7953
Fault Overview....7953
Associated Faults....7953
Fault Facts....7953
Possible Causes....7953
Pin-Point Test SPN 2374 FMI 6....7955
Tools Required....7955
Separate Stop and Turn Lamps Diagnostics....7957
Overview....7957
Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7958
Overview....7958
Fault Facts....7958
Possible Causes....7958
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....7962
Tools Required....7962
Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7966
Overview....7966
Fault Facts....7966
Possible Causes....7966
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....7968
Tools Required....7968
Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....7970
Overview....7970
Fault Facts....7970
Possible Causes....7970
Pin-Point Test - Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....7973
Tools Required....7973
Separate Stop and Turn Lamps- Stop Lamps Illuminating When Not Requested....7977
Overview....7977
Fault Facts....7977
Possible Causes....7977
Pin-Point Test - Separate Stop and Turn Lamps- Rear Stop Lamps Illuminating When Not Requested....7979
Tools Required....7979
Park / Marker Lights....7981
Overview....7981
Park and Marker Lights are activated using the center and top position of the tri stable Headlight Switch. The input signal to the Body Controller is sent from the EGC over J1939 datalink. The Body Controller receives the input message can send 2 separate....7981
Operational Checkout Procedure....7984
Overview....7984
Park Light Input Diagnostics....7988
Fault Overview....7988
Fault Facts....7988
Possible Causes....7988
Park Light Output - Not Illuminating....7990
Fault Overview....7990
Fault Facts....7990
Possible Causes....7990
Pin-Point Test - Park Light Output - Not Illuminating....7993
Tools Required....7993
Park Light Output Diagnostics - Illuminating When Not Requested....7995
Fault Overview....7995
Fault Facts....7995
Possible Causes....7995
Pin-Point Test - Park Light Output - Illuminating When Not Requested....7997
Tools Required....7997
SPN 2378 FMI 5 - Park Light UnderCurrent....7999
Fault Overview....7999
Associated Faults....7999
Fault Facts....7999
Possible Causes....7999
Pin-Point Test - SPN 2378 FMI 5....8001
Tools Required....8001
SPN 2378 FMI 6 - Park Light OverCurrent....8003
Fault Overview....8003
Associated Faults....8003
Fault Facts....8003
Possible Causes....8003
Pin-Point Test - SPN 2378 FMI 6....8005
Tools Required....8005
SPN 40242 FMI 2 - Marker Light Interrupt Switch Failure....8007
Fault Overview....8007
Associated Faults....8007
Fault Facts....8007
Possible Causes....8007
Trailer Lighting....8009
Overview....8009
Operational Checkout Procedure....8011
Overview....8011
Pin-Point Test - Trailer Lights Operational Checkout Procedure....8013
Tools Required....8013
Trailer Marker Lights - Not Illuminating....8016
Fault Overview....8016
Fault Facts....8016
Possible Causes....8016
Pin-Point Test - Trailer Marker Light Output - Not Illuminating....8019
Tools Required....8019
Trailer Tail Lights - Not Illuminating....8025
Fault Overview....8025
Fault Facts....8025
Possible Causes....8025
Pin-Point Test - Trailer Tail Light Output - Not Illuminating....8028
Tools Required....8028
Trailer Left Turn Lights - Not Illuminating....8034
Fault Overview....8034
Fault Facts....8034
Possible Causes....8034
Pin-Point Test - Trailer Left Turn Output - Not Illuminating....8037
Tools Required....8037
Trailer Right Turn Lights - Not Illuminating....8043
Fault Overview....8043
Fault Facts....8043
Possible Causes....8043
Pin-Point Test - Trailer Right Turn Output - Not Illuminating....8046
Tools Required....8046
Trailer Brake Lights - Not Illuminating....8052
Fault Overview....8052
Fault Facts....8052
Possible Causes....8052
Pin-Point Test - Trailer BrakeLight Output - Not Illuminating....8055
Tools Required....8055
9. Predictive Cruise Control....8061
Overview....8061
Operational Checkout Procedure....8065
Overview....8065
Predictive Cruise Control Module Diagnostics....8066
Pin-Point Tests - Predictive Cruise Control ....8069
Tools Required....8069
Predictive Cruise Control GPS Antenna Diagnostics....8077
10. Security System....8078
Theft Deterrent....8078
Overview....8078
Operational Checkout Procedure....8080
Theft Deterrent System Not Responding....8081
Fault Overview....8081
Fault Facts....8081
Possible Causes....8081
11. Transmission....8084
Auto Neutral....8084
12. Windshield Wiper System....8085
Windshield Wiper Diagnostics....8085
Overview....8085
Wiper Operation....8085
Park Operation....8085
Washer Operation....8085
Operational Checkout Procedure....8092
Overview....8092
Windshield Wiper Input 0 Not Working....8098
Fault Overview....8098
Fault Fact....8098
Possible Causes....8098
Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working....8101
Tools Required....8101
Windshield Wiper Input 1 Not Working....8106
Feature Overview....8106
Fault Fact....8106
Possible Causes....8106
Pin-Point Test - Windshield Wiper Input 1 Not Working....8108
Tools Required....8108
Windshield Wiper Input 2 Not Working....8113
Feature Overview....8113
Fault Fact....8113
Possible Causes....8113
Pin-Point Test - Windshield Wiper Input 2 Not Working....8116
Tools Required....8116
Windshield Wiper Low Speed Not Functioning....8121
Feature Code Overview....8121
Fault Facts....8121
Possible Causes....8121
Pin-Point Test - Windshield Wiper Low Speed Not Functioning....8126
Tools Required....8126
Windshield Wiper High Speed Not Functioning.....8134
Feature Code Overview....8134
Fault Facts....8134
Possible Causes....8134
Pin-Point Test - Windshield Wiper High Speed Not Functioning....8139
Tools Required....8139
SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit....8147
Fault Overview....8147
Associated Faults....8147
Fault Facts....8147
Possible Causes....8147
Pin-Point Test - SPN 2636 FMI 5....8149
Tools Required....8149
SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current....8151
Fault Overview....8151
Associated Faults....8151
Fault Facts....8151
Possible Causes....8151
Pin-Point Test - SPN 2636 FMI 6....8152
Tools Required....8152
SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or High Resistance....8154
Fault Overview....8154
Associated Faults....8154
Fault Facts....8154
Possible Causes....8154
Pin-Point Test - SPN 2637 FMI 5....8156
Tools Required....8156
SPN 2637 FMI 6 - Wiper High / Low Relay Over Current....8158
Fault Overview....8158
Associated Faults....8158
Fault Facts....8158
Possible Causes....8158
Pin-Point Test - SPN 2637 FMI 6....8160
Tools Required....8160
SPN 4057 FMI 5 - Wiper Motor Under Current....8162
Fault Overview....8162
Associated Faults....8162
Fault Facts....8162
Possible Causes....8162
Pin-Point Test - SPN 4057 FMI 5....8166
Tools Required....8166
SPN 4057 FMI 6 - Wiper Motor Over Current....8174
Fault Overview....8174
Associated Faults....8174
Fault Facts....8174
Possible Causes....8174
Pin-Point Test - SPN 4057 FMI 6....8178
Tools Required....8178
Windshield Washer Pump is Not Working with Windshield Wipers....8182
Feature Overview....8182
Fault Fact....8182
Possible Causes....8182
Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....8185
Tools Required....8185
Windshield Wiper Not Working with Washer Pump....8190
Feature Overview....8190
Fault Fact....8190
Possible Causes....8190
Pin-Point Test - Windshield Wiper Not Working with Washer Pump....8192
Tools Required....8192
Windshield Wiper and Washer Pump Not Working....8194
Feature Overview....8194
Fault Fact....8194
Possible Causes....8194
Pin-Point Test - Windshield Wiper and Washer Pump Not Working....8197
Tools Required....8197
Front End....8202
1. Hood, Grill, Fenders and Bumper Description....8204
BUMPER....8204
GRILLE....8204
Hood Assembly....8204
Hood Tilt Assist....8204
HOOD SEAL....8205
SPLASH SHIELDS....8205
AIR INTAKE....8205
FENDER....8205
FENDER EXTENSIONS....8205
Headlight Assembly....8205
2. Removal and Installation....8206
Bumper....8207
Bumper – Removal....8207
Bumper – Installation....8208
Bumper filler panels....8209
Bumper Panel – Removal....8209
Bumper Panel – Installation....8209
Grill and Bug Screen....8210
Grille and Bug Screen – Removal....8210
Grille and Bug Screen – Installation....8212
Splash Shields....8213
Splash Shields – Removal....8213
Splash Shields – Installation....8215
Hood....8216
Hood – Removal....8216
Hood – Installation....8218
Hood – Adjustment....8219
Tilt Assist Cylinder....8220
Tilt Assist Cylinder – Removal....8220
Tilt Assist Cylinder – Installation....8221
Torsion Bars....8222
Torsion Bar – Removal....8222
Torsion Bar – Installation....8224
Hood Latch....8225
Hood Latch – Removal....8225
Hood Latch – Installation....8226
Hood Seal....8227
Hood Seal – Removal....8227
Hood Seal – Installation....8227
Fender Extensions....8228
Fender Extensions – Removal....8228
Fender Extensions – Installation....8230
High Beam Headlight Assembly....8231
High Beam Headlight Assembly – Removal....8231
High Beam Headlight Assembly – Installation....8232
High Beam Bulb Replacement ....8232
High Beam Headlight Adjustment ....8232
Low Beam Headlight Assembly....8233
Low Beam Headlight Assembly – Removal....8233
Low Beam Headlight Assembly – Installation....8234
Low Beam Bulb Replacement ....8234
Fifth Wheels and Misc.....8238
1. FIFTH WHEEL INSTALLATION....8240
PRECAUTIONS....8240
MAINTENANCE....8240
REPLACEMENT....8240
Remove....8240
Install....8241
MOUNTING....8241
Mounting Angles....8241
Mounting Bolts....8242
Fixed (Non-Sliding) Fifth Wheels....8243
Sliding Fifth Wheels....8248
Clutch....8250
1. Description....8252
Clutch pedal....8253
Master Cylinder....8253
Reservoir....8253
Clutch Servo....8254
Hydraulic Hose....8254
Bleeder Valve....8255
2. Removal and Installation....8256
Reservoir....8257
Reservoir – Removal....8257
Reservoir – Installation....8257
Clutch Master Cylinder....8258
Clutch Master Cylinder – Removal....8258
Clutch Master Cylinder – Installation....8258
Clutch Servo....8260
Clutch Servo – Removal....8260
Clutch Servo – Installation....8260
Clutch Pedal....8261
Clutch Pedal – Removal....8261
Clutch Pedal – Installation....8262
3. Hydraulic Fluid Changing....8263
Checking the Fluid Level....8263
Reverse Pressure – Bleeding Pressure....8264
4. Troubleshooting....8269
Operating Condition and Possible Cause....8269
5. Specifications....8273
Fluid specifications....8273
Engines....8276
1. 1. Cooling Package Cleaning Procedures....8278
Overview....8278
1.1. Charge Air Cooler Cleaning Procedure....8280
Overview....8280
Tools Required....8280
Service Parts....8280
Charge Air Cooler Cleaning Procedure Setup....8281
Off-chassis Pressure Test....8282
Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation....8284
Charge Air Cooler Cleaning Procedure....8286
Flushing Procedure....8287
Cleaning Management System (CMS) Removal Procedure....8288
2. 2. Removal and Installation....8290
2.1. Removal and Installation....8291
Overview....8291
Equipment Conditions....8291
A/C Condenser - Removal ....8292
A/C Condenser - Installation....8294
Charge Air Cooler - Removal....8295
Charge Air Cooler - Installation....8300
Deaeration Tank - Removal....8302
Deaeration Tank - Installation....8303
Fan Belt - Removal....8304
Fan Belt - Installation....8306
Fan Shroud Removal – (Two-Piece)....8307
Fan Shroud Installation – (Two-Piece)....8311
Grille - Remove....8312
Grille - Install....8313
Hood-Tilt Assist Cylinder – Removal....8314
Hood-Tilt Assist Cylinder – Installation....8316
Power Steering Oil Cooler – Removal....8317
Power Steering Oil Cooler – Installation....8319
Radiator Assembly - Removal....8320
Radiator Assembly - Installation....8326
Radiator Core - Removal....8328
Radiator Core Installation....8332
Radiator Fan - Removal....8333
Radiator Fan - Installation....8334
Radiator Hose Heat Shrink Clamp - Removal and Installation....8335
Heat Shrink Clamp Removal....8335
Heat Shrink Clamp Installation....8336
Radiator Hose - Removal....8339
Radiator Hose - Installation ....8342
Transmission Oil Cooler – Removal....8343
Transmission Oil Cooler – Installation....8345
2.2. Test and Inspections....8346
Overview....8346
Equipment Conditions....8347
Coolant Drain Procedure....8350
Coolant Fill Procedure....8352
Coolant Drain Procedure (Optional)....8355
Coolant Fill Procedure (Optional)....8357
Deaeration Tank Inspection Procedure....8359
Deaeration Tank Cap Vacuum Relief Check....8360
Fan Drive Pulley Crack Inspection....8361
Fan Drive Pulley Nick Inspection....8362
Fuel Cooler Valve (FCV) Inspection Procedure....8363
Fuel Cooler Valve (FCV) Filter Screen – Removal....8363
Fuel Cooler Valve (FCV) Filter Screen – Installation....8364
Pressure Test Procedure....8365
2.3. Torque Chart....8366
3. Fan Drive....8368
Horton Drivemaster....8368
Overview....8368
Remove....8369
Install....8372
Transmissions....8374
1. 1. Fuller....8376
Overview....8376
2. 2. Eaton Fuller UltraShift....8377
Overview....8377
Service Information....8378
Rear Axle and Suspension....8380
1. Rear Suspension....8382
Air Suspensions....8382
Tandem....8382
Overview....8382
Fuel System....8384
1. Fuel System....8386
Overview....8386
Fuel Tank....8386
Removal and Installation....8387
Fuel Tanks....8387
Remove....8387
Install....8389
Fuel Tank Sender....8391
Remove....8391
Install....8393
Torque....8395
Torque Chart....8395
Cab....8396
1. Description....8400
Standard Cab and extended cab....8400
Cab Interior Trim Panels....8400
VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS....8401
WINDSHIELD....8402
ELECTRIC WINDSHIELD WIPERS....8403
WINDSHIELD WASHER....8404
IGNITION SWITCH CYLINDER....8404
CAB AIR SUSPENSION system....8405
2. Removal and Installation....8406
Windshield....8407
Windshield – Removal....8407
Windshield – Installation....8409
Rear Window....8412
Rear Window – Removal....8412
Rear Window – Installation....8414
Rear Side Window....8418
Rear Side Window – Removal....8418
Rear Side Window – Installation....8419
Latch – Removal....8420
Latch – Installation....8421
Hood Seal....8421
Hood Seal – Removal....8421
Hood Seal – Installation ....8421
CAB COWL TRAY....8422
Cab Cowl Tray – Removal....8422
Cab Cowl Tray – Installation....8422
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....8423
Windshield Wiper Arm and Blade Assembly – Removal....8423
Windshield Wiper Arm and Blade Assembly – Installation....8424
Windshield Wiper Assembly....8424
Windshield Wiper Assembly – Removal....8424
Windshield Wiper Assembly – Installation....8425
Windshield Washer Bottle With Pump Motor....8426
Windshield Washer Bottle With Pump Motor – Removal....8426
Windshield Washer Bottle With Pump Motor – Installation ....8427
Windshield Washer Pump Motor....8427
Windshield Washer Pump Motor – Removal....8427
Windshield Washer Pump Motor – Installation....8428
ELECTRIC WINDSHIELD WIPER MOTOR....8428
Electric Windshield Wiper Motor – Removal....8428
Electric Windshield Wiper Motor – Installation....8429
CAB DOORS....8430
Cab Doors – Removal....8430
Cab Doors – Installation....8433
DOOR HINGE....8434
Door Hinge – Removal....8434
Door Hinge – Installation....8435
DOOR STRIKER PIN....8435
Door Striker Pin – Removal....8435
Door Striker Pin – Installation....8436
DOOR CHECK BRACKET....8436
Door Check Bracket – Removal....8436
Door Check Bracket – Installation....8437
DOOR CHECK LINK....8437
Door Check Link – Removal....8437
Door Check Link – Installation....8438
DOOR TRIM PANEL....8439
Door Trim Panel – Removal....8439
Door Trim Panel – Installation....8440
DOOR VAPOR BARRIER....8440
Door Vapor Barrier – Removal....8440
Door Vapor Barrier – Installation....8441
WINDOW SLIDE BLOCK....8442
Window Slide Block – Removal....8442
Window Slide Block – Installation....8443
DOOR GLASS....8443
Door Glass – Removal....8443
Door Glass – Installation....8445
MODULAR DOOR HARDWARE ASSEMBLY....8446
Modular Door Hardware Assembly – Removal....8446
Modular Door Hardware Assembly – Installation....8449
Vent Window, Latch, And Seal....8451
Vent Window, Latch, And Seal – Removal....8451
Vent Window, Latch, And Seal – Installation....8452
DOOR LOCK CYLINDER....8453
Door Lock Cylinder – Removal....8453
Door Lock Cylinder – Installation....8454
WINDOW ELECTRIC MOTOR....8455
Window Electric Motor – Removal....8455
Window Electric Motor – Installation....8455
Regulator Arm Assembly....8456
Regulator Arm Assembly – Removal....8456
Regulator Arm Assembly – Installation....8459
OUTER DOOR HANDLE....8460
Outer Door Handle – Removal....8460
Outer Door Handle – Installation....8463
DOOR LATCH....8463
Door Latch – Removal....8463
Door Latch – Installation....8465
INNER DOOR HANDLE....8465
Inner Door Handle – Removal....8465
Inner Door Handle – Installation....8466
WINDOW RUN CHANNELS....8467
Window Run Channels – Removal....8467
Window Run Channels – Installation....8469
ELECTRIC WINDOW AND DOOR LOCK SWITCH....8470
Electric Window And Door Lock Switch – Removal....8470
Electric Window And Door Lock Switch – Installation....8471
ELECTRIC MIRROR SWITCH....8471
Electric Mirror Switch – Removal....8471
Electric Mirror Switch – Installation....8472
WEATHER SEALS....8472
Weather Seals – Removal....8472
Weather Seals – Installation....8472
SCUFF PLATE AND SEAT BELT RETRACTOR COVER....8473
Scuff Plate and Seat Belt Retractor Cover – Removal....8473
Scuff Plate and Seat Belt Retractor Cover – Installation....8473
SUN SHADE....8474
Sun Shade – Removal....8474
Sun Shade – Installation....8474
SUN VISOR AND CLIP....8475
Sun Visor and Clip – Removal....8475
Sun Visor and Clip – Installation....8475
Ignition Switch And Ignition Switch Cylinder....8476
Ignition Switch – Removal....8476
Ignition Switch – Installation....8477
Ignition Switch Cylinder – Removal....8478
Ignition Switch Cylinder – Installation....8479
INSTRUMENT PANEL....8480
Gauge Cluster – Removal....8480
Gauge Cluster – Installation....8481
Instrument Panel – Removal....8481
Instrument Panel – Installation....8484
FRONT SEATS....8486
Front Seat (Gra-Mag) – Removal....8486
Front Seat (Gra-Mag) – Installation....8489
Front Seat (National) – Removal....8490
Front Seat (National) – Installation....8491
REAR BENCH SEAT....8492
Rear Bench Seat – Removal....8492
Rear Bench Seat – Installation....8492
CORNER AND SIDE INTERIOR TRIM PANEL....8493
Corner and Side Interior Trim Panel – Removal....8493
Corner and Side Interior Trim Panel – Installation....8493
REAR INTERIOR TRIM PANEL....8494
Rear Interior Trim Panel – Removal....8494
Rear Interior Trim Panel – Installation....8494
HEADER CONSOLE PANEL....8495
Header Console Panel – Removal....8495
Header Console Panel – Installation....8499
HEADLINER TRIM PANEL (STANDARD CAB)....8500
Headliner Trim Panel (Standard Cab) – Removal....8500
Headliner Trim Panel (Standard Cab) – Installation....8501
HEADLINER TRIM PANEL (EXTENDED CAB)....8502
Headliner Trim Panel (Extended Cab) Front – Removal....8502
Headliner Trim Panel (Extended Cab) Front – Installation....8503
Headliner Trim Panel (Extended Cab) Rear – Removal....8504
Headliner Trim Panel (Extended Cab) Rear – Installation....8505
ENGINE COVER AND CUP HOLDER....8506
Cup Holder and Ashtray – Removal....8506
Cup Holder and Ashtray – Installation....8506
Engine Cover – Removal....8507
Engine Cover – Installation....8507
CAB....8508
Initial Procedures Before Cab Removal....8508
Cab – Removal....8511
Cab – Installation....8513
Final Procedures After Cab Installation....8514
Rear CAB Air Suspension Assembly....8514
Rear Cab Air Suspension Assembly – Removal....8514
Rear Cab Air Suspension Assembly – Installation....8516
FRONT CAB MOUNTING BUSHINGS....8517
Front Cab Mounting Bushings – Removal....8517
Front Cab Mounting Bushings – Installation....8518
CAB AIR SUSPENSION SYSTEM....8519
Height Control Valve – Removal....8519
Height Control Valve – Installation....8520
Shock Absorber – Removal....8521
Shock Absorber – Installation....8522
Suspension Air Spring (Bag) – Removal....8522
Suspension Air Spring (Bag) – Installation....8524
Lateral Control Rod – Removal....8525
Lateral Control Rod – Installation....8526
Jounce Bumper – Removal....8527
Jounce Bumper – Installation....8527
3. Troubleshooting....8528
ELECTRIC WINDSHIELD WIPER MOTOR....8528
WASHER PUMP MOTOR....8529
CAB AIR SUSPENSION SYSTEM....8529
4. Lubrication....8530
6,000 km (4,000 MILES), OR MONTHLY....8530
AS REQUIRED....8530
5. Adjustments....8531
CAB SQUARING....8531
CAB DOOR....8532
Door HINGE....8532
STRIKER PIN....8533
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....8534
Cab Air Suspension....8535
Ride Height....8535
Front Wheels....8538
Rear Wheels....8542
1. Wheels, Rims and Tires....8544
Wheel Components....8544
Warnings....8548
Service Procedure....8549
Tire Service....8549
Brake Service....8549
Wheel and Wheel Assemblies Removal and Installation....8550
Cast Spoke Wheels....8550
Removal....8550
Installation....8552
Disc Wheels....8553
Tire and Rim - Removal....8553
Tire and Rim - Installation....8556
OSHA Standards....8557
Wall Charts....8558
Care and Maintenance....8559
Wheel Studs and Mounting Nuts....8560
Installation, Tightening, and Alignment (Lateral Run-Out)....8562
Disc Wheels or Cast Spoke Wheels....8562
Cast Spoke Wheels....8563
Disc Wheels with (Ball Seat) Nuts....8565
Disc Wheels with Flange Nuts....8566
Wheel and Tire Balancing....8568
Static Balancing....8568
Dynamic Balancing....8568
Tire Care....8569
Inspection....8569
Inflation....8569
Loads....8569
Tire Matching....8569
Dual Tires....8569
Tandem Drive Axles....8569
Front Wheel Drive, 4x4, 6x6 and 8x6....8570
Radial and Bias Ply Tires....8570
Rotation....8570
Rotation Is Always Advisable:....8570
Rotation May Be Advisable:....8570
Alignment - Front Axle....8570
Alignment - Rear Axle....8571
Tire Wear....8571
Service Load and Inflation Charts....8572
Tire and Rim Combinations....8577
Ply Rating Vs. Load Range....8578
Torque....8579
tables....6572
Recommended Electrodes and Wires....6572
SMAW Method (HSLA Frames)....6572
GMAW Method (HSLA Frames)....6572
SMAW Method (Heat-Treated Frames)....6573
BOLT TORQUE CHART (PHOSPHATE AND OIL COATED)....6596
METRIC BOLT TORQUE CHART (PHOSPHATE AND OIL COATED)....6596
Nose Assembly Tool Numbers....6597
Hydraulic Installation Tool Numbers....6598
Collar Removal Tool Number....6598
Torque Specifications....6608
Torque Chart....6644
Drag Link Nut Torque Chart....6690
Dual Steering Gear Drag Link Nut Torque Chart....6693
Master Gear Drag Link Nut Torque Chart....6693
Drag Link Torque Chart....6704
Specifications....6747
M-Series Torque Chart....6748
All Steering Applications Torque Chart....6748
Special Tools....6749
Torque Chart....6752
Driveline Universal Joint Operating Angle Chart....6802
Procedures....6825
Torque Specifications....6850
Torque Specifications....6853
Torque Specifications....6855
Diagnostic Section....6857
500K Input Diagnostic Section....6884
Feature Codes....6918
Fault Codes....6918
Symptoms....6919
Feature Code....6933
Diagnostic Trouble Codes....6934
AC Output Ratings....6951
AC Output Ratings....6959
Modules on J1939 Public bus....6998
J1939 Public communication faults....6999
System Pressure Test Chart....7148
6.265....7172
Expected System Static Pressure ....7228
System Performance Test Specifications....7234
Oil Capacity by Component....7270
Amperage Draw at 70°F (21°C)....7515
Temperature vs. Resistance....7519
Temperature vs. Resistance....7523
Torque Chart....7578
System Pressure Test Chart ....7578
Specification....7645
Specification....7648
Specification....7652
Specification....7653
Specification....7657
Specification....7659
Fuel gauge feature codes....7688
Fuel Gauge Fault Codes....7688
DEF level feature codes....7695
DEF level fault codes....7695
Transmission temperature feature codes....7697
Transmission temperature fault codes....7697
Transmission oil temp sensor resistance specification....7702
Measure resistance of transmission oil temperature circuit at Connector 1702....7702
Measure resistance of transmission oil temperature sensor....7702
Air gauge feature codes....7703
Air 1 gauge fault codes....7704
Check for short to GND in Primary Air Pressure signal circuit....7708
Check for short to GND in Primary Air Pressure signal circuit B40....7709
Check for VREF and GND at Primary Air Pressure Transducer....7709
Check for Open or high resistance in Primary Air Pressure signal circuit....7709
Check for Open or high resistance in Primary Air Pressure signal circuit A40....7709
Check for Open or high resistance in Primary Air Pressure signal circuit B40....7710
Body Controller output test....7710
Air 2 gauge fault codes....7711
Check for short to GND in Secondary Air Pressure signal circuit....7716
Check for short to GND in Secondary Air Pressure signal circuit B40A....7717
Check for VREF and GND at Secondary Air Pressure Transducer....7717
Check for Open or high resistance in Secondary Air Pressure signal circuit....7717
Check for Open or high resistance in Secondary Air Pressure signal circuit A40A....7717
Check for Open or high resistance in Secondary Air Pressure signal circuit B40A....7718
Body Controller output test....7718
Coolant temperature feature codes....7719
Coolant temperature fault codes....7719
Oil pressure feature codes....7720
Oil pressure fault codes....7720
Oil temperature feature codes....7721
Oil temperature fault codes....7721
Engine speed feature codes....7722
Engine speed fault codes....7722
Vehicle speed feature codes....7723
Vehicle speed fault codes....7723
Fault codes....7724
Ambient Air Temperature Sensor Table....7725
Feature Codes....7729
Fog Light Symptom Diagnostics....7729
Fog Light Fault Code Diagnostics....7729
Feature Codes....7767
Low Beam Headlight Diagnostics....7767
High Beam Headlight Diagnostics....7769
Software Feature Codes....7845
Normal Operation....7850
Symptom Diagnostics....7850
Fault Code Diagnostics....7851
Diagnostic Section....7869
Software Feature Codes....7869
Turn Signal Input and Front Turn Lamp Diagnostics....7880
Combined Stop and Turn Lamps....7927
Separate Stop and Turn Lamps....7957
Feature Codes....7982
Park / Marker Lights....7983
Feature Codes....8009
Trailer Lights Symptom Diagnostics....8010
Diagnostics....8063
Feature Codes....8078
Theft Deterrent Diagnostics....8079
Feature Codes....8089
Windshield Wiper Diagnostics....8090
Washer Pump Diagnostics....8091
Windshield Wiper Input Switch....8091
Torque Chart....8236
Torque Chart Cummins® ISX15 Engine....8367
Torque....8537
SERVICE LOAD AND INFLATION CHART (NOT MICHELIN) (For Trucks, Buses and Trailers in Normal Highway Service)....8572
SERVICE LOAD AND INFLATION CHART (NOT MICHELIN) (For Trucks, Buses and Trailers in Normal Highway Service) (Cont.)....8573
SERVICE LOAD AND INFLATION CHART (NOT MICHELIN) (For Trucks, Buses and Trailers in Normal Highway Service) (Cont.)....8574
SERVICE LOAD AND INFLATION CHART (MICHELIN ONLY) (For Trucks, Buses and Trailers in Normal Highway Service)....8575
SERVICE LOAD AND INFLATION CHART (MICHELIN ONLY) (For Trucks, Buses and Trailers in Normal Highway Service) (Cont.)....8576
TIRE AND RIM COMBINATIONS - Tires Designed for Normal Highway Service....8577
Ply Rating vs. Load Range....8578
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Revision 1 (Supersedes 0000001601, 0000001843 and 0000002222) Service Manual....8581
toc....8583
Table of Contents....8583
1. Description....8595
1.1. Cooling Package Visual Inspection....8600
2. Cooling Package Cleaning Procedures....8601
2.1. Cleaning Cooling Package (MaxxForce® 9, and 10 Engines) ....8602
2.2. Cleaning Cooling Package (Navistar® 11 and 13 Engines) ....8603
2.3. Charge Air Cooler Cleaning Procedure....8606
Overview....8606
Tools Required....8607
Service Parts....8607
2.3.1. Charge Air Cooler Cleaning Procedure Setup....8607
2.3.2. Off-chassis Pressure Test....8608
2.3.3. Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation....8610
2.3.4. Charge Air Cooler Cleaning Procedure....8612
2.3.5. Flushing Procedure....8613
2.3.6. Cleaning Management System (CMS) Removal Procedure....8614
3. PayStar® and 9900....8616
3.1. PayStar® and 9900 Description ....8622
3.1.1. Deaeration Tank ....8622
3.1.2. Fan Shroud ....8622
3.1.3. A/C Condenser ....8622
3.1.4. Transmission Oil Cooler ....8622
3.1.5. Radiator ....8622
3.1.6. Charge Air Cooler ....8622
3.1.7. Low-Temperature Radiator ....8622
3.1.8. Fan Drive....8623
3.2. Coolant Drain and Pressure Test Procedures....8625
3.2.1. Coolant Drain Procedure (Recommended)....8627
3.2.2. Pressure Test (Recommended)....8629
3.2.3. Coolant Fill Procedure (Recommended)....8631
3.2.4. Coolant Gravity Drain Procedure (Optional)....8634
3.2.5. Coolant Fill Procedure (Optional) Cummins® ISB6.7 Engine)....8635
3.2.6. Coolant Fill Procedure – MaxxForce 11 Liter, 13 Liter, 15 Liter (Optional)....8637
3.2.7. Coolant Fill Procedure – Cummins® ISX 15 Engines (Optional)....8640
3.3. PayStar® and 9900 Removal and Installation....8642
3.3.1. Splash Panel – Removal....8643
3.3.2. Splash Panel – Installation....8643
3.3.3. Grille – Removal....8644
3.3.4. Grille Installation....8644
3.3.5. Surge Tank (Cummins® ISB6.7 Engine) – Removal....8645
3.3.6. Surge Tank (Cummins® ISB6.7 Engine) – Installation....8645
3.3.7. Deaeration Tank – Removal....8647
3.3.8. Deaeration Tank – Installation....8648
3.3.9. A/C Condenser (N13 Engine) – Removal....8649
3.3.10. A/C Condenser (N13 Engine) – Installation....8650
3.3.11. A/C Condenser (Cummins® ISX) – Removal....8650
3.3.12. A/C Condenser (Cummins® ISX) – Installation....8651
3.3.13. Upper Fan Shroud (N13 Engine) – Removal....8652
3.3.14. Upper Fan Shroud (N13) – Installation....8654
3.3.15. Lower Fan Shroud (N13) – Removal ....8655
3.3.16. Lower Fan Shroud (N13) – Installation....8658
3.3.17. Fan Shroud (Two and Three Piece) Cummins® ISX15 Engines – Removal....8659
3.3.18. Fan Shroud (Two Piece) Cummins® ISX15 Engines – Installation ....8662
3.3.19. Fan Belt N13 – Removal....8663
3.3.20. Fan Belt (N13) – Installation....8664
3.3.21. Fan Belt (MaxxForce® 15 Engine) – Removal....8664
3.3.22. Fan Belt (MaxxForce® 15) – Installation....8666
3.3.23. Alternator Fan Belt (MaxxForce® 15) – Removal....8666
3.3.24. Alternator Fan Belt (MaxxForce® 15) – Installation....8667
3.3.25. Fan Belt (Cummins®ISX15) – Removal....8668
3.3.26. Fan Belt (Cummins® ISX15) – Installation....8669
3.3.27. Transmission Oil Cooler (Cross-member Mounted) – Removal....8670
3.3.28. Transmission Oil Cooler (Cross-member mounted) – Installation....8671
3.3.29. Transmission Oil Cooler (Front Mounted) – Removal....8672
3.3.30. Transmission Oil Cooler (Front Mounted) – Installation....8672
3.3.31. Radiator Hose Heat Shrink Clamp – Removal and Installation....8674
Heat Shrink Clamp – Removal....8674
Heat Shrink Clamp – Installation....8675
3.3.32. Radiator Hose (N13) – Removal....8677
3.3.33. Radiator Hose (N13) – Installation....8680
3.3.34. Radiator Hose (Series 9900 with Cummins® ISX15) – Removal ....8681
3.3.35. Radiator Hose (Series 9900 with Cummins® ISX15) – Installation....8684
3.3.36. Front Charge Air Cooler (N13) – Removal....8685
3.3.37. Front Charge Air Cooler (N13) – Installation....8686
3.3.38. Rear Charge Air Cooler (N13) – Removal....8687
3.3.39. Rear Charge Air Cooler (N13) – Installation....8687
3.3.40. Charge Air Cooler (Cummins® ISX15) – Removal....8688
3.3.41. Charge Air Cooler (Cummins®ISX15) – Installation....8689
3.3.42. Low-Temperature Radiator – Removal....8690
3.3.43. Low-Temperature Radiator – Installation....8692
3.3.44. Radiator Assembly (N13) – Removal....8693
3.3.45. Radiator Assembly (N13) – Installation ....8696
3.3.46. Radiator Assembly (Cummins®ISX15) – Removal....8697
3.3.47. Radiator Assembly (Cummins®ISX15) – Installation....8702
3.3.48. Recirculation Seals (MaxxForce® 11 or 13 L) – Removal....8705
3.3.49. Recirculation Seals (MaxxForce® 11 or 13 L) – Installation....8706
3.3.50. Recirculation Seals (MaxxForce® 15 L) – Removal ....8707
3.3.51. Recirculation Seals (MaxxForce® 15) – Installation ....8710
3.3.52. Radiator Core (MaxxForce® 11 L or 13 L) – Removal....8710
3.3.53. Radiator Core (MaxxForce® 11 L or 13 L) – Installation....8712
3.3.54. Radiator Core (MaxxForce® 15 L) – Removal....8712
3.3.55. Radiator Core (MaxxForce® 15 L) – Installation....8714
3.3.56. Radiator Core- Removal – (Cummins® ISX15) ....8715
3.3.57. Radiator Core Installation – (Cummins® ISX15) ....8718
3.3.58. Power Steering Oil Cooler (Cummins® ISX15) – Removal....8719
3.3.59. Power Steering Oil Cooler (Cummins® ISX15) – Installation....8719
3.4. PayStar® Inspection Procedures....8720
3.4.1. Deaeration Tank Inspection Procedure....8720
3.4.2. Deaeration Tank Cap Vacuum Relief Check....8721
3.4.3. Fan Drive Pulley Crack Inspection....8722
3.4.4. Fan Drive Pulley Nick Inspection....8722
3.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....8723
Fuel Cooler Valve (FCV) Filter Screen – Removal....8723
Fuel Cooler Valve (FCV) Filter Screen – Installation....8724
3.5. Torque Chart....8725
4. ProStar®....8727
4.1. ProStar®General Description....8733
4.1.1. Deaeration Tank....8733
4.1.2. Fan Shroud....8733
4.1.3. A/C Condenser....8733
4.1.4. Transmission Oil Cooler....8733
4.1.5. Radiator....8733
4.1.6. Charge Air Cooler....8733
4.1.7. Low-Temperature Radiator....8733
4.1.8. Fan Drive....8733
4.1.9. Power Steering Oil Cooler....8734
4.2. ProStar® Coolant Drain, Pressure Test, and Fill procedures ....8735
4.2.1. Coolant Drain Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....8739
4.2.2. Pressure Test Procedure – Navistar® 11, 13, 15, and Cummins® ISX15 (Recommended)....8741
4.2.3. Coolant Fill Procedure – Navistar® 11, 13, 15 and Cummins® ISX15 (Recommended)....8742
4.2.4. Coolant Drain Procedure – Navistar® 11, 13, 15, Cummins® ISX15 (Optional)....8745
4.2.5. Coolant Fill Procedure – Navistar® 11, 13, 15 (Optional)....8746
4.2.6. Coolant Fill Procedure – Cummins® ISX Engines (Optional)....8749
4.3. ProStar ® Removal and Installation....8751
4.3.1. Grille – Removal....8752
4.3.2. Grille – Installation....8752
4.3.3. Deaeration Tank Removal – Navistar® 11, 13, 15....8752
4.3.4. Deaeration Tank – Installation Navistar® 11, 13, N13, 15....8753
4.3.5. Deaeration Tank Removal – Cummins® ISX15....8754
4.3.6. Deaeration Tank Installation – Cummins® ISX15....8755
4.3.7. A/C Condenser Removal – MaxxForce® 11, 13 and N13....8756
4.3.8. A/C Condenser Installation – MaxxForce® 11, 13 or N13 ....8759
4.3.9. A/C Condenser Removal – Navistar® 15 L ....8760
4.3.10. A/C Condenser Installation – Navistar® 15 L ....8761
4.3.11. A/C Condenser Removal – Cummins® ISX15 ....8762
4.3.12. A/C Condenser Installation – Cummins® ISX15....8763
4.3.13. Fan Shroud Removal – MaxxForce® 11, 13, N13....8764
4.3.14. Fan Shroud Installation – MaxxForce® 11, 13 L and N13....8770
4.3.15. Fan Shroud Removal – (Three-Piece Upper) Navistar® 15 ....8770
4.3.16. Fan Shroud Installation – (Three-Piece Upper) Navistar® 15 ....8772
4.3.17. Fan Shroud Removal – (Three-Piece Lower) Navistar® 15 ....8773
4.3.18. Fan Shroud Installation – (Three-Piece Lower) Navistar® 15....8773
4.3.19. Fan Shroud (One-Piece) Removal – Navistar® 15....8774
4.3.20. Fan Shroud Installation – (One-Piece) Navistar® 15....8775
4.3.21. Fan Shroud Removal – (Two-Piece) Cummins® ISX15....8776
4.3.22. Fan Shroud Installation – (Two-Piece) Cummins® ISX15....8780
4.3.23. Radiator Fan Removal – Navistar® 11, 13....8780
4.3.24. Radiator Fan Installation – Navistar® 11, 13 ....8781
4.3.25. Radiator Fan Removal (With Three-Piece Fan Shroud) – Navistar® 15....8781
4.3.26. Radiator Fan Installation (With Three-Piece Fan Shroud) – Navistar® 15....8782
4.3.27. Radiator Fan Removal (With One-Piece Fan Shroud) – Navistar® 15....8782
4.3.28. Radiator Fan Installation (With One-Piece Fan Shroud) – Navistar® 15....8783
4.3.29. Radiator Fan Removal – Cummins® ISX15....8784
4.3.30. Radiator Fan Installation – Cummins® ISX15....8784
4.3.31. Fan Drive Removal – Navistar® 11, 13....8785
4.3.32. Fan Drive Installation – Navistar® 11, 13....8787
4.3.33. Fan Drive Removal – Navistar® 15....8787
4.3.34. Fan Drive Installation – Navistar® 15....8788
4.3.35. Fan Drive Assembly Removal – Cummins® ISX15 (Horton)....8788
4.3.36. Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ....8791
4.3.37. Fan Belt Removal – Navistar® 11, 13....8792
4.3.38. Fan Belt Installation – Navistar® 11, 13....8793
4.3.39. Fan Belt Removal – Navistar® 15 ....8793
4.3.40. Fan Belt Installation – Navistar® 15....8795
4.3.41. Alternator Fan Belt Removal – Navistar® 15 ....8795
4.3.42. Alternator Fan Belt Installation – Navistar® 15 ....8797
4.3.43. Fan Belt Removal – Cummins® ISX15 ....8797
4.3.44. Fan Belt Installation – Cummins® ISX15....8799
4.3.45. Radiator Hose Heat Shrink Clamp Removal and Installation....8799
Heat Shrink Clamp Removal....8799
Heat Shrink Clamp Installation....8800
4.3.46. Radiator Hose Removal – Navistar® 11, 13 ....8804
4.3.47. Radiator Hose Installation – Navistar® 11, 13....8805
4.3.48. Radiator Hose Removal – Navistar® 15 ....8806
4.3.49. Radiator Hose Installation – Navistar® 15....8807
4.3.50. Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Removal – Navistar® N13....8808
4.3.51. Exhaust Gas Recirculation (EGR) Valve / Cooler Hose Installation – Navistar® N13....8810
4.3.52. Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Removal – Navistar® 15 ....8813
4.3.53. Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Installation – Navistar® 15....8815
4.3.54. Radiator Hose Removal – Cummins® ISX15....8818
4.3.55. Radiator Hose Installation – Cummins® ISX15 ....8820
4.3.56. Recirculation Seals Removal – Navistar® 11, 13....8821
4.3.57. Recirculation Seals Installation – Navistar® 11, 13 ....8822
4.3.58. Recirculation Seals Removal – Navistar® 15 ....8822
4.3.59. Recirculation Seals Installation – Navistar® 15....8823
4.3.60. Charge Air Cooler Removal – Navistar® 11, 13, 15....8824
4.3.61. Charge Air Cooler Installation – Navistar® 11, 13, 15....8825
4.3.62. Charge Air Cooler Removal – Cummins® ISX15....8825
4.3.63. Charge Air Cooler Installation – Cummins® ISX15....8829
4.3.64. Hood-Tilt Assist Cylinder – Removal....8830
4.3.65. Hood-Tilt Assist Cylinder – Installation....8832
4.3.66. Low-Temperature Radiator Removal – Navistar® 11, 13....8833
4.3.67. Low-Temperature Radiator Installation – Navistar® 11, 13....8835
4.3.68. Low-Temperature Radiator Removal – Navistar® 15....8836
4.3.69. Low-Temperature Radiator Installation – Navistar® 15....8840
4.3.70. Radiator Assembly Removal – Navistar® 11, 13....8841
4.3.71. Radiator Assembly Installation – Navistar® 11, 13....8842
4.3.72. Radiator Assembly Removal – Navistar® 15....8844
4.3.73. Radiator Assembly Installation – Navistar® 15....8846
4.3.74. Radiator Assembly Removal – Cummins® ISX15....8847
4.3.75. Radiator Assembly Installation – Cummins® ISX15....8853
4.3.76. Radiator Core Removal – Navistar® 11, 13....8855
4.3.77. Radiator Core Installation – Navistar® 11, 13....8858
4.3.78. Radiator Core Removal – Navistar® 15....8859
4.3.79. Radiator Core Installation – Navistar® 15....8861
4.3.80. Radiator Core- Removal – Cummins® ISX15 ....8862
4.3.81. Radiator Core Installation – Cummins® ISX15 ....8866
4.3.82. Power Steering Oil Cooler – Removal....8867
4.3.83. Power Steering Oil Cooler – Installation....8869
4.3.84. Transmission Oil Cooler Removal (Cummins® ISX15 ONLY)....8869
4.3.85. Transmission Oil Cooler – Installation....8870
4.4. ProStar® Inspection Procedures....8872
4.4.1. Deaeration Tank Inspection Procedure....8872
4.4.2. Deaeration Tank Cap Vacuum Relief Check....8873
4.4.3. Fan Drive Pulley Crack Inspection....8874
4.4.4. Fan Drive Pulley Nick Inspection....8874
4.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....8875
Fuel Cooler Valve (FCV) Filter Screen – Removal....8875
Fuel Cooler Valve (FCV) Filter Screen – Installation....8876
4.5. Torque Chart Navistar® Engines....8877
5. TranStar®....8880
5.1. TranStar® General Description....8885
5.1.1. Deaeration Tank....8885
5.1.2. Fan Shroud....8885
5.1.3. A/C Condenser....8885
5.1.4. Transmission Oil Cooler....8885
5.1.5. Radiator....8885
5.1.6. Charge Air Cooler....8885
5.1.7. Low-Temperature Radiator....8885
5.1.8. Fan Drive....8885
5.2. TranStar® Coolant Drain, Pressure Test, and Fill procedures....8886
5.2.1. Coolant Drain, Pressure Test, and Fill procedures (Recommended)....8889
5.2.2. Pressure Test Procedure (Recommended)....8891
5.2.3. Coolant Fill Procedure (Recommended)....8894
5.2.4. Coolant Drain Procedure (Optional)....8897
5.3. TranStar® Removal and Installation....8898
5.3.1. Grille – Removal....8899
5.3.2. Grille – Installation....8899
5.3.3. Deaeration Tank – Removal....8899
5.3.4. Deaeration Tank – Installation....8900
5.3.5. A/C Condenser – Removal....8902
5.3.6. A/C Condenser – Installation....8904
5.3.7. Fan Shroud – Removal....8905
5.3.8. Fan Shroud – Installation....8908
5.3.9. Radiator Fan – Removal....8908
5.3.10. Radiator Fan – Installation....8909
5.3.11. Fan Clutch – Removal....8910
5.3.12. Fan Clutch – Installation....8911
5.3.13. Fan Belt – Removal....8912
5.3.14. Fan Belt – Installation....8914
5.3.15. Heat Shrink Clamp Removal and Installation....8914
Heat Shrink Clamp Removal....8914
Heat Shrink Clamp Installation....8915
5.3.16. Radiator Hose – Removal....8918
5.3.17. Radiator Hose – Installation....8922
5.3.18. Charge Air Cooler – Removal....8923
5.3.19. Charge Air Cooler – Installation....8925
5.3.20. Low-Temperature Radiator – Removal....8926
5.3.21. Low-Temperature Radiator – Installation....8927
5.3.22. Radiator Assembly – Removal....8928
5.3.23. Radiator Assembly – Installation....8930
5.3.24. Radiator Core – Removal....8931
5.3.25. Radiator Core – Installation....8933
5.3.26. Transmission Oil Cooler (Crossmember mounted) – Removal....8934
5.3.27. Transmission Oil Cooler (Crossmember mounted) – Installation....8934
5.4. TranStar® Inspection Procedures....8936
5.4.1. Deaeration Tank Inspection Procedure....8936
5.4.2. Deaeration Tank Cap Vacuum Relief Check....8937
5.4.3. Fan Drive Pulley Crack Inspection....8938
5.4.4. Fan Drive Pulley Nick Inspection....8938
5.4.5. Fuel Cooler Valve (FCV) Inspection Procedure....8939
Fuel Cooler Valve (FCV) Filter Screen – Removal....8939
Fuel Cooler Valve (FCV) Filter Screen – Installation....8940
5.5. Torque Chart....8941
6. WorkStar®....8942
6.1. WorkStar® and 9900 Description....8948
6.1.1. Surge Tank (If Equipped) ....8948
6.1.2. Deaeration Tank....8948
6.1.3. Fan Shroud....8948
6.1.4. Fan Drive....8948
6.1.5. A/C Condenser....8948
6.1.6. Radiator....8948
6.1.7. Charge Air Cooler....8948
6.1.8. Cross-Member....8948
6.1.9. Low-Temperature Radiator....8949
6.1.10. Low Temperature Radiator (LTR) Thermostat....8949
6.1.11. Fuel Cooler....8949
6.1.12. Transmission Oil Cooler....8949
6.2. WorkStar® Coolant Drain, Pressure Test, and Fill procedures....8950
6.2.1. Coolant Drain Procedure (Recommended)....8953
6.2.2. Pressure Test Procedure (Recommended)....8955
6.2.3. Coolant Fill Procedure (Recommended)....8958
6.2.4. Coolant Gravity Drain Procedure (Optional)....8961
6.2.5. Coolant Fill Procedure (MaxxForce® 9, and 10 Engines) (Optional)....8962
6.2.6. Coolant Fill Procedure (Navistar® 11 and 13 Engines) (Optional)....8964
6.2.7. Coolant Fill Procedure (optional) (Cummins® ISB6.7 Engine)....8966
6.3. WorkStar® Removal and Installation....8969
6.3.1. Grille (Standard) – Removal....8970
6.3.2. Grille (Standard) – Installation....8970
6.3.3. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....8970
6.3.4. Grille (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....8971
6.3.5. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....8971
6.3.6. Grille (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....8972
6.3.7. Splash Panel (Standard) – Removal....8972
6.3.8. Splash Panel (Standard) – Installation....8973
6.3.9. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....8973
6.3.10. Splash Panel (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....8974
6.3.11. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....8974
6.3.12. Splash Panel (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....8975
6.3.13. Surge Tank (with Cummins® ISB6.7 Engine) – Removal....8975
6.3.14. Surge Tank (with Cummins® ISB6.7 Engine) – Installation....8976
6.3.15. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Removal....8976
6.3.16. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Standard) – Installation....8977
6.3.17. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....8978
6.3.18. Deaeration Tank (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....8979
6.3.19. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....8979
6.3.20. Deaeration Tank (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....8980
6.3.21. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Removal ....8981
6.3.22. Deaeration Tank Hose (Single Mega Bracket) Cummins® ISB6.7 Engine – Installation....8983
6.3.23. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Removal....8983
6.3.24. A/C Condenser (MaxxForce® 9 and 10 Engines) (Standard) – Installation....8984
6.3.25. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....8985
6.3.26. A/C Condenser (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....8986
6.3.27. A/C Condenser (Navistar® 11 and 13 Engines) – Removal....8986
6.3.28. A/C Condenser (Navistar® 11 and 13 Engines) – Installation....8987
6.3.29. A/C Condenser (ISB6.7) Engine – Removal....8988
6.3.30. A/C Condenser (ISB6.7 Engine) – Installation....8988
6.3.31. Fan Belt with A/C (Cummins® ISB6.7 Engine) - Removal ....8989
6.3.32. Fan Belt with A/C (Cummins® ISB6.7 Engine) – Installation ....8989
6.3.33. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Removal....8991
6.3.34. Fan Shroud (MaxxForce® 9 and 10 Engines) (Standard) – Installation....8993
6.3.35. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....8994
6.3.36. Fan Shroud (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....8995
6.3.37. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Removal....8995
6.3.38. Fan Shroud (Navistar® 11 and 13 Engines) (Standard) – Installation....8997
6.3.39. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....8998
6.3.40. Upper Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9000
6.3.41. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9000
6.3.42. Lower Fan Shroud (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation ....9002
6.3.43. Fan Shroud (Cummins® ISB6.7 Engine) 7 similar - Removal....9002
6.3.44. Fan Shroud - Installation....9003
6.3.45. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Removal....9003
6.3.46. Fan and 12TSY Fan Drive (Borg-Warner SA85) Viscous Type, Screw On – Installation....9004
6.3.47. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Removal....9004
6.3.48. 12TTD Fan Drive Borg–Warner 842B Electronic Viscous Fan Type – Installation....9006
6.3.49. Radiator Fan (Standard) – Removal....9007
6.3.50. Radiator Fan (Standard) – Installation....9008
6.3.51. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....9008
6.3.52. Radiator Fan (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....9009
6.3.53. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9010
6.3.54. Radiator Fan (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9010
6.3.55. Heat Shrink Clamp Removal and Installation....9011
Heat Shrink Clamp Removal....9011
Heat Shrink Clamp Installation....9012
6.3.56. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Removal....9014
6.3.57. Radiator Hose (MaxxForce® 9 and 10 Engines) (Standard) – Installation....9016
6.3.58. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....9016
6.3.59. Radiator Hose (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....9019
6.3.60. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Removal....9020
6.3.61. Radiator Hose (Navistar® 11 and 13 Engines) (Standard) – Installation....9022
6.3.62. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9022
6.3.63. Radiator Hoses (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9026
6.3.64. Coolant Package – Removal....9027
Overview....9027
6.3.65. Coolant Package – Installation....9031
6.3.66. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....9033
6.3.67. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....9034
6.3.68. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....9035
6.3.69. Charge Air Cooler (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....9035
6.3.70. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....9036
6.3.71. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....9039
6.3.72. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9040
6.3.73. Front Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9041
6.3.74. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....9042
6.3.75. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....9044
6.3.76. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9044
6.3.77. Rear Charge Air Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9045
6.3.78. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Removal....9046
6.3.79. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Standard) – Installation....9048
6.3.80. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal....9048
6.3.81. Low-Temperature Radiator (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation....9049
6.3.82. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Removal....9049
6.3.83. Low-Temperature Radiator (Navistar® 11 and 13 Engines) (Standard and Enhanced Vision) – Installation....9052
6.3.84. Low Temperature Radiator (LTR) Thermostat – Removal....9053
6.3.85. Low Temperature Radiator (LTR) Thermostat – Installation....9054
6.3.86. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Removal....9056
6.3.87. Radiator Core (MaxxForce® 9 and 10 Engines) (Standard) – Installation....9060
6.3.88. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Removal ....9062
6.3.89. Radiator Core (MaxxForce® 9 and 10 Engines) (Enhanced Vision) – Installation ....9068
6.3.90. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Removal....9071
6.3.91. Radiator Core (Navistar® 11 and 13 Engines) (Standard) – Installation....9073
6.3.92. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9074
6.3.93. Radiator Core (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9076
6.3.94. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Removal....9077
6.3.95. Transmission Oil Cooler (MaxxForce® 9 and 10 Engines) (Standard) – Installation....9078
6.3.96. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Removal....9079
6.3.97. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Standard) – Installation....9080
6.3.98. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9080
6.3.99. Transmission Oil Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9081
6.3.100. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Removal....9081
6.3.101. Fuel Cooler (Navistar® 11 and 13 Engines) (Enhanced Vision) – Installation....9082
6.3.102. Low Temperature Radiator Hoses – Removal....9082
6.3.103. Low Temperature Radiator (LTR) Thermostat Hose – Installation....9084
6.4. WorkStar® Inspection Procedures....9086
6.4.1. Deaeration Tank Inspection Procedure....9086
6.4.2. Deaeration Tank Cap Vacuum Relief Check....9087
6.4.3. Fan Drive Pulley Crack Inspection....9088
6.4.4. Fan Drive Pulley Nick Inspection....9088
6.4.5. 12TSY Fan Drive (Borg-Warner SA85) Viscous Type Inspection Procedures....9089
6.4.6. 12TTD Borg – Warner 842B Visctronics Inspection Procedure....9090
6.4.7. Fuel Cooler Valve (FCV) Inspection Procedure....9090
Fuel Cooler Valve (FCV) Filter Screen – Removal....9090
Fuel Cooler Valve (FCV) Filter Screen – Installation....9092
6.5. Torque Chart....9093
7. 12THT Horton DriveMaster Fan Drive System....9097
7.1. 12THT Horton Drivemaster Fan Drive System Removal and Installation....9097
7.1.1. 12THT Radiator Fan (N13) – Removal....9097
7.1.2. 12THT Radiator Fan (N13) – Installation....9097
7.1.3. 12THT Radiator Fan (Cummins® ISX15) – Removal....9098
7.1.4. 12THT Radiator Fan Cummins® ISX15 – Installation....9098
7.1.5. Fan Removal – (12THZ and 12THT Horton DA) (optional)....9099
7.1.6. Fan Installation – (12THZ and 12THT Horton DA) (optional)....9099
7.1.7. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Removal....9100
7.1.8. 12THT Horton (DA) Non-Serviceable Fan Drive with ISB6.7 – Installation....9101
7.1.9. 12THT Horton (DMA) Serviceable Fan Drive – Removal....9101
7.1.10. 12THT Horton DriveMaster Advantage (DMA) Serviceable Fan Drive – Installation....9105
7.1.11. 12THT Pulley Bearing – Removal....9106
7.1.12. 12THT Pulley Bearing – Installation....9106
7.1.13. 12THT Fan Drive Friction Liner– Removal....9107
7.1.14. 12THT Fan Drive Friction Liner – Installation....9109
7.1.15. 12THT Clutch Pack Seal Face – Removal....9110
7.1.16. 12THT Clutch Pack Seal Face – Installation....9110
7.1.17. 12THT Air Cartridge – Removal....9110
7.1.18. 12THT Air Cartridge – Installation....9111
7.2. 12THT Horton Drivemaster Fan Drive System Inspection Procedures....9113
7.2.1. Fan Drive Movement / Clutch Pack Bearing Check....9113
7.2.2. Clutch Pack Face Seal....9114
7.2.3. Cartridge Assembly Seal and Spring....9115
7.2.4. Friction Liner Measurement....9116
7.2.5. Fan Drive Bearing Measurement and Inspection....9117
7.3. 12THT Horton Drivemaster Fan Drive System Diagnostics....9118
7.3.1. 12THT Horton DriveMaster Fan Drive Operational Checks....9118
Overview....9118
Tools Required....9118
Operational Checks – Start Fan Drive Diagnostics Here.....9118
Visual Air Leak Check....9118
7.3.2. Symptom 1: Fan Always On....9121
7.3.3. Symptom 2: Fan Always Off....9137
7.3.4. Symptom 3: Cycles Too Frequently....9143
7.3.5. Symptom 4: Excessive Noise From Fan Drive....9145
8. 12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics ....9147
8.1. Start Diagnostics here: 12TTD Borg-Warner 842B Visctronic Fan Drive....9147
Overview....9147
Tools Required....9147
Operational Checks – Start Fan Drive Diagnostics Here....9147
8.2. Symptom 1: Fan Always ON....9149
8.3. Symptom 2: Fan Always OFF....9155
8.4. Symptom 3: Cycles Too Frequently....9172
8.5. Symptom 4: Excessive Noise From Fan Drive....9175
9. 12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....9177
9.1. Start Diagnostics Here: 12TSY Borg-Warner SA85 Fan Drive Assembly....9177
Overview....9177
Tools Required....9177
10. 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly....9179
10.1. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly Removal and Installation....9179
Tools Required....9179
10.1.1. 12TKY Borg-Warner Fan Drive Clutch Lining – Removal....9179
10.1.2. 12TKY Borg-Warner Fan Drive Clutch Lining – Installation....9179
10.1.3. 12TKY Borg-Warner Fan Drive and Hub Assembly – Removal....9180
10.1.4. 12TKY Borg-Warner Fan Drive and Hub Assembly – Installation....9180
10.2. 12TKY Borg-Warner K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Inspection....9182
10.2.1. 12TKY Borg-Warner Fan Drive Clutch Friction Lining Inspection....9182
10.3. Start Diagnostics here: 12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly System Diagnostics....9183
Overview....9183
Tools Required....9183
Operational Checks – Start Fan Drive Diagnostics here.....9183
10.4. Symptom 1: Fan Always On....9185
10.5. Symptom 2: Fan Always Off....9186
10.6. Symptom 3: Fan Cycles Too Frequently....9187
10.7. Clutch Will Not Engage....9187
10.8. Clutch Will Not Disengage....9188
10.9. Air Leak In Drive....9189
10.10. Symptom 4: Excessive Noise From Fan Drive....9190
11. 12THX Horton Stratis V-Master-Ultra Viscous Fan Drive Assembly System....9193
11.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly Removal and Installation....9193
11.1.1. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Removal....9193
11.1.2. 12THX Horton V-Master-Ultra Viscous Fan Drive Assembly — Installation....9194
11.2. 12THX Horton Stratis Viscous Fan Drive Assembly System Diagnostics....9195
11.2.1. 12THX Horton Stratis Viscous Fan Drive Assembly Diagnostics – Operations Checks....9195
Overview....9195
Tools Required....9195
Operational Checks – Start Fan Drive Diagnostics here.....9195
Visual Air Leak Check....9195
11.3. 12THX Horton Stratis Fan Drive Inspection, Pin Point Test, and ServiceMaxx™ Engine Fan Test....9198
11.3.1. Fan Drive Inspection....9198
11.3.2. Fan Drive Pin Point Test....9199
11.4. ServiceMaxx Engine Fan Test™....9199
11.5. Engine Fan Test Results....9202
11.5.1. Engine Fan Test Overview....9202
11.5.2. Properly Working Fan Hub Assembly....9202
11.6. Fan Engages Prematurely....9203
11.7. Symptom 1: Fan Always On....9203
11.8. Symptom 2: Fan Always Off....9204
11.9. Symptom 3: Fan Cycles Too Frequently....9205
11.10. Symptom 4: Excessive Noise From Fan Drive....9206
12. Abbreviations and Acronyms....9208
13. Terminology....9209
tables....8725
Table 7Torque Chart....8725
Table 13Torque Chart Navistar® Engines....8877
Table 14Torque Chart Cummins® ISX15 Engine....8879
Table 20Torque Chart....8941
Table 28Torque Chart....9093
0000857080 - ProStar Model NF2AD00 Built December 2015 and After (Euro V) Electrical Circuit Diagrams Australian Market....9212
0000863170 - 2010-2016 ProStar _ TranStar Technician Manual (Service and Diagnostic), Revision 18....9601
toc....9603
Table of Contents....9603
Safety Terminology....9606
Safety Instructions....9606
Work Area....9606
Safety Equipment....9606
Protective Measures....9606
Vehicle....9606
Engine....9607
Fire Prevention....9607
Batteries....9607
Compressed Air....9607
Tools....9607
Fluids Under Pressure....9608
Fuel....9608
Removal of Tools, Parts, and Equipment....9608
Frame....9609
1. Description....9611
Bumper....9611
Overview....9611
Two Piece Tilt-away Bumper....9611
One Piece Stationary Bumper....9612
Three Piece Tilt-away Bumper....9612
Three Piece Stationary Bumper....9612
Grille and Bug Screen....9613
Hood Assembly....9613
Hood Tilt Assist....9613
Hood Seal....9613
Splash Shields....9613
Air Intake....9613
Fender....9613
Fender Extensions....9613
Headlight Assembly....9613
2. Removal and Installation....9614
Equipment Conditions....9614
Tilt-away Bumper....9615
Removal....9615
Overview....9615
Equipment Conditions....9615
Procedure....9615
Installation....9619
Procedure....9619
Two Piece Tilt-away Bumper Panels....9620
Removal....9620
Overview....9620
Equipment Conditions....9620
Procedure....9620
Installation....9626
Procedure....9626
Bumper Latch....9628
Removal....9628
Overview....9628
Equipment Conditions....9628
Procedure....9629
Installation....9630
Torque Specifications....9630
Procedure....9630
Tilt Bracket....9631
Removal....9631
Overview....9631
Equipment Conditions....9631
Procedure....9631
Installation....9634
Procedure....9634
One Piece Stationary Bumper....9635
Removal....9635
Overview....9635
Equipment Conditions....9635
Procedure....9635
Installation....9637
Procedure....9637
One Piece Stationary Bumper Filler Panels....9638
Removal....9638
Overview....9638
Equipment Conditions....9638
Procedure....9638
Installation....9640
Torque Specifications....9640
Procedure....9640
Three Piece Bumper....9641
Overview....9641
Seal....9641
Removal....9641
Overview....9641
Equipment Conditions....9641
Procedure....9642
Follow-on Procedure....9642
Installation....9643
Torque Specifications....9643
Procedure....9643
Follow-on Procedure....9643
Upper Reinforcement Tubes....9644
Removal....9644
Overview....9644
Equipment Conditions....9644
Procedure....9644
Follow-on Procedure....9645
Installation....9646
Procedure....9646
Follow-on Procedure....9646
Lower Reinforcement Tubes....9647
Removal....9647
Overview....9647
Equipment Conditions....9647
Procedure....9647
Follow-on Procedure....9647
Installation....9648
Procedure....9648
Follow-on Procedure....9648
Left and Right Bumper Panel....9649
Removal....9649
Overview....9649
Equipment Conditions....9649
Procedure....9649
Follow-on Procedure....9650
Installation....9651
Procedure....9651
Follow-on Procedure....9651
Fixed Assembly....9652
Removal....9652
Overview....9652
Equipment Conditions....9652
Procedure....9652
Follow-on Procedure....9653
Installation....9654
Procedure....9654
Follow-on Procedure....9654
Air Intake Grille....9655
Removal....9655
Overview....9655
Equipment Conditions....9655
Procedure....9655
Follow-on Procedure....9655
Installation....9656
Procedure....9656
Follow-on Procedure....9656
Grille and Bug Screen....9657
Removal....9657
Equipment Condition....9657
Procedure....9657
Installation....9659
Procedure....9659
Splash Shields....9660
Removal....9660
Procedure....9660
Installation....9663
Procedure....9663
Hood....9664
Removal....9664
Equipment Condition....9664
Procedure....9664
Installation....9669
Procedure....9669
Follow-On Procedure....9670
Adjustment....9671
Equipment Condition....9671
Procedure....9671
Hood Tilt Assist....9673
Removal....9673
Equipment Condition....9673
Procedure....9673
Installation....9675
Procedure....9675
Torsion Bars....9676
Removal....9676
Procedure....9676
Installation....9677
Procedure....9677
Hood Latch....9678
Removal....9678
Equipment Condition....9678
Procedure....9678
Installation....9680
Procedure....9680
Hood Mirror....9681
Removal....9681
Procedure....9681
Installation....9683
Equipment Condition....9683
Procedure....9683
Hood Seal....9684
Removal....9684
Procedure....9684
Installation....9685
Torque Specifications....9685
Procedure....9685
Hood and Fender Panels....9686
Removal....9687
Tools Required....9687
Equipment Condition....9687
Procedure....9688
Installation....9696
Tools Required....9696
Equipment Condition....9696
Procedure....9697
Follow-On Procedure....9700
Fender Extensions....9701
Removal....9701
Procedure....9701
Installation....9703
Procedure....9703
Headlight Assembly....9704
Removal....9704
Procedure....9704
Installation....9705
Procedure....9705
Replacement....9706
Procedure....9706
Adjustment....9707
Equipment Condition....9707
Procedure....9707
Front Axle....9709
Front Suspension....9713
1. MaxxPower™ Front Air Suspension....9715
Overview....9715
Air System....9717
Overview....9717
Height Control Valves....9718
Overview....9718
Air Springs....9719
Overview....9719
Shock Absorbers....9721
Overview....9721
Torque Rods and Sway Bar....9722
Overview....9722
Overview....9722
Transverse Torque Rod and Cross Member....9724
Overview....9724
Remove and Install Procedures....9725
Height Control Valves....9725
Removal....9725
Equipment Condition....9725
Procedure....9725
Installation....9727
Procedure....9727
Follow-On Procedure....9727
Air Springs....9728
Removal....9728
Equipment Conditions....9728
Procedure....9728
Installation....9730
Procedure....9730
Follow-On Procedure....9731
Shock Absorber....9732
Removal....9732
Procedure....9732
Installation....9733
Procedure....9733
Sway Bar (03AZD)....9734
Removal....9734
Procedure....9734
Installation....9735
Procedure....9735
Integrated Sway Bar Assembly (03AZD and 03AZG)....9737
Removal....9737
Procedure....9737
Installation....9738
Procedure....9738
Follow-On Procedure....9738
Lower Torque Rods (03AZD)....9739
Removal....9739
Equipment Conditions....9739
Procedure....9739
Installation....9740
Procedure....9740
Follow-On Procedure....9740
Upper Torque Rods....9741
Removal....9741
Equipment Conditions....9741
Procedure....9741
Installation....9742
Equipment Conditions....9742
Procedure....9742
Follow-On Procedure....9742
Transverse Torque Rod....9743
Removal....9743
Equipment Conditions....9743
Procedure....9743
Installation....9745
Procedure....9745
Checks and Adjustments....9746
Ride Height....9746
Check Ride Height....9746
Equipment Conditions....9746
Procedure....9746
Follow-On Procedure....9749
Ride Height Adjustment....9750
Equipment Conditions....9750
Procedure....9750
Front Axle Caster....9752
Left Front Wheel Caster Angle....9752
Overview....9752
Rear Frame Angle....9753
Overview....9753
Decrease Caster Adjustment....9754
Equipment Conditions....9754
Procedure....9754
Increase Caster Adjustment....9756
Equipment Conditions....9756
Procedure....9756
Torque....9758
Brakes....9759
1. Air Systems....9761
Air Compressors....9761
MCAC 465 Air Compressor....9761
Overview....9761
Cylinder Head....9762
Crankcase....9763
Name Plate....9763
Compressor Maintenance....9763
Oil Leakage At The Head Gasket Inspection....9769
Air Brake System and Accessory Leakage Test....9770
Air Compressor Discharge Temperature and Air Dryer Inlet Temperature Test....9771
Governor Malfunction Test....9772
Governor Control Line Test....9773
Compressor Clutch Operation - No Air Charging Test....9774
Compressor Clutch Operation - Continuous Air Charging Test....9775
Removal....9776
Overview....9776
Special Tools....9776
Equipment Conditions....9776
Procedure....9776
Follow-On Procedure....9777
Installation....9778
Overview....9778
Special Tools....9778
Equipment Conditions....9778
Procedure....9778
Follow-On Procedure....9779
Cylinder Head Disassembly....9780
Equipment Conditions....9780
Procedure....9780
Follow-On Procedure....9781
Crankcase Disassembly....9782
Procedure....9782
Follow-On Procedure....9788
Crankcase Assembly....9789
Procedure....9789
Follow-On Procedure....9795
Cylinder Head Assembly....9796
Procedure....9796
Follow-On Procedure....9797
Steering....9799
1. Steering Wheel and Steering Column Assembly....9801
Description....9801
Steering Wheel....9801
Clock Spring....9801
Steering Column....9802
Remove and Install Procedures....9803
Equipment Conditions....9803
Steering Wheel....9804
Overview....9804
Removal....9805
Procedure....9805
Installation....9807
Procedure....9807
Clock Spring....9809
Removal....9809
Equipment Conditions....9809
Procedure....9809
Installation....9812
Procedure....9812
Follow-On Procedure....9813
Steering Column....9814
Overview....9814
Removal....9814
Equipment Conditions....9814
Procedure....9814
Installation....9816
Procedure....9816
Follow-On Procedure....9816
Checks and Adjustments....9817
Steering Wheel....9817
Check....9817
Procedure....9817
Adjustment....9817
Overview....9817
Procedure....9817
Follow-On Procedure....9817
Torque....9818
2. Power Steering Gear: Sheppard M-Series....9819
Identification....9819
Operation....9822
OIL FLOW THROUGH THE GEAR....9822
Steering System Diagnostics....9825
Diagnostic Overview....9825
Define the Concern....9825
Perform Visual Inspection....9825
Inspect Mechanical Components....9825
Hydraulic Diagnosis....9825
Oil Flow and Pressure Recommendations....9828
Common Complaints....9828
Troubleshooting....9831
Symptoms Table....9831
Re-phasing Column....9834
Troubleshooting Checklist....9835
Preventative Maintenance....9836
Fluid and Filter Change....9836
Input Shaft Seal Replacement — Disassembly....9838
Input Shaft Seal Replacement — Assembly....9842
Bleeding....9845
Single Gear System....9845
Dual Steering Gears....9847
Set Relief Plungers....9850
Overview....9850
Equipment Conditions....9850
Procedure....9850
Pitman Arm....9852
Removal....9852
Overview....9852
Equipment Conditions....9852
Procedure....9852
Installation....9854
Overview....9854
Equipment Conditions....9854
Procedure....9856
Steering Gear....9862
Disassembly....9862
Sub-assembly Repair....9877
M-SERIES - OPTIONAL INTEGRAL RELIEF VALVE....9877
Clean....9879
Inspection....9880
Overview....9880
Parts Discolored (Blue)....9880
Broken Housing....9881
Housing or Piston Scoring....9882
Sector Shaft Roller (Bearing Wear)....9883
Actuating Shaft....9884
Thrust Bearings....9885
(Pitted, Rough)....9885
(Broken or Distorted)....9885
Actuating Shaft Thread Wear....9886
Piston Rings Cut, Pinched, Sheered or Worn....9887
Reassembly....9888
Procedure....9888
Follow-On Procedure....9904
Dual Steering System....9906
Description....9906
Operation....9906
Integral Slave Gear....9909
Adjustments....9911
Final....9911
Axle Stop....9911
Specifications....9912
Torque....9913
Special Tools....9914
Glossary of Terms and Definitions....9915
Drivelines....9917
1. Propeller Shaft....9919
Overview....9919
Basic Function....9920
Universal Joints....9920
Overview....9920
Slip Joint....9921
Overview....9921
Center (Carrier) Bearing....9922
Overview....9922
Maintenance....9923
Service Checks....9923
Full Round End Yokes....9926
Removal....9926
Overview....9926
Equipment Conditions....9926
Procedure....9926
Disassembly....9928
Procedure....9928
Clean and Inspect....9929
Procedure....9929
Assembly....9930
Procedure....9930
Installation....9932
Overview....9932
Procedure....9932
Half Round End Yokes....9935
Removal....9935
Overview....9935
Equipment Conditions....9935
Procedure....9935
Clean and Inspect....9936
Procedure....9936
Installation....9937
Procedure....9937
Center (Carrier) Bearing....9939
Removal....9939
Overview....9939
Equipment Conditions....9939
Procedure....9939
Disassembly....9940
Assembly....9941
Procedure....9941
Installation....9942
Procedure....9942
Slip Joint....9943
Disassembly....9943
Procedure....9943
Assembly....9944
Overview....9944
Torque Specifications....9944
Procedure....9944
Outside / Inside Snap Ring Yoke Universal Joint....9945
Disassembly....9945
Procedure....9945
Assembly....9947
Procedure....9947
Cross Bearing and End Surfaces....9950
Clean and Inspect....9950
Procedure....9950
Vibration....9951
Overview....9951
Possible Causes....9951
Types of Vibration....9953
Transverse Vibration....9953
Overview....9953
Torsional Vibration....9954
Overview....9954
Checking Propeller Shaft Runout (Propeller Shaft Installed)....9955
Overview....9955
Torque Specifications....9955
Equipment Conditions....9955
Procedure....9955
Propeller Shaft Phasing....9956
Overview....9956
Balancing Propeller Shaft....9957
Overview....9957
Re-phasing Propeller Shaft....9957
Equipment Conditions....9957
Procedure....9957
Adding Weight to Propeller Shaft....9958
Procedure....9958
Checking Driveline Angles....9960
Overview....9960
Driveline Angle Measurement....9960
Equipment Conditions....9960
Procedure....9960
Joint Working Angle Cancellation....9965
Overview....9965
How JWAs Change with Load....9966
Overview....9966
Troubleshooting....9968
Troubleshooting Chart....9968
Lubrication....9970
Universal Joint....9970
Overview....9970
Slip Joint....9971
Overview....9971
Torque....9972
Special Tools....9973
Exhaust....9975
Electrical / Software....9979
1. Diagnostic Trouble Code (DTC) List....9987
2. Electronic Service Tools (EST)....9991
Diamond Logic® Builder....9991
Overview....9991
Selecting an Interface Cable....9993
Overview....9993
Special Tools....9993
Equipment Conditions....9993
Selection Procedure....9993
Follow-On Procedure....9994
Connecting to a Vehicle....9995
Overview....9995
Special Tools....9995
Equipment Conditions....9995
Connection Procedure....9995
Follow-On Procedure....9996
Activating Diagnostic Mode....9997
Overview....9997
Special Tools....9997
Equipment Conditions....9997
Activation Procedure....9997
Follow-On Procedure....9998
Starting a Session....9999
Overview....9999
Special Tools....9999
Equipment Conditions....9999
Starting Procedure....9999
Follow-On Procedure....10000
Viewing Fault Codes....10001
Overview....10001
Special Tools....10001
Equipment Conditions....10001
Viewing Procedure....10001
Follow-On Procedure....10001
Clearing Fault Codes....10002
Overview....10002
Special Tools....10002
Equipment Conditions....10002
Clearing Procedure....10002
Follow-On Procedure....10002
Modifying Signals Tab....10003
Overview....10003
Special Tools....10003
Equipment Conditions....10003
Modify Watched Signal Columns....10003
Modify Watched Signals....10004
Follow-On Procedure....10004
Programming Modules....10005
Overview....10005
Special Tools....10005
Equipment Conditions....10005
Programming Procedure....10006
Follow-On Procedure....10009
Input Not Recognized by Body Control Module....10010
Overview....10010
Special Tools....10010
Equipment Conditions....10010
Troubleshooting Procedure....10010
Follow-On Procedure....10011
Output Not Commanded by Body Control Module....10012
Overview....10012
Special Tools....10012
Equipment Conditions....10012
Troubleshooting Procedure....10012
Follow-On Procedure....10013
3. General Electrical Repair....10014
Electrical Connector Cleaning....10014
Overview....10014
Special Tools....10014
Specifications....10014
Equipment Conditions....10014
Cleaning Procedure....10014
Follow-On Procedure....10014
4. 12 Volt Electrical System....10015
Auto Start Stop....10015
With Switch Control....10015
Overview....10015
Operational Checkout Procedure....10017
Overview....10017
Battery Box....10019
Overview....10019
Battery Box Locations....10021
Left Side Battery Box (Standard)....10021
Auxiliary Battery Box (Between the Frame Rails)....10022
Auxiliary Battery Box (Left Side Mounted)....10023
Battery Disconnect Procedure....10024
Disconnect Batteries....10024
Reconnect Battery Procedure....10025
Torque Specifications....10025
Reconnect Batteries....10025
Battery Terminal Cleaning....10027
Overview....10027
Special Tools....10027
Equipment Conditions....10027
Cleaning Procedure....10028
Follow-On Procedure....10028
Battery Disconnect Switch....10029
Overview....10029
Cooper Bussmann Inverter....10030
Overview....10030
Overview....10030
Inverter Diagnostics....10030
Operational Checkout Procedure....10032
Diagnostic Steps....10032
Inverter Inoperative....10034
Symptom Overview....10034
Symptom Facts....10034
Possible Causes....10034
Diagnostic Steps....10035
Pin-Point Test - Inverter Inoperative....10036
Tools Required....10036
E01 – DC Input Under-Voltage Shutdown....10038
Fault Code Overview....10038
Fault Facts....10038
Possible Causes....10038
Diagnostic Steps....10039
Pin-Point Test - E01....10040
Tools Required....10040
E02 – DC Input Over-Voltage Shutdown....10042
Fault Code Overview....10042
Fault Facts....10042
Possible Causes....10042
Diagnostic Steps....10043
Pin-Point Test - E02....10044
Tools Required....10044
E03 – Inverter Output Overload....10045
Fault Code Overview....10045
Fault Facts....10045
Possible Causes....10045
Diagnostic Steps....10046
E04 – Inverter Over-Temperature Shutdown....10047
Fault Code Overview....10047
Fault Facts....10047
Possible Causes....10047
Diagnostic Steps....10048
E05 – DC Input Under-Voltage Warning....10049
Fault Code Overview....10049
Fault Facts....10049
Possible Causes....10049
Diagnostic Steps....10050
Pin-Point Test - E05....10051
Tools Required....10051
E06 – Inverter Output Overload Warning....10053
Fault Code Overview....10053
Fault Facts....10053
Possible Causes....10053
Diagnostic Steps....10054
E07 – Inverter Over-Temperature Warning....10055
Fault Code Overview....10055
Fault Facts....10055
Possible Causes....10055
Diagnostic Steps....10056
E10 – Charger Output Over-Voltage Shutdown....10057
Fault Code Overview....10057
Fault Facts....10057
Possible Causes....10057
Diagnostic Steps....10058
E11 – Battery Not Accepting Charge....10059
Fault Code Overview....10059
Fault Facts....10059
Possible Causes....10059
Diagnostic Steps....10060
Pin-Point Test - E11....10061
Tools Required....10061
E12 – Transfer Relay Over-Temperature Shutdown....10063
Fault Code Overview....10063
Fault Facts....10063
Possible Causes....10063
Diagnostic Steps....10064
Remote Start Stop....10065
Overview....10065
500K....10067
Overview....10067
Operational Checkout Procedure....10068
Overview....10068
Not Operating with 500K....10069
Fault Overview....10069
Fault Facts....10069
Possible Causes....10069
Pin-Point Test - Remote Start / Stop Not Operating with 500K....10075
Tools Required....10075
250K....10076
Overview....10076
Operational Checkout Procedure....10078
Starting and Charging....10079
Overview....10079
Operational Checkout Procedure....10080
Electrical System Operational Checkout Procedure....10080
Starting System....10081
Overview....10081
Battery Pack....10081
Starter....10081
Control....10081
No Click No Crank....10082
Overview....10082
Possible Causes....10082
Click No Crank....10084
Overview....10084
Possible Causes....10084
Low Cranking Speed....10086
Overview....10086
Possible Causes....10086
250K Input Diagnostics....10087
Overview....10087
Manual Transmission Starter Input Diagnostics....10088
Manual Transmission Start Input Pinpoint Tests....10091
Tools Required....10091
Automatic Transmission Starter Input Diagnostics....10099
Automatic Transmission Starter Input Pinpoint Tests....10101
Tools Required....10101
500K Input Diagnostics....10104
Overview....10104
Key Switch and Grid Control....10104
Crank Inhibit....10104
GridCtrl_CrankInhibit....10104
Crank_Inhibit_Reason....10105
Lower_Clutch_Signal....10105
Neutral_Status_TCM....10105
Transmission_Engine_Crank_Enable (SPN 2900 - J1939 signal)....10105
Hood_Switch....10105
500K Input Operational Checkout Procedure....10107
Overview....10107
Park Brake Switch Diagnostics....10111
Overview....10111
Tools Required....10111
Equipment Condition....10111
Test Setup....10111
Possible Causes....10111
Charging System....10114
Overview....10114
Battery Pack....10114
Alternator....10114
Red Battery Warning Light....10115
Overview....10115
Possible Causes....10115
Repeated Jump Starts....10117
Overview....10117
Possible Causes....10117
Battery Gauge Reading High....10119
Overview....10119
Possible Causes....10119
Battery Gauge Reading Low / Fluctuating....10120
Overview....10120
Possible Causes....10120
Tests and Inspections....10122
Individual Battery Test....10122
Overview....10122
Special Tools....10122
Equipment Condition....10122
Test Setup....10122
Test Procedure....10123
Expected Outcome....10125
Follow-On Procedure....10125
Electrical System Test....10126
Overview....10126
Special Tools....10126
Equipment Condition....10127
Test Setup....10127
Battery Pack Test Procedure....10129
Starter System Test Procedure....10132
Charging System Test Procedure....10134
Expected Outcome....10137
Follow-On Procedure....10137
Cable Drop Test....10138
Overview....10138
Special Tools....10138
Equipment Condition....10138
Test Setup....10138
Test Procedure....10138
Expected Outcome....10141
Follow-On Procedure....10141
Parasitic Draw Test....10142
Overview....10142
Special Tools....10142
Equipment Condition....10142
Test Setup....10142
Test Procedure....10142
Expected Outcome....10145
Follow-On Procedure....10145
Manual Engine Bar Test....10146
Overview....10146
Tools Required....10146
Equipment Condition....10146
Test Setup....10146
Test Procedure....10146
Expected Outcome....10146
Follow-On Procedure....10146
Starter Control Circuit Test....10147
Overview....10147
Tools Required....10147
Equipment Condition....10147
Test Setup....10147
Test Procedure....10147
Expected Outcome....10148
Follow-On Procedure....10148
Ring Gear Inspection....10149
Overview....10149
Special Tools....10149
Equipment Conditions....10149
Inspection Procedure....10149
Expected Outcome....10150
Follow-On Procedure....10150
Electrical System Inspection....10151
Overview....10151
Tools Required....10151
Equipment Condition....10151
Inspection Procedure....10151
Expected Outcome....10152
Follow-On Procedure....10152
5. Accessories....10154
Steering Wheel Switches....10154
Overview....10154
Tests....10157
Cruise Control Steering Wheel Switch Circuit Test....10157
Pin-Point Tests - Cruise Control Steering Wheel Switch....10159
Tools Required....10159
Multiplexed Steering Wheel Switch Circuit Test....10163
Pin-Point Tests - Multiplexed Steering Wheel Switch....10165
Tools Required....10165
Radio Control Steering Wheel Switch Circuit Test....10169
Pin-Point Tests - Radio Control Steering Wheel Switch....10171
Tools Required....10171
6. Collision Avoidance Systems....10175
Collision Mitigation System....10175
Bendix Wingman Fusion....10175
Overview....10175
Adaptive Cruise Control (ACC)....10177
Alerts....10177
Collision Mitigation Braking....10178
SafetyDirect Capability....10178
Stationary Vehicle Braking (SVB)....10178
Tech Tips....10180
Operational Checkout Procedure....10181
Overview....10181
Symptom 2: Camera Sensor Loss of Communication....10184
Overview....10184
Fault Facts....10184
Tools Required....10184
Possible Causes....10184
Symptom 3: SafetyDirect Module Loss of Communication....10187
Overview....10187
Fault Facts....10187
Tools Required....10187
Possible Causes....10187
Camera Removal....10190
Special Tools....10190
Torque Specifications....10190
Equipment Conditions....10190
Removal Procedure....10190
Follow-On Procedure....10191
Camera Installation....10192
Special Tools....10192
Torque Specifications....10192
Equipment Conditions....10192
Installation Procedure....10192
Follow-On Procedure....10193
SafetyDirect Module High Roof Removal....10194
Special Tools....10194
Torque Specifications....10194
Equipment Conditions....10194
Removal Procedure....10194
Follow-On Procedure....10196
SafetyDirect Module High Roof Installation....10197
Special Tools....10197
Equipment Conditions....10197
Installation Procedure....10197
Follow-On Procedure....10199
SafetyDirect Module Low Roof Removal....10200
Special Tools....10200
Torque Specifications....10200
Equipment Conditions....10200
Removal Procedure....10200
Follow-On Procedure....10200
SafetyDirect Module Low Roof Installation....10201
Special Tools....10201
Torque Specifications....10201
Equipment Conditions....10201
Installation Procedure....10201
Follow-On Procedure....10201
7. Data Links....10202
J1708....10202
Switch Pack Electrical Tests....10202
Overview....10202
Special Tools....10202
Equipment Condition....10202
Test Setup....10202
Test Procedure....10202
Follow-On Procedure....10205
500K J1939....10206
Overview....10206
500K Diagnostic Connector Overview....10206
J1939 Public Bus....10208
Overview....10208
J1939 Bus Faults....10208
Bus open on the backbone....10209
Bus open or loss of power to an individual module....10209
Bus short....10210
J1939 Public communication bus....10210
J1939 Communication Faults with Navistar Launcher....10214
Overview....10214
Associated Symptoms....10214
Fault Facts....10214
J1939 Public Bus Operational Check....10216
Overview....10216
J1939 Bus Integrity Checks....10217
Overview....10217
J1939 Diagnostics – Bus Open....10218
Overview....10218
J1939 Public bus diagnostics - Open in IP Harness....10223
J1939 Public bus diagnostics - Open in Forward Chassis Harness....10228
J1939 Diagnostics- Bus inactive....10233
J1939 Center IP diagnostics – SP1024....10236
J1939 Center IP Diagnostics - SP1025....10240
J1939 Center IP diagnostics — SP1026....10244
J1939 Right IP Harness diagnostics....10247
J1939 Left IP Harness Module Diagnostics....10249
J1939 Forward / Center Chassis Module Diagnostics....10251
J1939 Powertrain harness diagnostics — Navistar engine....10253
J1939 Powertrain harness diagnostics — Cummins engine....10255
8. Engine....10256
Cummins Diagnostics....10256
Table Of Contents....10256
Fault Code Diagnostics....10257
Fault Code List....10257
SPN 111 FMI 1 (Cummins FC 235) - Coolant Level - Data Valid But Below Normal Operating Range - Most Severe Level....10259
Fault Overview....10259
Associated Faults....10259
Fault Facts....10259
Conditions For Clearing The Fault Codes....10259
Possible Causes....10259
SPN 111 FMI 3 (Cummins FC 195) - Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source....10271
Fault Overview....10271
Associated Faults....10271
Fault Facts....10271
Conditions For Clearing The Fault Codes....10271
Possible Causes....10271
SPN 111 FMI 4 (Cummins FC 196) - Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source....10283
Fault Overview....10283
Associated Faults....10283
Fault Facts....10283
Conditions For Clearing The Fault Codes....10283
Possible Causes....10283
SPN 111 FMI 17 (Cummins FC 2448) - Coolant Level - Data Valid But Below Normal Operating Range - Least Severe Level....10295
Fault Overview....10295
Associated Faults....10295
Fault Facts....10295
Conditions For Clearing The Fault Codes....10295
Possible Causes....10295
SPN 111 FMI 18 (Cummins FC 197) - Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level....10307
Fault Overview....10307
Associated Faults....10307
Fault Facts....10307
Conditions For Clearing The Fault Codes....10307
Possible Causes....10307
SPN 1569 FMI 15 (Cummins FC 6255) - Engine Protection Torque Derate - Data Valid But Above Normal Operating Range - Least Severe Level....10319
Fault Overview....10319
Associated Faults....10319
Fault Facts....10319
Conditions For Clearing The Fault Codes....10319
Possible Causes....10319
SPN 1569 FMI 31 (Cummins FC 3714) - Engine Protection Torque Derate - Condition Exists....10320
Fault Overview....10320
Associated Faults....10320
Fault Facts....10320
Conditions For Clearing The Fault Codes....10320
Possible Causes....10320
SPN 1761 FMI 1 (Cummins FC 1673) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Most Severe Level....10321
Fault Overview....10321
Associated Faults....10321
Fault Facts....10321
Conditions For Clearing The Fault Codes....10321
Possible Causes....10321
SPN 1761 FMI 3 (Cummins FC 1669) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Above Normal or Shorted to High Source....10322
Fault Overview....10322
Associated Faults....10322
Fault Facts....10322
Conditions For Clearing The Fault Codes....10322
Possible Causes....10322
SPN 1761 FMI 4 (Cummins FC 1668) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit - Voltage Below Normal or Shorted to Low Source....10323
Fault Overview....10323
Associated Faults....10323
Fault Facts....10323
Conditions For Clearing The Fault Codes....10323
Possible Causes....10323
SPN 1761 FMI 9 (Cummins FC 4677) Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Abnormal Update Rate ....10324
Fault Overview....10324
Associated Faults....10324
Fault Facts....10324
Conditions For Clearing The Fault Codes....10324
Possible Cause....10324
SPN 1761 FMI 10 (Cummins FC 4769) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Abnormal Rate of Change....10329
Fault Overview....10329
Associated Faults....10329
Fault Facts....10329
Conditions For Clearing The Fault Codes....10329
Possible Causes....10329
SPN 1761 FMI 11 (Cummins FC 4739) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Root Cause Not Known....10332
Fault Overview....10332
Associated Faults....10332
Fault Facts....10332
Conditions For Clearing The Fault Codes....10332
Possible Causes....10332
SPN 1761 FMI 13 (Cummins FC 4732) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor - Out of Calibration....10333
Fault Overview....10333
Associated Faults....10333
Fault Facts....10333
Conditions For Clearing The Fault Codes....10333
Possible Causes....10333
SPN 1761 FMI 17 (Cummins FC 3497) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range - Least Severe Level....10334
Fault Overview....10334
Associated Faults....10334
Fault Facts....10334
Conditions For Clearing The Fault Codes....10334
Possible Causes....10334
SPN 1761 FMI 18 (Cummins FC 3498) - Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data Valid But Below Normal Operating Range -Moderately Severe Level ....10335
Fault Overview....10335
Associated Faults....10335
Fault Facts....10335
Conditions For Clearing The Fault Codes....10335
Possible Causes....10335
SPN 3031 FMI 2 (Cummins FC 1679) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data Erratic, Intermittent, or Incorrect....10336
Fault Overview....10336
Associated Faults....10336
Fault Facts....10336
Conditions For Clearing The Fault Codes....10336
Possible Causes....10336
SPN 3031 FMI 3 (Cummins FC 1678) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Above Normal or Shorted to High Source ....10338
Fault Overview....10338
Associated Faults....10338
Fault Facts....10338
Conditions For Clearing The Fault Codes....10338
Possible Causes....10338
SPN 3031 FMI 4 (Cummins FC 1677) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage Below Normal or Shorted to Low Source....10339
Fault Overview....10339
Associated Faults....10339
Fault Facts....10339
Conditions For Clearing The Fault Codes....10339
Possible Causes....10339
SPN 3031 FMI 9 (Cummins FC 4572) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Abnormal Update Rate....10340
Fault Overview....10340
Associated Faults....10340
Fault Facts....10340
Conditions For Clearing The Fault Codes....10340
Possible Cause....10340
SPN 3031 FMI 11 (Cummins FC 4737) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Root Cause Not Known....10345
Fault Overview....10345
Associated Faults....10345
Fault Facts....10345
Conditions For Clearing The Fault Codes....10345
Possible Causes....10345
SPN 3031 FMI 13 (Cummins FC 4731) - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Out of Calibration....10346
Fault Overview....10346
Associated Faults....10346
Fault Facts....10346
Conditions For Clearing The Fault Codes....10346
Possible Causes....10346
SPN 3364 FMI 2 (Cummins FC 3878) - Aftertreatment Diesel Exhaust Fluid Quality - Data Erratic, Intermittent, or Incorrect....10347
Fault Overview....10347
Associated Faults....10347
Fault Facts....10347
Conditions For Clearing The Fault Codes....10347
Possible Causes....10347
SPN 3364 FMI 3 (Cummins FC 1686) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Above Normal or Shorted to High Source....10348
Fault Overview....10348
Associated Faults....10348
Fault Facts....10348
Conditions For Clearing The Fault Codes....10348
Possible Cause....10348
SPN 3364 FMI 4 - (Cummins 1685) - Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage Below Normal or Shorted to Low Source....10350
Fault Overview....10350
Associated Faults....10350
Fault Facts....10350
Conditions For Clearing The Fault Codes....10350
Possible Cause....10350
SPN 3364 FMI 9 (Cummins FC 3868) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Update Rate....10352
Fault Overview....10352
Associated Faults....10352
Fault Facts....10352
Conditions For Clearing The Fault Codes....10352
Possible Cause....10352
SPN 3364 FMI 10 (Cummins FC 4277) - Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate of Change ....10357
Fault Overview....10357
Associated Faults....10357
Fault Facts....10357
Conditions For Clearing The Fault Codes....10357
Possible Causes....10357
SPN 3364 FMI 11 (Cummins FC 1715) - Aftertreatment Diesel Exhaust Fluid Quality - Root Cause Not Known....10360
Fault Overview....10360
Associated Faults....10360
Fault Facts....10360
Conditions For Clearing The Fault Codes....10360
Possible Causes....10360
SPN 3364 FMI 13 (Cummins FC 1714) - Aftertreatment Diesel Exhaust Fluid Quality - Out of Calibration....10361
Fault Overview....10361
Associated Faults....10361
Fault Facts....10361
Conditions For Clearing The Fault Codes....10361
Possible Causes....10361
SPN 3364 FMI 15 (Cummins FC 4842) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal Operating Range - Least Severe Level....10362
Fault Overview....10362
Associated Faults....10362
Fault Facts....10362
Conditions For Clearing The Fault Codes....10362
Possible Causes....10362
SPN 3364 FMI 18 (Cummins FC 3867) - Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Below Normal Operating Range - Moderately Severe Level....10364
Fault Overview....10364
Associated Faults....10364
Fault Facts....10364
Conditions For Clearing The Fault Codes....10364
Possible Causes....10364
SPN 3521 FMI 11 (Cummins FC 4768) - Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known....10366
Fault Overview....10366
Associated Faults....10366
Fault Facts....10366
Conditions For Clearing The Fault Codes....10366
Possible Causes....10366
SPN 3521 FMI 16 (Cummins FC 6765) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Above Normal Operating Range - Moderately Severe Level....10367
Fault Overview....10367
Associated Faults....10367
Fault Facts....10367
Conditions For Clearing The Fault Codes....10367
Possible Causes....10367
SPN 3521 FMI 18 (Cummins FC 6766) - Aftertreatment Diesel Exhaust Fluid Property - Data Valid But Below Normal Operating Range - Moderately Severe Level....10369
Fault Overview....10369
Associated Faults....10369
Fault Facts....10369
Conditions For Clearing The Fault Codes....10369
Possible Causes....10369
SPN 3521 FMI 31 (Cummins FC 4235) - Aftertreatment 1 Diesel Exhaust Fluid Property- Condition Exists....10371
Fault Overview....10371
Associated Faults....10371
Fault Facts....10371
Conditions For Clearing The Fault Codes....10371
Possible Causes....10371
SPN 4096 FMI 31 (Cummins FC 3547) - Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition Exists....10373
Fault Overview....10373
Associated Faults....10373
Fault Facts....10373
Conditions For Clearing The Fault Codes....10373
Possible Causes....10373
SPN 5246 FMI 0 (Cummins FC 3712) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Most Severe Level....10374
Fault Overview....10374
Associated Faults....10374
Fault Facts....10374
Conditions For Clearing The Fault Codes....10374
Possible Causes....10374
SPN 5246 FMI 15 (Cummins FC 4134) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Least Severe Level....10375
Fault Overview....10375
Associated Faults....10375
Fault Facts....10375
Conditions For Clearing The Fault Codes....10375
Possible Causes....10375
SPN 5246 FMI 16 (Cummins FC 6254) - Aftertreatment SCR Operator Inducement - Data Valid But Above Normal Operating Range - Moderately Severe Level....10376
Fault Overview....10376
Associated Faults....10376
Fault Facts....10376
Conditions For Clearing The Fault Codes....10376
Possible Causes....10376
Tests and Inspections....10377
Overview....10377
DEF Head Unit Coolant Line Routing Inspection....10378
Overview....10378
Tools Required....10378
Equipment Condition....10378
Inspection Procedure....10378
Expected Outcome....10379
DEF Quality Test....10380
Overview....10380
Tools Required....10380
Equipment Condition....10380
Test Procedure....10380
Expected Outcome....10381
DEFTHV Coolant Flow Test....10382
Overview....10382
Tools Required....10382
Equipment Condition....10382
Test Setup....10382
Test Procedure....10382
Expected Outcome....10382
9. HVAC....10383
On-Highway HVAC System....10383
Front HVAC System (Day Cab)....10384
Overview....10384
Condenser....10385
A/C compressor....10385
HVAC controller....10385
Air Distribution (General)....10386
Air Distribution....10388
NORM A/C / Instrument Panel Vent (A)....10389
MAX A/C (B)....10389
Bi-Level A/C (C)....10389
Heat and Ventilation Floor (D)....10389
Bi-Level Defrost / Heat (E)....10389
Defrost (F)....10389
A/C Refrigerant Flow....10390
Compression....10390
Condensation....10391
Expansion....10391
Evaporation....10391
General Operation of the HVAC Electrical System....10391
Operational Checkout Procedure....10393
Overview....10393
Special Tools....10393
A/C Blows Warm All the Time (Incorrect System Pressure)....10396
Overview....10396
Fault Facts....10396
Special Tools....10396
Possible Causes....10396
Heater Does Not Blow Warm....10400
Overview....10400
Associated Faults....10400
Fault Facts....10400
Special Tools....10400
Possible Causes....10400
Compressor Does Not Cycle....10402
Overview....10402
Associated Faults....10402
Fault Facts....10402
Special Tools....10402
Possible Causes....10402
Operator Not Able to Control Air Flow Outlet....10405
Overview....10405
Fault Facts....10405
Special Tools....10405
Possible Causes....10405
SPN 876 FMI 5 – HVAC Compressor Clutch Engagement Undercurrent....10409
Overview....10409
Associated Faults....10409
Fault Facts....10409
Special Tools....10409
Possible Causes....10409
SPN 1552 FMI 2 – A/C Control Head Temperature Mix DM1....10410
Overview....10410
Associated Faults....10410
Fault Facts....10410
Special Tools....10410
Possible Causes....10410
SPN 2609 FMI 15 – A/C Refrigerant Low Charge Protection....10412
Overview....10412
Associated Faults....10412
Fault Facts....10412
Possible Causes....10412
SPN 2609 FMI 16 – A/C High Pressure Protection....10413
Overview....10413
Associated Faults....10413
Fault Facts....10413
Possible Causes....10413
SPN 3981 FMI 2 – Defrost Door Actuator - Data Intermittent or Incorrect....10415
Overview....10415
Associated Faults....10415
Fault Facts....10415
Special Tools....10415
Possible Causes....10415
SPN 3984 FMI 2 – Recirculation Door Actuator - Data Intermittent or Incorrect....10417
Overview....10417
Associated Faults....10417
Fault Facts....10417
Special Tools....10417
Possible Causes....10417
SPN 3985 FMI 9 – HVAC Control Module Circuit Failed To Communicate With the Body Control Module....10419
Overview....10419
Associated Faults....10419
Fault Facts....10419
Special Tools....10419
Possible Causes....10419
SPN 520465 FMI 2 – HVAC Control Module - Multiple Actuator Faults....10422
Overview....10422
Associated Faults....10422
Fault Facts....10422
Special Tools....10422
Possible Causes....10422
Rear HVAC System (Sleeper)....10426
Overview....10426
Rear Air Distribution (General)....10429
Rear Air Distribution (A/C)....10430
Rear Air Distribution (Heat)....10430
A/C Refrigerant Flow – Sleeper A/C System....10431
General Operation of the Rear HVAC Electrical System....10433
Operational Checkout Procedure....10434
Overview....10434
Special Tools....10434
Dash Switches Don’t Control Rear A/C....10436
Overview....10436
Fault Facts....10436
Special Tools....10436
Possible Causes....10436
Operator Not Able to Control Rear HVAC from Rear Controls....10439
Overview....10439
Fault Facts....10439
Special Tools....10439
Possible Causes....10439
SPN 2058 FMI 9 – Rear HVAC Data Link Communication Failure....10442
Overview....10442
Associated Faults....10442
Fault Facts....10442
Special Tools....10442
Possible Causes....10442
SPN 2058 FMI 14 – Rear HVAC Data Link Communication Failure....10448
Overview....10448
Associated Faults....10448
Fault Facts....10448
Special Tools....10448
Possible Causes....10448
SPN 3982 FMI 2 – A/C Rear Blower Speed Control Switch Error....10454
Overview....10454
Associated Faults....10454
Fault Facts....10454
Special Tools....10454
Possible Causes....10454
SPN 3983 FMI 2 – Cab HVAC Rear Temperature Control Switch Error....10455
Overview....10455
Associated Faults....10455
Fault Facts....10455
Special Tools....10455
Possible Causes....10455
Tests....10456
A/C Compressor Clutch Electrical Tests....10458
Overview....10458
Special Tools....10458
Equipment Condition....10458
Test Setup....10458
Test Procedure....10458
Follow-On Procedure....10461
A/C Compressor Compression Test....10462
Overview....10462
Special Tools....10462
Equipment Condition....10462
Test Procedure....10462
Expected Outcome....10462
A/C Pressure Readings Indicating Problems....10463
Overview....10463
Special Tools....10463
Equipment Condition....10463
Low-Side Pressure Low, High-Side Pressure Low....10464
Possible Causes....10464
Low-Side Pressure Low, High-Side Pressure Normal or High....10465
Possible Causes....10465
High-Side and Low-Side Pressures Normal or Slightly Low, Duct Output Not Cold....10466
Possible Causes....10466
Low-Side Pressure Normal, High-Side Pressure High....10467
Possible Causes....10467
Low-Side Pressure High, High-Side Pressure Low....10468
Possible Causes....10468
Low-Side Pressure High, High-Side Pressure Normal....10469
Possible Causes....10469
Low-Side Pressure High, High-Side Pressure High....10470
Possible Causes....10470
High-Side Pressure Excessively High or Low....10470
A/C Request Electrical Tests....10471
Overview....10471
Special Tools....10471
Equipment Condition....10471
Test Setup....10471
Test Procedure....10471
Follow-On Procedure....10472
A/C System Restriction Test....10473
Overview....10473
Special Tools....10473
Equipment Condition....10473
Test Setup....10473
Test Procedure....10473
Follow-On Procedure....10474
Blend Door Tests....10475
Overview....10475
Special Tools....10475
Equipment Condition....10475
Test Setup....10475
Test Procedure....10476
Follow-On Procedure....10481
Blower Motor Electrical Tests....10482
Overview....10482
Special Tools....10482
Equipment Condition....10482
Test Setup....10482
Test Procedure....10482
Follow-On Procedure....10484
Body Control Module Power and Ground Tests....10485
Overview....10485
Special Tools....10485
Equipment Condition....10485
Test Setup....10485
Test Procedure....10485
Follow On Procedure....10488
Charge Quantity Measurement Test....10489
Overview....10489
Special Tools....10489
Equipment Condition....10489
Test Setup....10489
Test Procedure....10489
Expected Outcome....10489
Compressor Clutch Signal Test....10490
Overview....10490
Special Tools....10490
Equipment Condition....10490
Test Setup....10490
Test Procedure....10491
Follow-On Procedure....10493
Control Head Electrical Tests....10494
Overview....10494
Special Tools....10494
Equipment Condition....10494
Test Setup....10494
Follow On Procedure....10496
Freeze Probe Electrical Tests....10497
Overview....10497
Special Tools....10497
Equipment Condition....10497
Test Setup....10497
Test Procedure....10497
Follow On Procedure....10499
Front A/C System Functional Test....10500
Overview....10500
Special Tools....10500
Equipment Condition....10500
Test Setup....10500
Test Procedure....10500
Follow On Procedure....10500
Heater Core Seal Leak Test....10501
Overview....10501
Special Tools....10501
Equipment Condition....10501
Test Setup....10501
Test Procedure....10502
Follow-On Procedure....10503
HVAC Actuator Calibration Procedure....10504
Overview....10504
Special Tools....10504
Specifications....10504
Equipment Condition....10504
Calibration Procedure....10504
Follow-On Procedure....10504
Refrigerant Leak Detection Test....10505
Overview....10505
Special Tools....10505
Equipment Condition....10505
Test Setup....10505
Refrigerant Present Test Procedure....10506
No Refrigerant Present Test Procedure....10507
No Refrigerant Present - High Pressure Nitrogen Test Procedure....10507
Follow-On Procedure....10509
Low-Pressure Switch Electrical Tests....10510
Overview....10510
Special Tools....10510
Equipment Condition....10510
Test Setup....10510
Test Procedure....10510
Follow-On Procedure....10512
Mode Door Tests....10513
Overview....10513
Special Tools....10513
Equipment Conditions....10513
Test Setup....10513
Test Procedure....10514
Follow-On Procedure....10519
Pressure Transducer Electrical Tests....10520
Overview....10520
Special Tools....10520
Equipment Condition....10520
Test Setup....10520
Four-wire Pressure / Temperature Reading Test Procedure....10521
Three-wire Pressure Transducer Test Procedure....10523
Follow-On Procedure....10524
Pressure Transducer Functional Test....10525
Overview....10525
Special Tools....10525
Equipment Condition....10525
Test Setup....10525
Pressure Test Procedure....10525
Temperature Test Procedure....10525
Rear HVAC Input Test....10527
Overview....10527
Special Tools....10527
Equipment Condition....10527
Test Setup....10527
Test Procedure....10527
Follow On Procedure....10529
Rear A/C System Functional Test....10530
Overview....10530
Special Tools....10530
Equipment Condition....10530
Test Setup....10530
Test Procedure....10530
Follow-On Procedure....10531
Rear Blend Door Electrical Tests....10532
Overview....10532
Special Tools....10532
Equipment Condition....10532
Test Setup....10532
Test Procedure....10532
Expected Outcome....10534
Rear Blend Door Movement Test....10535
Overview....10535
Special Tools....10535
Equipment Condition....10535
Test Setup....10535
Test Procedure....10535
Expected Outcome....10535
Rear Blower Motor Electrical Test....10536
Overview....10536
Special Tools....10536
Equipment Condition....10536
Test Setup....10536
Test Procedure....10536
Expected Outcome....10539
Rear HVAC Controller Electrical Test....10540
Overview....10540
Special Tools....10540
Equipment Condition....10540
Test Setup....10540
Test Procedure....10540
Expected Outcome....10540
Rear HVAC Analog Switch Electrical Tests....10541
Overview....10541
Special Tools....10541
Equipment Condition....10541
Test Setup....10541
Blower Switch Test Procedure....10541
Follow-On Procedure....10542
Temperature Switch Test Procedure....10543
Follow-On Procedure....10544
Rear HVAC Digital Switch Electrical Tests....10545
Overview....10545
Special Tools....10545
Equipment Condition....10545
Test Setup....10545
Test Procedure....10545
Follow-On Procedure....10547
Recirculation Door Tests....10548
Overview....10548
Special Tools....10548
Equipment Condition....10548
Test Setup....10548
Test Procedure....10549
Follow-On Procedure....10554
Refrigerant Identification....10555
Overview....10555
Special Tools....10555
Equipment Condition....10555
Test Setup....10555
Test Procedure....10555
Follow-On Procedure....10555
Static Refrigerant Pressure Test....10556
Overview....10556
Special Tools....10556
Equipment Condition....10556
Test Setup....10556
Test Procedure....10556
Follow On Procedure....10557
Dynamic Refrigerant Pressure Test....10558
Overview....10558
Special Tools....10558
Equipment Condition....10558
Test Setup....10558
Test Procedure....10558
Follow-On Procedure....10559
Inspections....10560
A/C System Internal Damage Inspection....10561
Overview....10561
Special Tools....10561
Equipment Condition....10561
Inspection Procedure....10561
Follow-On Procedure....10564
HVAC System Inspection....10565
Overview....10565
Special Tools....10565
Equipment Condition....10565
Inspection Procedure....10566
Follow-On Procedure....10573
HVAC Module Inspection....10574
Overview....10574
Special Tools....10574
Equipment Condition....10574
Inspection Procedure....10574
Follow-On Procedure....10575
Rear A/C Electrical System Inspection....10576
Overview....10576
Special Tools....10576
Equipment Condition....10576
Inspection Procedure....10576
Follow-On Procedure....10577
No Idle A/C System....10578
Overview....10578
Component Locations....10579
System Operation....10582
Blower Motor....10584
Linear Power Module (LPM)....10584
Discharge Temperature Sensor....10584
Inlet Temperature Sensor....10584
System Controller....10584
Compressor Controller....10584
Blend Door Actuator....10585
Flow Control Valve....10585
HVAC Control Panel....10585
Engine Preheat Switch....10585
HVAC Filter....10585
No Idle Condenser....10585
No Idle Condenser Fan....10586
Evaporator (Shared)....10586
No Idle A/C Compressor....10586
No Idle Receiver-Drier....10586
No Idle High Pressure Switch....10586
Heater Coil (Shared)....10586
HVAC Plumbing....10587
Expansion Valve....10587
HVAC Drain Tube....10588
No Idle Coolant Heater....10588
Coolant Shutoff Valves....10588
Circuit Diagram....10589
Diagnostics....10590
Operational Checkout Procedures....10591
Overview....10591
Special Tools....10591
Symptoms....10594
System INOP....10594
Overview....10594
Special Tools....10594
Possible Causes....10594
Short Run Time....10609
Overview....10609
Possible Causes....10609
No Air Flow From Vents....10611
Overview....10611
Special Tools....10611
Possible Causes....10611
Blows Warm When Cold Requested....10623
Overview....10623
Special Tools....10623
Possible Causes....10623
Blows Cold When Warm is Requested....10642
Overview....10642
Tools Required....10642
Possible Causes....10642
Excessive System Cycling....10650
Overview....10650
Tools Required....10650
Possible Causes....10650
Noisy or Vibrates....10659
Overview....10659
Possible Causes....10659
Fault Codes....10661
SPN 109 FMI 14 – Pressure Switch Circuit Open....10661
Fault Overview....10661
Associated Faults....10661
Fault Facts....10661
Special Tools....10661
Possible Causes....10661
SPN 168 FMI 3 – Battery Voltage High....10664
Fault Overview....10664
Associated Faults....10664
Fault Facts....10664
Special Tools....10664
Possible Causes....10664
SPN 168 FMI 4 – Voltage Low....10665
Fault Overview....10665
Associated Faults....10665
Fault Facts....10665
Special Tools....10665
Possible Causes....10665
SPN 1547 FMI 0 – Inlet Temp Sensor High....10667
Fault Overview....10667
Associated Faults....10667
Fault Facts....10667
Special Tools....10667
Possible Causes....10667
SPN 1547 FMI 1 - Inlet Temp Sensor Low....10669
Fault Overview....10669
Associated Faults....10669
Fault Facts....10669
Special Tools....10669
Possible Causes....10669
SPN 1548 FMI 3 – Discharge Temp Sensor High....10671
Fault Overview....10671
Associated Faults....10671
Fault Facts....10671
Special Tools....10671
Possible Causes....10671
SPN 1548 FMI 4 – Discharge Temp Sensor Low....10673
Fault Overview....10673
Associated Faults....10673
Fault Facts....10673
Special Tools....10673
Possible Causes....10673
SPN 2058 FMI 9 – Rear A/C Data Link Communication Failure....10675
Fault Overview....10675
Associated Faults....10675
Fault Facts....10675
Special Tools....10675
Possible Causes....10675
SPN 2058 FMI 14 – Rear A/C Data Link Communication Failure....10687
Fault Overview....10687
Associated Faults....10687
Fault Facts....10687
Special Tools....10687
Possible Causes....10687
SPN 520210 FMI 6 – Blower Output short Circuit....10699
Fault Overview....10699
Associated Faults....10699
Fault Facts....10699
Special Tools....10699
Possible Causes....10699
SPN 520808 FMI 14 – No idle Compressor Relay Open / short....10705
Fault Overview....10705
Associated Faults....10705
Fault Facts....10705
Special Tools....10705
Possible Causes....10705
SPN 520810 FMI 14 – Condenser Fan Relay short / Open....10720
Fault Overview....10720
Associated Faults....10720
Fault Facts....10720
Special Tools....10720
Possible Causes....10720
Tests and Inspections....10733
Amperage Draw Test....10733
Overview....10733
Tools Required....10733
Equipment Condition....10733
Test Setup....10733
Test Procedure....10733
Expected Outcome....10735
Follow-On Procedure....10735
Blend Door Calibration Procedure....10736
Overview....10736
Tools Required....10736
Equipment Condition....10736
Test Setup....10736
Test Procedure....10736
Expected Outcome....10737
Follow-On Procedure....10737
Discharge Temperature Sensor Electrical Test....10738
Overview....10738
Tools Required....10738
Equipment Condition....10738
Test Setup....10738
Test Procedure....10738
Expected Outcome....10740
Follow-On Procedure....10740
Inlet Temperature Sensor Electrical Test....10741
Overview....10741
Tools Required....10741
Equipment Condition....10741
Test Setup....10741
Test Procedure....10741
Expected Outcome....10743
Follow-On Procedure....10743
No idle A/C Electrical System Inspection....10745
Overview....10745
Tools Required....10745
Equipment Conditions....10745
Inspection Procedure....10745
Expected Outcome....10747
Follow-On procedure....10748
No-Idle HVAC Controller Electrical Test....10749
Overview....10749
Special Tools....10749
Equipment Condition....10749
Test Setup....10749
Test Procedure....10749
Expected Outcome....10751
ESPAR Auxiliary Heater....10752
Overview....10752
Regular Maintenance....10753
Monthly....10753
Every 1000 operating hours....10753
Connecting EDiTH to heater....10754
Starting and using EDiTH software....10754
Reading fault codes....10760
Clearing fault codes....10760
Removing controller lock....10761
ESPAR Fault Code Diagnostics....10762
Overview....10762
10 – Overvoltage / Shutdown....10764
Fault Code Overview....10764
11 – Undervoltage / Shutdown....10765
Fault Code Overview....10765
Pin-Point Tests....10767
Tools Required....10767
12 – Overheating....10768
Fault Code Overview....10768
14 – Possible Overheating Detected (Differential Evaluation)....10769
Fault Code Overview....10769
15 – Operation Lock – Heater has Overheated More than 10 Times....10770
Fault Code Overview....10770
17 – Overheating — Emergency Off....10771
Fault Code Overview....10771
20 – Glow Plug – Interruption....10772
Fault Code Overview....10772
Pin-Point Tests....10773
Tools Required....10773
21 – Glow Plug Output: Short Circuit, Overload or Accidental Ground....10774
Fault Code Overview....10774
30 – Speed of Combustion Fan motor Outside Tolerance Range....10775
Fault Code Overview....10775
31 – Combustion Fan Motor Open Circuit....10776
Fault Code Overview....10776
Pin-Point Tests....10777
Tools Required....10777
32 – Combustion Fan Motor Short Circuit, Overload or Accidental Ground....10778
Fault Code Overview....10778
39 – Vehicle Blower Relay Control – Short Circuit, Overload or Earth Short....10779
Fault Code Overview....10779
41 – Water Pump – Interruption....10780
Fault Code Overview....10780
Pin-Point Tests....10781
Tools Required....10781
42 – Water Pump – Short Circuit, Overload or Earth Short....10782
Fault Code Overview....10782
Pin-Point Tests....10783
Tools Required....10783
47 – Metering Pump – Short Circuit, Overload or Earth Short....10784
Fault Code Overview....10784
Pin-Point Tests....10786
Tools Required....10786
48 – Metering Pump – Interruption....10787
Fault Code Overview....10787
50 – Operation Lock Because of Too Many Failed Starting Attempts....10788
Fault Code Overview....10788
51 – Time Exceeded – Blowing Cold....10789
Fault Code Overview....10789
52 – Safety Time Exceeded....10790
Fault Code Overview....10790
53 – Flame Aborted from Control Stage “Large”....10792
Fault Code Overview....10792
54 – Flame Aborted from Control Stage “Boost”....10793
Fault Code Overview....10793
56 – Flame Aborted from Control Stage “Small”....10794
Fault Code Overview....10794
60 – Temperature Sensor – Interruption....10795
Fault Code Overview....10795
61 – Temperature Sensor – Short-Circuit, Overload or Accidental Ground....10796
Fault Code Overview....10796
64 – Flame Sensor – Interruption....10797
Fault Code Overview....10797
65 – Flame Sensor – Short-Circuit, Overload or Accidental Ground....10798
Fault Code Overview....10798
71 – Overheating Sensor – Interruption....10799
Fault Code Overview....10799
72 – Overheating Sensor – Short-Circuit, Overload or Accidental Ground....10800
Fault Code Overview....10800
90 – Controller Defect....10801
Fault Code Overview....10801
91 – External Interference Voltage....10802
Fault Code Overview....10802
92 – Controller Defect....10803
Fault Code Overview....10803
93 – Controller Defect....10804
Fault Code Overview....10804
94 – Controller Defect....10805
Fault Code Overview....10805
95 – Controller Defect....10806
Fault Code Overview....10806
96 – Controller Defect....10807
Fault Code Overview....10807
97 – Controller Defect....10808
Fault Code Overview....10808
98 – Controller Defect....10809
Fault Code Overview....10809
99 – Controller Defect....10810
Fault Code Overview....10810
100 – Controller Defect....10811
Fault Code Overview....10811
101 – Controller Defect....10812
Fault Code Overview....10812
Symptom Diagnostics....10813
Overview....10813
Tests and Inspections....10815
Blower Motor Test....10815
Tools Required....10815
Test Setup....10815
Test Procedure....10815
Expected Outcome....10815
Coolant Circuit Inspection....10816
Inspection Setup....10816
Inspection Procedure....10816
Expected Outcome....10816
Connector Inspection....10817
Inspection Setup....10817
Inspection Procedure....10817
Expected Outcome....10817
Flame Sensor Test....10818
Tools Required....10818
Test Setup....10818
Test Procedure....10818
Expected Outcome....10818
Fuel Intake Inspection....10820
Inspection Setup....10820
Inspection Procedure....10820
Expected Outcome....10820
Fuel Pump Quantity Test....10821
Tools Required....10821
Test Setup....10821
Test Procedure....10821
Expected Outcome....10822
Glow Pin Test....10823
Tools Required....10823
Test Setup....10823
Test Procedure....10823
Expected Outcome....10823
Glow Plug Filter Inspection....10824
Inspection Setup....10824
Inspection Procedure....10824
Expected Outcome....10824
Follow-on Procedure....10824
Intake and exhaust air Inspection....10825
Inspection Setup....10825
Inspection Procedure....10825
Expected Outcome....10825
Integrated Fuel Filter Inspection....10826
Inspection Setup....10826
Inspection Procedure....10826
Expected Outcome....10826
Overheat Sensor Test....10827
Tools Required....10827
Test Setup....10827
Test Procedure....10827
Expected Outcome....10828
Temperature Sensor Test....10829
Tools Required....10829
Test Setup....10829
Test Procedure....10829
Expected Outcome....10829
Auxiliary Battery Box....10831
Overview....10831
10. Instrumentation / Gauges....10833
Overview....10833
Operational Checkout Procedure....10834
Overview....10834
EGC Programming....10836
Overview....10836
Voltage....10837
Overview....10837
Possible Causes....10837
Special Tools....10837
Fuel Level ....10839
Overview....10839
Possible Causes....10839
DEF Level....10846
Overview....10846
Possible Causes....10846
Transmission Temperature....10848
Overview....10848
Possible Causes....10848
Pin-point Tests....10853
Air Gauges....10854
Diagnostics....10854
Overview....10854
Symptoms - Air 1 Gauge....10855
Overview....10855
Possible Causes....10855
Pin-Point Tests - Air 1 Gauge....10859
Tools Required....10859
Symptoms - Air 2 Gauge....10862
Overview....10862
Possible Causes....10862
Pin-Point Tests - Air 2 Gauge....10866
Tools Required....10866
Engine Coolant Temperature....10870
Overview....10870
Engine Oil Pressure....10871
Overview....10871
Engine Oil Temperature....10872
Overview....10872
Engine Speed (Tachometer)....10873
Overview....10873
Vehicle Speed (Speedometer)....10874
Overview....10874
Outside Air Temperature....10875
Overview....10875
11. Lighting Systems....10878
Fog Lights....10878
Overview....10878
Operational Checkout Procedure....10881
Overview....10881
Fog Light Input Diagnostics....10884
Fault Overview....10884
Fault Facts....10884
Possible Causes....10884
Fog Light Output - Not Illuminating....10886
Fault Overview....10886
Fault Facts....10886
Possible Causes....10886
Pin-Point Test - Fog Light Output - Not Illuminating....10891
Tools Required....10891
Fog Light Output Diagnostics - Illuminating When Not Requested....10895
Fault Overview....10895
Fault Facts....10895
Possible Causes....10895
Pin-Point Test -Fog Light Output - Illuminating When Not Requested....10898
Tools Required....10898
SPN 2388 FMI 5 - Left Fog Light Open Circuit....10900
Fault Overview....10900
Associated Faults....10900
Fault Facts....10900
Possible Causes....10900
Pin-Point Test - SPN 2388 FMI 5....10902
Tools Required....10902
SPN 2388 FMI 6 - Left Fog Light Short to GND....10904
Fault Overview....10904
Associated Faults....10904
Fault Facts....10904
Possible Causes....10904
Pin-Point Test - SPN 2388 FMI 6....10906
Tools Required....10906
SPN 4008 FMI 5 - Right Fog Light Open Circuit....10908
Fault Overview....10908
Associated Faults....10908
Fault Facts....10908
Possible Causes....10908
Pin-Point Test - SPN 4008 FMI 5....10910
Tools Required....10910
SPN 4008 FMI 6 - Right Fog Light Short to GND....10912
Fault Overview....10912
Associated Faults....10912
Fault Facts....10912
Possible Causes....10912
Pin-Point Test - SPN 4008 FMI 6....10914
Tools Required....10914
Headlights and Daytime Running Lights....10916
Overview....10916
Operational Checkout Procedure....10921
Overview....10921
Low Beam Input Diagnostics....10926
Fault Overview....10926
Fault Facts....10926
Possible Causes....10926
Low Beam Output Diagnostics - Not illuminating....10928
Fault Overview....10928
Fault Facts....10928
Possible Causes....10928
Pin-Point Test - Low Beam Head Lamp Output - Not Illuminating....10933
Tools Required....10933
Low Beam Output Diagnostics - Illuminating When Not Requested....10937
Fault Overview....10937
Fault Facts....10937
Possible Causes....10937
Pin-Point Test - Low Beam Head Lamp Output - Illuminating When Not Requested....10940
Tools Required....10940
SPN 2653 FMI 5 - Left Low Beam Open Circuit....10942
Fault Overview....10942
Associated Faults....10942
Fault Facts....10942
Possible Causes....10942
Pin-Point Test - SPN 2653 FMI 5....10944
Tools Required....10944
Pin-Point Test - SPN 2653 FMI 5....10945
SPN 2653 FMI 6 - Left Low Beam Short to GND....10946
Fault Overview....10946
Associated Faults....10946
Fault Facts....10946
Possible Causes....10946
Pin-Point Test - SPN 2653 FMI 6....10948
Tools Required....10948
SPN 2655 FMI 5 - Right Low Beam Open Circuit....10950
Fault Overview....10950
Associated Faults....10950
Fault Facts....10950
Possible Causes....10950
Pin-Point Test - SPN 2655 FMI 5....10952
Tools Required....10952
SPN 2655 FMI 6 - Right Low Beam Short to GND....10954
Fault Overview....10954
Associated Faults....10954
Fault Facts....10954
Possible Causes....10954
Pin-Point Test - SPN 2655 FMI 6....10956
Tools Required....10956
High Beam Input Diagnostics....10958
Fault Overview....10958
Fault Facts....10958
Possible Causes....10958
Pin-Point Test - High Beam Lamps Input....10961
Tools Required....10961
High Beam Output Diagnostics - Not Illuminating....10966
Fault Overview....10966
Fault Facts....10966
Possible Causes....10966
Pin-Point Test - High Beam Head Lamp Output - Not Illuminating....10971
Tools Required....10971
High Beam Output Diagnostics - Illuminating When Not Requested....10975
Fault Overview....10975
Fault Facts....10975
Possible Causes....10975
Pin-Point Test - High Beam Head Lamp Output - Illuminating When Not Requested....10978
Tools Required....10978
SPN 4011 FMI 5 - Left High Beam Open Circuit....10980
Fault Overview....10980
Associated Faults....10980
Fault Facts....10980
Possible Causes....10980
Pin-Point Test - SPN 4011 FMI 5....10982
Tools Required....10982
SPN 4011 FMI 6 - Left High Beam Short to Ground....10984
Fault Overview....10984
Associated Faults....10984
Fault Facts....10984
Possible Causes....10984
Pin-Point Test - SPN 4011 FMI 6....10986
Tools Required....10986
SPN 4012 FMI 5 - Right High beam Open Circuit....10988
Fault Overview....10988
Associated Faults....10988
Fault Facts....10988
Possible Causes....10988
Pin-Point Test - SPN 4012 FMI 5....10990
Tools Required....10990
SPN 4012 FMI 6 - Right High Beam Short to Ground....10992
Fault Overview....10992
Associated Faults....10992
Fault Facts....10992
Possible Causes....10992
Pin-Point Test - SPN 4012 FMI 6....10994
Tools Required....10994
Brake Switch....10996
Overview....10996
Operational Checkout Procedure....10999
Brake Switch is Not Working....11002
Feature Code Overview....11002
Fault Facts....11002
Possible Causes....11002
Pin-Point Test - Feature Code 4091 / 4092....11005
Tools Required....11005
SPN 597 FMI 0 - Brake Switch Input short to PWR with Air Brakes 4091 / 4092....11009
Fault Overview....11009
Associated Faults....11009
Fault Facts....11009
Possible Causes....11009
Pin-Point Test - SPN 597 FMI 0 with Air Brakes (4091 / 4092)....11011
Tools Required....11012
SPN 597 FMI 1 - Brake Switch Reading Below Normal Range with Air Brakes 4091 / 4092....11015
Fault Overview....11015
Associated Faults....11015
Fault Facts....11015
Possible Causes....11015
SPN 597 FMI 2 - Brake Switch Inputs Do Not Match....11017
Fault Overview....11017
Associated Faults....11017
Fault Facts....11017
Possible Causes....11017
Stop, Turn, and Hazard Lights....11019
Overview....11019
Operational Checkout Procedure....11020
Overview....11020
Turn Signal, Hazard, and Front Turn Lamp Diagnostics....11028
Overview....11028
Hazard Input Diagnostics....11031
Overview....11031
Fault Facts....11031
Possible Causes....11031
Pin-Point Test - Hazard Input Diagnostics....11034
Tools Required....11034
Turn Signal Input Diagnostics....11040
Overview....11040
Fault Facts....11040
Possible Causes....11040
Pin-Point Test - Turn Signal Input Diagnostics....11043
Tools Required....11043
Front Turn Lamp Not Illuminating....11049
Overview....11049
Fault Facts....11049
Possible Causes....11049
Pin-Point Test- Front Turn Lamp Output Not Illuminating....11053
Tools Required....11053
Front Turn Lamps Illuminating When Not Requested....11057
Overview....11057
Fault Facts....11057
Possible Causes....11057
Pin-Point Test - Front Turn Lamps Illuminating When Not Requested....11059
Tools Required....11059
SPN 2368 FMI 5 - Left Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....11061
Fault Overview....11061
Associated Faults....11061
Fault Facts....11061
Possible Causes....11061
Pin-Point Test SPN 2368 FMI 5....11063
Tools Required....11063
SPN 2368 FMI 6 - Left Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....11065
Fault Overview....11065
Associated Faults....11065
Fault Facts....11065
Possible Causes....11065
Pin-Point Test SPN 2368 FMI 6....11067
Tools Required....11067
SPN 2370 FMI 5 - Right Front Turn Lamp Undercurrent with Combined Stop and Turn Lamps....11069
Fault Overview....11069
Associated Faults....11069
Fault Facts....11069
Possible Causes....11069
Pin-Point Test SPN 2370 FMI 5....11071
Tools Required....11071
SPN 2370 FMI 6 - Right Front Turn Lamp Overcurrent with Combined Stop and Turn Lamps....11073
Fault Overview....11073
Associated Faults....11073
Fault Facts....11073
Possible Causes....11073
Pin-Point Test SPN 2370 FMI 6....11075
Tools Required....11075
Combined Stop and Turn Lamps Diagnostics....11077
Overview....11077
Combined Stop and Turn Lamps - Rear Turn Lamp Not Illuminating....11079
Overview....11079
Fault Facts....11079
Possible Causes....11079
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....11083
Tools Required....11083
Combined Stop and Turn Lamps - Rear Turn Lamps Illuminating When Not Requested....11087
Overview....11087
Fault Facts....11087
Possible Causes....11087
Pin-Point Test - Combined Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....11089
Tools Required....11089
SPN 2372 FMI 5 - Left Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....11091
Fault Overview....11091
Associated Fault....11091
Fault Facts....11091
Possible Causes....11091
Pin-Point Test SPN 2372 FMI 5....11093
Tools Required....11093
SPN 2372 FMI 6 - Left Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....11095
Fault Overview....11095
Associated Faults....11095
Fault Facts....11095
Possible Causes....11095
Pin-Point Test SPN 2372 FMI 6....11097
Tools Required....11097
SPN 2374 FMI 5 - Right Rear Turn Lamp Undercurrent with Combined Stop and Turn Lamps....11099
Fault Overview....11099
Associated Faults....11099
Fault Facts....11099
Possible Causes....11099
Pin-Point Test SPN 2374 FMI 5....11101
Tools Required....11101
SPN 2374 FMI 6 - Right Rear Turn Lamp Overcurrent with Combined Stop and Turn Lamps....11103
Fault Overview....11103
Associated Faults....11103
Fault Facts....11103
Possible Causes....11103
Pin-Point Test SPN 2374 FMI 6....11105
Tools Required....11105
Separate Stop and Turn Lamps Diagnostics....11107
Overview....11107
Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....11108
Overview....11108
Fault Facts....11108
Possible Causes....11108
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamp Not Illuminating....11112
Tools Required....11112
Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....11116
Overview....11116
Fault Facts....11116
Possible Causes....11116
Pin-Point Test - Separate Stop and Turn Lamps- Rear Turn Lamps Illuminating When Not Requested....11118
Tools Required....11118
Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....11120
Overview....11120
Fault Facts....11120
Possible Causes....11120
Pin-Point Test - Separate Stop and Turn Lamps- Stop Lamp Not Illuminating....11123
Tools Required....11123
Separate Stop and Turn Lamps- Stop Lamps Illuminating When Not Requested....11127
Overview....11127
Fault Facts....11127
Possible Causes....11127
Pin-Point Test - Separate Stop and Turn Lamps- Rear Stop Lamps Illuminating When Not Requested....11129
Tools Required....11129
Park / Marker Lights....11131
Overview....11131
Operational Checkout Procedure....11134
Overview....11134
Park Light Input Diagnostics....11138
Fault Overview....11138
Fault Facts....11138
Possible Causes....11138
Park Light Output - Not Illuminating....11140
Fault Overview....11140
Fault Facts....11140
Possible Causes....11140
Pin-Point Test - Park Light Output - Not Illuminating....11143
Tools Required....11143
Park Light Output Diagnostics - Illuminating When Not Requested....11145
Fault Overview....11145
Fault Facts....11145
Possible Causes....11145
Pin-Point Test - Park Light Output - Illuminating When Not Requested....11147
Tools Required....11147
SPN 2378 FMI 5 - Park Light UnderCurrent....11149
Fault Overview....11149
Associated Faults....11149
Fault Facts....11149
Possible Causes....11149
Pin-Point Test - SPN 2378 FMI 5....11151
Tools Required....11151
SPN 2378 FMI 6 - Park Light OverCurrent....11153
Fault Overview....11153
Associated Faults....11153
Fault Facts....11153
Possible Causes....11153
Pin-Point Test - SPN 2378 FMI 6....11155
Tools Required....11155
SPN 4024 FMI 2 - Marker Light Interrupt Switch Failure....11157
Fault Overview....11157
Associated Faults....11157
Fault Facts....11157
Possible Causes....11157
Trailer Lighting....11159
Overview....11159
Operational Checkout Procedure....11161
Overview....11161
Pin-Point Test - Trailer Lights Operational Checkout Procedure....11163
Tools Required....11163
Trailer Marker Lights - Not Illuminating....11166
Fault Overview....11166
Fault Facts....11166
Possible Causes....11166
Pin-Point Test - Trailer Marker Light Output - Not Illuminating....11169
Tools Required....11169
Trailer Tail Lights - Not Illuminating....11175
Fault Overview....11175
Fault Facts....11175
Possible Causes....11175
Pin-Point Test - Trailer Tail Light Output - Not Illuminating....11178
Tools Required....11178
Trailer Left Turn Lights - Not Illuminating....11184
Fault Overview....11184
Fault Facts....11184
Possible Causes....11184
Pin-Point Test - Trailer Left Turn Output - Not Illuminating....11187
Tools Required....11187
Trailer Right Turn Lights - Not Illuminating....11193
Fault Overview....11193
Fault Facts....11193
Possible Causes....11193
Pin-Point Test - Trailer Right Turn Output - Not Illuminating....11196
Tools Required....11196
Trailer Brake Lights - Not Illuminating....11202
Fault Overview....11202
Fault Facts....11202
Possible Causes....11202
Pin-Point Test - Trailer BrakeLight Output - Not Illuminating....11205
Tools Required....11205
12. Predictive Cruise Control....11211
Overview....11211
Operational Checkout Procedure....11215
Overview....11215
Predictive Cruise Control Module Diagnostics....11216
Pin-Point Tests - Predictive Cruise Control ....11219
Tools Required....11219
Predictive Cruise Control GPS Antenna Diagnostics....11227
13. Security System....11229
Theft Deterrent....11229
Overview....11229
Operational Checkout Procedure....11231
Theft Deterrent System Not Responding....11232
Fault Overview....11232
Fault Facts....11232
Possible Causes....11232
14. Transmission....11235
Auto Neutral....11235
15. Windshield Wiper System....11236
Windshield Wiper Diagnostics....11236
Overview....11236
Wiper Operation....11236
Park Operation....11236
Washer Operation....11236
Operational Checkout Procedure....11243
Overview....11243
Windshield Wiper Input 0 Not Working....11249
Fault Overview....11249
Fault Fact....11249
Possible Causes....11249
Pin-Point Test - Windshield Wiper Input Circuit 0 Not Working....11252
Tools Required....11252
Windshield Wiper Input 1 Not Working....11257
Feature Overview....11257
Fault Fact....11257
Possible Causes....11257
Pin-Point Test - Windshield Wiper Input 1 Not Working....11259
Tools Required....11259
Windshield Wiper Input 2 Not Working....11264
Feature Overview....11264
Fault Fact....11264
Possible Causes....11264
Pin-Point Test - Windshield Wiper Input 2 Not Working....11267
Tools Required....11267
Windshield Wiper Low Speed Not Functioning....11272
Feature Code Overview....11272
Fault Facts....11272
Possible Causes....11272
Pin-Point Test - Windshield Wiper Low Speed Not Functioning....11277
Tools Required....11277
Windshield Wiper High Speed Not Functioning.....11285
Feature Code Overview....11285
Fault Facts....11285
Possible Causes....11285
Pin-Point Test - Windshield Wiper High Speed Not Functioning....11290
Tools Required....11290
SPN 2636 FMI 5 - Wiper ON / OFF Relay Under Current or Open Circuit....11298
Fault Overview....11298
Associated Faults....11298
Fault Facts....11298
Possible Causes....11298
Pin-Point Test - SPN 2636 FMI 5....11300
Tools Required....11300
SPN 2636 FMI 6 - Wiper ON / OFF Relay Over Current....11302
Fault Overview....11302
Associated Faults....11302
Fault Facts....11302
Possible Causes....11302
Pin-Point Test - SPN 2636 FMI 6....11303
Tools Required....11303
SPN 2637 FMI 5 - Wiper High / Low Relay Under Current or High Resistance....11305
Fault Overview....11305
Associated Faults....11305
Fault Facts....11305
Possible Causes....11305
Pin-Point Test - SPN 2637 FMI 5....11307
Tools Required....11307
SPN 2637 FMI 6 - Wiper High / Low Relay Over Current....11309
Fault Overview....11309
Associated Faults....11309
Fault Facts....11309
Possible Causes....11309
Pin-Point Test - SPN 2637 FMI 6....11311
Tools Required....11311
SPN 4057 FMI 5 - Wiper Motor Under Current....11313
Fault Overview....11313
Associated Faults....11313
Fault Facts....11313
Possible Causes....11313
Pin-Point Test - SPN 4057 FMI 5....11317
Tools Required....11317
SPN 4057 FMI 6 - Wiper Motor Over Current....11325
Fault Overview....11325
Associated Faults....11325
Fault Facts....11325
Possible Causes....11325
Pin-Point Test - SPN 4057 FMI 6....11329
Tools Required....11329
Windshield Washer Pump is Not Working with Windshield Wipers....11333
Feature Overview....11333
Fault Fact....11333
Possible Causes....11333
Pin-Point Test - Windshield Washer Pump is Not Working with Windshield Wipers....11336
Tools Required....11336
Windshield Wiper Not Working with Washer Pump....11341
Feature Overview....11341
Fault Fact....11341
Possible Causes....11341
Pin-Point Test - Windshield Wiper Not Working with Washer Pump....11343
Tools Required....11343
Windshield Wiper and Washer Pump Not Working....11345
Feature Overview....11345
Fault Fact....11345
Possible Causes....11345
Pin-Point Test - Windshield Wiper and Washer Pump Not Working....11348
Tools Required....11348
Front End....11353
Fifth Wheels and Misc.....11357
Clutch....11361
1. Hydraulic Clutch Service....11363
Hydraulic Clutch System Description....11363
Overview....11363
Clutch Pedal....11363
Master Cylinder....11364
Reservoir....11364
Air Assist Servo and Slave Cylinder....11364
Hydraulic Hose....11365
Bleeder Valve....11366
Remove and Install Procedures....11367
Equipment Conditions....11367
Reservoir....11368
Removal....11368
Procedure....11368
Installation....11369
Procedure....11369
Clutch Master Cylinder....11370
Removal....11370
Procedure....11370
Installation....11371
Procedure....11371
Air Assist Servo / Slave Cylinder....11373
Removal....11373
Procedure....11373
Installation....11374
Procedure....11374
Clutch Pedal....11375
Removal....11375
Procedure....11375
Installation....11376
Torque Specifications....11376
Procedure....11376
Hydraulic Fluid Change and System Bleeding....11377
Overview....11377
Checking Fluid Level....11377
Reverse Pressure Bleeding Procedure....11378
Overview....11378
Equipment Conditions....11378
Procedure....11378
Hydraulic Clutch System Bleeding....11380
Overview....11380
Tools Required....11380
Equipment Conditions....11381
Procedure....11381
Diagnosis and Troubleshooting....11383
Specifications....11387
Torque....11388
Engines....11389
1. Cooling System....11393
Overview....11393
Deaeration Tank....11398
Fan Shroud....11398
A/C Condenser....11398
Transmission Oil Cooler....11398
Radiator....11398
Charge Air Cooler....11398
Low-Temperature Radiator....11398
Fan Drive....11398
Power Steering Oil Cooler....11399
Cooling Package Cleaning Procedures....11399
Overview....11399
Cooling Package (Navistar® 11 and 13 Engines) - Clean....11400
Charge Air Cooler Cleaning Procedure....11402
Overview....11402
Tools Required....11402
Service Parts....11402
Charge Air Cooler Cleaning Procedure Setup....11403
Off-chassis Pressure Test....11404
Charge Air Cooler (CAC) Cleaning Management System (CMS) Installation....11406
Charge Air Cooler Cleaning Procedure....11408
Flushing Procedure....11409
Cleaning Management System (CMS) Removal Procedure....11410
Removal and Installation....11412
Overview....11412
Equipment Conditions....11412
A/C Condenser - MaxxForce® 11, 13 and N13....11413
Removal....11413
Procedure....11413
Installation....11416
Procedure....11416
Follow-On Procedure....11416
A/C Condenser - MaxxForce® 15 L ....11417
Removal....11417
Equipment Conditions....11417
Procedure....11417
Installation....11418
Equipment Conditions....11418
Procedure....11418
Follow-On Procedure....11418
A/C Condenser - Cummins® ISX15 ....11419
Removal....11419
Equipment Conditions....11419
Procedure....11419
Installation....11421
Procedure....11421
Follow-On Procedure....11421
Alternator Fan Belt - MaxxForce® 15 ....11422
Removal....11422
Equipment Conditions....11422
Procedure....11422
Installation....11424
Torque Specifications....11424
Equipment Conditions....11424
Procedure....11424
Charge Air Cooler - MaxxForce® 11, 13, and 15....11425
Removal....11425
Equipment Conditions....11425
Procedure....11425
Installation....11427
Equipment Conditions....11427
Procedure....11427
Follow-On Procedure....11427
Charge Air Cooler - Cummins® ISX15....11428
Removal....11428
Equipment Conditions....11428
Procedure....11428
Installation....11433
Equipment Conditions....11433
Procedure....11433
Follow-On Procedure....11434
Deaeration Tank - MaxxForce® 11, 13, and 15....11435
Removal....11435
Overview....11435
Equipment Conditions....11435
Procedure....11435
Installation....11437
Equipment Conditions....11437
Procedure....11437
Follow-On Procedure....11437
Deaeration Tank - Cummins® ISX15....11438
Removal....11438
Overview....11438
Equipment Conditions....11438
Procedure....11438
Follow-On Procedure....11438
Installation....11439
Equipment Conditions....11439
Procedure....11439
Follow-On Procedure....11439
EGR Valve / Cooler Hose - Navistar® N13....11440
Removal....11440
Equipment Conditions....11440
Procedure....11440
Installation....11443
Torque Specifications....11443
Procedure....11443
Follow-On Procedure....11445
EGR Valve / Cooler Hose - MaxxForce® 15 ....11446
Removal....11446
Equipment Conditions....11446
Procedure....11446
Installation....11448
Torque Specifications....11448
Procedure....11448
Follow-On Procedure....11450
Engine Coolant Level (ECL) Sensor....11451
Removal....11451
Overview....11451
Special Tools....11451
Equipment Conditions....11452
Procedure....11453
Follow-On Procedure....11453
Installation....11454
Overview....11454
Special Tools....11454
Torque Specification....11455
Equipment Conditions....11455
Procedure....11456
Follow-On Procedure....11456
Fan Belt - MaxxForce® 11 and 13....11457
Removal....11457
Equipment Conditions....11457
Procedure....11457
Installation....11459
Torque Specifications....11459
Equipment Conditions....11459
Procedure....11459
Follow-On Procedure....11459
Fan Belt - MaxxForce® 15 ....11460
Removal....11460
Equipment Conditions....11460
Procedure....11460
Fan Belt Installation – MaxxForce® 15....11462
Torque Specifications....11462
Equipment Conditions....11462
Procedure....11462
Follow-On Procedure....11462
Fan Belt - Cummins® ISX15 ....11463
Removal....11463
Equipment Conditions....11463
Procedure....11463
Installation....11465
Torque Specifications....11465
Equipment Conditions....11465
Procedure....11465
Follow-On Procedure....11465
Fan Drive - MaxxForce® 11 and 13....11466
Removal....11466
Special Tools....11466
Equipment Conditions....11466
Procedure....11466
Installation....11468
Special Tools....11468
Equipment Conditions....11468
Procedure....11468
Follow-On Procedure....11468
Fan Drive - MaxxForce® 15....11469
Removal....11469
Special Tools....11469
Equipment Conditions....11469
Procedure....11469
Installation....11470
Special Tools....11470
Procedure....11470
Follow-On Procedure....11470
Fan Drive Assembly - Cummins® ISX15 (Horton)....11471
Removal....11471
Overview....11471
Removal and Installation....11473
Removal and Installation....11473
Fan Drive Assembly Removal - Cummins® ISX15 (Horton)....11473
Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ....11476
Fan Shroud Removal – MaxxForce® 11, 13, and Navistar® N13....11477
Fan Shroud Installation – MaxxForce® 11, 13 L and Navistar® N13....11483
Fan Shroud Removal – (Three-Piece Upper) MaxxForce® 15 ....11484
Fan Shroud Installation – (Three-Piece Upper) MaxxForce® 15 ....11486
Fan Shroud Removal – (Three-Piece Lower) MaxxForce® 15 ....11487
Fan Shroud Installation – (Three-Piece Lower) MaxxForce® 15....11488
Fan Shroud Removal – (One-Piece) MaxxForce® 15....11489
Fan Shroud Installation – (One-Piece) MaxxForce® 15....11491
Fan Shroud Removal – (Two-Piece) Cummins® ISX15....11492
Fan Shroud Installation – (Two-Piece) Cummins® ISX15....11496
Grille - Remove....11497
Grille - Install....11498
Hood-Tilt Assist Cylinder – Removal....11499
Hood-Tilt Assist Cylinder – Installation....11501
Low-Temperature Radiator Removal – MaxxForce® 11 and 13....11502
Low-Temperature Radiator Installation – MaxxForce® 11 and 13....11504
Low-Temperature Radiator Removal – MaxxForce® 15....11505
Low-Temperature Radiator Installation – MaxxForce® 15....11509
Power Steering Oil Cooler – Removal....11511
Power Steering Oil Cooler – Installation....11513
Radiator Assembly Removal – MaxxForce® 11 and 13....11514
Radiator Assembly Installation – MaxxForce® 11 and 13....11516
Radiator Assembly Removal – MaxxForce® 15....11517
Radiator Assembly Installation – MaxxForce® 15....11519
Radiator Assembly Removal – Cummins® ISX15....11520
Radiator Assembly Installation – Cummins® ISX15....11526
Radiator Core Removal – MaxxForce® 11 and 13....11528
Radiator Core Installation – MaxxForce® 11 and 13....11531
Radiator Core Removal – MaxxForce® 15....11532
Radiator Core Installation – MaxxForce® 15....11534
Radiator Core- Removal – Cummins® ISX15 ....11535
Radiator Core Installation – Cummins® ISX15 ....11539
Radiator Fan Removal – MaxxForce® 11 and 13....11540
Radiator Fan Installation – MaxxForce® 11 and 13 ....11541
Radiator Fan Removal (With Three-Piece Fan Shroud) – MaxxForce® 15....11542
Radiator Fan Installation (With Three-Piece Fan Shroud) – MaxxForce® 15....11543
Radiator Fan Removal (With One-Piece Fan Shroud) – MaxxForce® 15....11544
Radiator Fan Installation (With One-Piece Fan Shroud) – MaxxForce® 15....11545
Radiator Fan Removal – Cummins® ISX15....11546
Radiator Fan Installation – Cummins® ISX15....11547
Radiator Hose Heat Shrink Clamp Removal and Installation....11548
Heat Shrink Clamp Removal....11548
Heat Shrink Clamp Installation....11549
Radiator Hose Removal – MaxxForce® 11 and 13 ....11552
Radiator Hose Installation – MaxxForce® 11 and 13....11554
Radiator Hose Removal – MaxxForce® 15 ....11555
Radiator Hose Installation – MaxxForce® 15....11557
Radiator Hose Removal – Cummins® ISX15....11558
Radiator Hose Installation – Cummins® ISX15 ....11561
Recirculation Seals Removal – MaxxForce® 11 and 13....11562
Recirculation Seals Installation – MaxxForce® 11 and 13 ....11563
Recirculation Seals Removal – MaxxForce® 15 ....11564
Recirculation Seals Installation – MaxxForce® 15....11566
Transmission Oil Cooler Removal (Cummins® ISX15 ONLY)....11567
Transmission Oil Cooler – Installation....11569
Test and Inspections....11570
Overview....11570
Equipment Conditions....11571
Coolant Drain Procedure – Navistar® 11, 13, 15 and Cummins® ISX15....11574
Coolant Fill Procedure – Navistar® 11, 13, 15 and Cummins® ISX15....11576
Coolant Drain Procedure – Navistar® 11, 13, 15, Cummins® ISX15 (Optional)....11579
Coolant Fill Procedure – Navistar® 11, 13, 15 (Optional)....11580
Coolant Fill Procedure – Cummins® ISX Engines (Optional)....11583
Deaeration Tank Inspection Procedure....11585
Deaeration Tank Cap Vacuum Relief Check....11586
Fan Drive Pulley Crack Inspection....11587
Fan Drive Pulley Nick Inspection....11588
Fuel Cooler Valve (FCV) Inspection Procedure....11589
Fuel Cooler Valve (FCV) Filter Screen – Removal....11589
Fuel Cooler Valve (FCV) Filter Screen – Installation....11590
Pressure Test Procedure – Navistar® 11, 13, 15, and Cummins® ISX15....11591
Torque Chart Navistar® Engines....11592
12THT Horton DriveMaster Fan Drive System....11595
Removal and Installation....11595
Air Cartridge – Removal....11595
Air Cartridge – Installation....11597
Clutch Pack Seal Face – Removal....11599
Clutch Pack Seal Face – Installation....11600
Fan Removal – (12THZ and 12THT Horton DA) (optional)....11601
Fan Installation – (12THZ and 12THT Horton DA) (optional)....11602
Fan Drive Friction Liner– Removal....11603
Fan Drive Friction Liner – Installation....11606
Horton (DA) Non-Serviceable Fan Drive Removal – with ISB6.7 ....11607
Horton (DA) Non-Serviceable Fan Drive Installation – with ISB6.7 ....11609
Horton (DMA) Serviceable Fan Drive – Removal....11610
Horton (DMA) Serviceable Fan Drive – Installation ....11615
Pulley Bearing – Removal....11616
Pulley Bearing – Installation....11617
Radiator Fan Removal – (N13)....11618
Radiator Fan Installation – (N13)....11619
Radiator Fan Removal – (Cummins® ISX15)....11620
Radiator Fan Installation – (Cummins® ISX15)....11621
Inspection Procedures....11622
Cartridge Assembly Seal and Spring....11622
Clutch Pack Face Seal....11623
Fan Drive Bearing Measurement and Inspection....11624
Fan Drive Movement / Clutch Pack Bearing Check....11625
Friction Liner Measurement....11627
Diagnostics....11628
Overview....11628
Tools Required....11628
Visual Air Leak Check....11629
Symptom 1: Fan Always On....11630
Equipment Conditions....11631
Symptom 2: Fan Always Off....11647
Symptom 3: Cycles Too Frequently....11654
Symptom 4: Excessive Noise From Fan Drive....11656
12TTD Borg-Warner 842B Visctronic Fan Drive System Diagnostics....11658
Overview....11658
Tools Required....11658
Operational Checks – Start Fan Drive Diagnostics Here....11658
Symptom 1: Fan Always ON....11660
Symptom 2: Fan Always OFF....11666
Symptom 3: Cycles Too Frequently....11683
Symptom 4: Excessive Noise From Fan Drive....11685
12TSY Borg-Warner SA85 Viscous Fan Drive Assembly System Diagnostics....11687
Overview....11687
Tools Required....11687
12TKY Borg-Warner Kysor K32 ON / OFF Type Pneumatic Actuated Fan Drive Assembly....11689
Overview....11689
Removal and Installation....11689
Tools Required....11689
Fan Drive Clutch Lining – Removal....11690
Fan Drive Clutch Lining – Installation....11691
Fan Drive and Hub Assembly – Removal....11692
Fan Drive and Hub Assembly – Installation....11693
Fan Drive Clutch Friction Lining Inspection....11694
Diagnostics....11695
Overview....11695
Tools Required....11695
Operational Checks....11695
Clutch Will Not Engage....11697
Clutch Will Not Disengage....11698
Air Leak In Drive....11699
Excessive Noise From Fan Drive....11700
12THX Horton Stratis V-Master-Ultra Viscous Fan Drive Assembly System....11703
Overview....11703
Screen Shots....11703
Removal and Installation....11705
Fan Drive Removal....11705
Fan Drive Installation....11707
Diagnostics....11708
Operational Checkout Procedure....11708
Overview....11708
Fan Engages Prematurely....11710
Symptom 1: Fan Always On....11711
Fault Overview....11711
Fault Facts....11711
Possible Causes....11711
Symptom 3: Fan Cycles Too Frequently....11713
Fault Overview....11713
Fault Facts....11713
Possible Causes....11713
Symptom 4: Excessive Noise From Fan Drive....11715
Test and Inspections....11717
Fan Drive Inspection....11717
Overview....11717
Equipment Conditions....11717
Inspection Setup....11717
Fan Drive Pin Point Test....11718
ServiceMaxx Engine Fan Test™....11719
Overview....11719
Tools Required....11719
Equipment Conditions....11719
Test Setup....11719
Test Procedure....11719
On/Off Two Speed Fan....11721
Variable Speed Fan....11721
Good Variable Speed Fan Tests....11723
Overview....11723
Bad Variable Speed Fan Tests....11724
Overview....11724
Expected Outcome....11726
Follow-On Procedure....11726
Transmissions....11727
Rear Axle and Suspension....11731
1. 2010–2015 International® Ride Optimized Suspension (IROS)....11733
Overview....11733
Height Control Valve....11735
Overview....11735
Operation....11737
Service Checks (Valve on Truck)....11738
Ride Height Adjustment....11739
Air Lines....11740
Overview....11740
Shock Absorbers....11741
Overview....11741
Torque Rods....11742
Overview....11742
Remove and Install....11743
Suspension Air Springs....11744
Removal....11744
Install....11747
Shock Absorbers....11748
Removal....11748
Install....11750
Main Support Members....11751
Remove....11751
Install....11752
Torque Rods....11754
Remove....11754
Install....11755
Main Support Member Bushings....11756
Overview....11756
Install....11758
Overview....11758
Special Tools....11758
Torque Specifications....11758
Equipment Condition....11758
Procedure....11759
Follow-On Procedure....11760
Check U-bolt Nut Torque and U-bolt Nut Tightening Procedure....11761
Ride Height Adjustment Procedure....11762
Overview....11762
Special Tools....11762
Specifications....11762
Equipment Conditions....11762
Procedure....11762
Follow-On Procedure....11765
Travel exceeds specification:....11765
Travel is less than specification:....11766
Torque....11767
2. 2016 International® Ride Optimized Suspension (IROS)....11769
Overview....11769
Height Control Valve....11770
Overview....11770
Tests....11771
Height Control Valve Service Test....11771
Overview....11771
Tools Required....11771
Equipment Condition....11771
Test Setup....11771
Test Procedure....11771
Expected Outcome....11772
Follow-On Procedure....11772
Ride Height Adjustment Procedure....11773
Overview....11773
Special Tools....11773
Specifications....11773
Equipment Conditions....11773
Procedure....11773
Follow-On Procedure....11776
Travel exceeds specification:....11776
Travel is less than specification:....11777
Remove and Install....11778
Height Control Valve....11778
Remove....11778
Install....11779
Main Support Members....11780
Remove....11780
Install....11783
Main Support Member Bushings....11785
Remove....11785
Install....11787
Suspension Air Springs....11788
Remove....11788
Install....11790
Shock Absorbers....11791
Remove....11791
Install....11792
Torque Rods....11793
Remove....11793
Install....11794
U-bolts and U-bolt Nuts....11795
Install....11795
Overview....11795
Special Tools....11795
Torque Specifications....11795
Equipment Condition....11795
Procedure....11796
Follow-On Procedure....11797
Checking / Retightening U-Bolt Nut Torque ....11798
Torque....11799
Fuel System....11801
1. Fuel System....11803
Overview....11803
Fuel Tank....11803
Removal and Installation....11808
Fuel Tanks....11808
Remove....11808
Install....11810
Fuel Tank Sender....11812
Remove....11812
Install....11814
Torque....11816
Torque Chart....11816
Fuel Tank Diagnostics....11817
Fuel Tanks Not Equalizing....11818
Overview....11818
Fault Facts....11818
Special Tools....11818
Possible Causes....11818
Fuel Tank Vent Test....11821
Overview....11821
Special Tools....11821
Equipment Conditions....11821
Test Setup....11821
Test Procedure....11821
Expected Outcome....11821
Cab....11823
1. Overview....11831
Day Cab And Sleeper Cab....11831
Cab Interior Trim Panels....11833
Vehicle Identification Number (VIN) Tag Location....11834
Windshield....11835
Electric Windshield Wipers....11836
Windshield Washer....11837
Ignition Switch Cylinder....11838
2. Removal and Installation....11839
Equipment Conditions....11839
B-pillar Trim Panel....11840
Overview....11840
Removal....11840
Installation....11841
Cab....11842
Initial Procedures Before Cab Removal....11842
Equipment Conditions....11842
Removal....11844
Squaring....11846
Overview....11846
Installation....11847
Final Procedures After Cab Installation....11848
Cab Air Suspension System....11849
Height Control Valve - Removal....11849
Height Control Valve - Installation....11851
Shock Absorber - Removal....11852
Shock Absorber - Installation....11853
Suspension Air Spring (Bag) - Removal....11854
Suspension Air Spring (Bag) - Installation....11855
Lateral Control Rod - Removal....11856
Lateral Control Rod - Installation....11857
Jounce Bumper - Removal....11858
Jounce Bumper - Installation....11859
Rear Air Suspension Assembly - Removal....11860
Rear Air Suspension Assembly - Installation....11862
Cab Cowl Tray....11863
Removal....11863
Installation....11865
Cab Doors....11866
Removal....11866
Installation....11869
Chassis skirts....11870
Removal....11870
Installation....11873
Door Check Bracket....11874
Removal....11874
Installation....11875
Door Check Link....11876
Removal....11876
Installation....11877
Door Glass....11878
Removal....11878
Installation....11880
Door Handle - Inner....11881
Removal....11881
Installation....11883
Door Handle - Outer....11884
Removal....11884
Installation....11886
Door Hinge....11887
Removal....11887
Installation....11888
Door Latch....11889
Removal....11889
Installation....11890
Door Lock Cylinder....11891
Removal....11891
Installation....11892
Dash Panel....11893
Gauge Cluster - Removal....11893
Gauge Cluster - Installation....11894
Dash Panel - Removal....11894
Dash Panel - Installation....11898
Door Striker Pin....11899
Removal....11899
Installation....11900
Door Trim Panel....11901
Removal....11901
Installation....11903
Door Vapor Barrier....11904
Removal....11904
Installation....11905
Electric Mirror Switch....11906
Removal....11906
Installation....11907
Electric Window And Door Lock Switch....11908
Removal....11908
Installation....11909
Electric Windshield Wiper Motor....11910
Removal....11910
Installation....11911
Engine Cover And Cup Holder....11912
Cup Holder and Ashtray - Removal....11912
Cup Holder and Ashtray - Installation....11913
One-piece Engine Cover - Removal....11914
One-piece Engine Cover - Installation....11915
Two-piece Engine Cover - Removal....11916
Two-piece Engine Cover - Installation....11917
Front Cab Mounting Insulators....11918
Removal....11918
Installation....11919
Front Seats....11920
Removal....11920
Installation....11921
Header Console Panel....11922
Removal....11922
Installation....11926
Headliner Trim Panel....11927
Removal....11927
Installation....11929
Hood Seal....11930
Removal....11930
Installation....11931
Ignition Switch And Ignition Switch Cylinder....11932
Overview....11932
Ignition Switch - Removal....11932
Ignition Switch - Installation....11934
Ignition Switch Cylinder - Removal....11935
Ignition Switch Cylinder - Installation....11937
Kick Panel....11938
Removal....11938
Installation....11939
Modular Door Hardware Assembly....11940
Removal....11940
Installation....11943
Predictive Cruise Control Module....11944
Overview....11944
Module....11944
Removal....11944
Install....11946
Antenna Harness....11948
Removal....11948
Install....11949
Rear Window Glass....11950
Removal....11950
Installation....11952
Regulator Arm Assembly....11961
Removal....11961
Installation....11965
Scuff Plate and Seat Belt Retractor Cover....11966
Removal....11966
Installation....11967
Sleeper Interior....11968
Overview....11968
Air Line Cabinet - Removal....11968
Air Line Cabinet - Installation....11969
Upper Tower Cabinet - Removal....11970
Upper Tower Cabinet - Installation....11971
Lower Tower Cabinet - Removal....11972
Lower Tower Cabinet – Installation....11973
Rear Wardrobe Cabinet – Removal....11974
Rear Wardrobe Cabinet - Installation....11975
Lower Bunk Assembly - Removal....11976
Lower Bunk Assembly – Installation....11977
Upper Bunk Assembly - Removal....11978
Upper Bunk Assembly - Installation....11979
Sleeper Control Panel - Removal....11980
Sleeper Control Panel - Installation....11981
Lower Side Trim Panel - Removal....11982
Lower Side Trim Panel - Installation....11984
Upper Side Trim Panel - Removal....11985
Upper Side Trim Panel - Installation....11987
Lower Rear Trim Panel - Removal....11988
Lower Rear Trim Panel - Installation....11989
Upper Rear Trim Panel - Removal....11990
Upper Rear Trim Panel - Installation....11991
T-rail Corner Panel - Removal....11992
T-rail Corner Panel - Installation....11993
Sleeper Headliner - Removal....11994
Sleeper Headliner - Installation....11995
Rear Wall Speaker - Removal....11996
Rear Wall Speaker - Installation....11997
Sleeper Interior “Suite”....11998
Table Assembly - Removal....11998
Table Assembly - Installation....11999
Cup Holder - Removal....12000
Cup Holder - Installation....12001
Upper Tower Cabinet - Removal....12001
Upper Tower Cabinet - Installation....12003
Lower Tower Cabinet - Removal....12004
Lower Tower Cabinet - Installation....12005
Side Airline Cabinet - Removal....12006
Side Airline Cabinet - Installation....12008
Rear Airline Cabinet - Removal....12009
Rear Airline Cabinet - Installation....12010
Corner Speaker and HVAC Duct Work - Removal....12011
Corner Speaker and HVAC Duct Work - Installation....12013
Sleeper Control Panel - Removal....12014
Sleeper Control Panel - Installation....12015
Bunk Mattress - Removal....12016
Bunk Mattress - Installation....12018
Bunk Frame Assembly - Removal....12019
Bunk Frame Assembly - Installation....12020
Bunk Hinge Assembly - Removal....12021
Bunk Hinge Assembly - Installation....12022
Bunk Latch Assembly - Removal....12023
Bunk Latch Assembly - Installation....12025
Side Trim Panel - Removal....12026
Side Trim Panel - Installation....12028
Rear Trim Panel - Removal....12029
Rear Trim Panel - Installation....12030
Sleeper Headliner and Dome Lights - Removal....12031
Sleeper Headliner and Dome Lights - Installation....12033
Sleeper Floor Mat - Removal....12034
Sleeper Floor Mat - Installation....12036
Sleeper Vent Window Assembly, handle, and seal....12037
Overview....12037
Sleeper Vent Window Assembly - Removal....12037
Sleeper Vent Window Assembly - Installation....12039
Sleeper Vent Window Assembly Handle - Removal....12040
Sleeper Vent Window Assembly Handle - Installation....12041
Steering Column Trim Panel....12042
Removal....12042
Installation....12043
Sunshade....12044
Removal....12044
Installation....12045
Sun Visor and Clip....12046
Removal....12046
Installation....12047
Vent Window, Latch, and Seal....12048
Removal....12048
Installation....12050
Weather Seals....12051
Removal....12051
Installation....12051
Window Electric Motor....12052
Removal....12052
Installation....12053
Window Run Channels....12054
Removal....12054
Installation....12056
Window Slide Block....12057
Removal....12057
Installation....12059
Windshield....12060
Removal....12060
Overview....12060
Special Tools....12060
None....12060
Equipment Condition....12060
Procedure....12061
Follow-On Procedure....12062
Installation....12063
Overview....12063
Special Tools....12063
None....12063
Equipment Conditions....12063
Procedure....12063
Follow-On Procedure....12065
Windshield Washer Bottle With Pump Motor....12066
Removal....12066
Installation....12067
Windshield Wiper Arm and Blade Assembly....12068
Removal....12068
Installation....12069
Windshield Wiper Assembly....12070
Removal....12070
Installation....12070
3. Troubleshooting....12072
Electric Windshield Wiper Motor....12072
Washer Pump Motor....12073
Cabin Air Suspension System....12074
4. Adjustments....12075
Overview....12075
Cab Squaring....12075
Overview....12075
Cab Door....12076
Overview....12076
Door Hinge....12077
Striker Pin....12078
Windshield Wiper Arm and Blade Assembly....12079
Day Cab Ride Height....12080
Sleeper Cab Ride Height....12083
5. Tire Pressure Monitoring System (Feature Code 16VCM)....12084
Overview....12084
Operation....12087
Tire Pressure Monitoring Electrical System....12088
Overview....12088
SAE J1939 Communication....12091
‘Lost’ SAE J1939 Communication....12091
LIN Bus Communication....12091
Tire Pressure Monitoring Controller Diagnostics....12092
Battery Voltage Circuit Diagnostics....12092
Overview....12092
Tire Pressure Sensors....12093
Overview....12093
Sensor Diagnostics....12093
Fast Transmit Mode....12093
Sensor Initialization....12094
Tire Pressure Antennas....12095
Overview....12095
Antenna Diagnostics....12095
Feature Functions....12096
Overview....12096
Monitoring Tire Pressure and Tire Temperature....12096
Tire Pressure Warnings....12097
Tire Pressure Diagnostics....12100
Overview....12100
Low Pressure Diagnostic Mode....12100
Extremely Low Pressure Diagnostic Mode....12100
High Pressure Diagnostic Mode....12101
Tire Temperature Diagnostics....12102
Overview....12102
High Temperature Diagnostic Mode....12102
Caution When Performing TPMS Service....12103
General Diagnostic Information....12104
Overview....12104
Diagnostic Trouble Codes....12104
Displaying Diagnostic Trouble Codes....12104
Definitions:....12105
Frequently Asked Questions....12122
Question: ....12122
Answer:....12122
Question:....12122
Answer:....12122
Question:....12122
Answer:....12122
Question:....12122
Answer:....12123
Tire Pressure Monitoring System Setup....12124
Power-Up/Down Conditions....12124
Warnings....12124
Power LED....12125
Standby LED....12125
LCD Screen....12125
Keypad Functionality....12125
Tire Transmitter ID Programming....12129
Replacing a Wheel / Rim....12129
Rotating the Wheels....12134
Overview....12134
Keeping Track of Wheel Locations....12134
Procedure....12135
Tire Pressure Setup....12140
Menu Descriptions....12140
Operation....12143
Monitoring Display....12143
Wheel Sensor Service procedure....12145
Recommendation for Mounting and Demounting Tires....12148
(1) Demounting tire process (demount wheel SENSOR before removing the tire):....12148
(2) Standard Mounting Process (installed wheel SENSOR):....12150
(3) Mounting tire process using automated equipment (installed wheel SENSOR):....12151
6. 2016 Sleeper Cab Air Suspension (0516AAC)....12153
Overview....12153
Tests....12154
Height Control Valve Service Test....12154
Overview....12154
Tools Required....12154
Equipment Condition....12154
Test Setup....12154
Test Procedure....12154
Expected Outcome....12155
Follow-On Procedure....12155
Sleeper Cab Ride Height Dimensions and Adjustment Test....12156
Overview....12156
Tools Required....12156
Equipment Condition....12156
Test Setup....12156
Test Procedure....12156
Expected Outcome....12157
Follow-on Procedure....12157
If ride height exceeds specification:....12157
If ride height is less than specification:....12157
Remove and Install....12158
Air Spring Support Bracket....12158
Remove....12158
Install....12161
Cab Suspension Air Springs....12164
Remove....12164
Install....12165
Height Control Valve....12166
Remove....12166
Install....12167
Shock Absorber....12169
Remove....12169
Install....12170
Torque Rod....12171
Remove....12171
Install....12172
Torque....12173
7. RollTek Supplemental Restraint System (SRS)....12174
Overview....12174
Diagnostics....12177
Overview....12177
RollTek SRS Operational Check....12178
RollTek SRS Symptoms....12178
RollTek SRS Wiring Diagnostics....12179
Removal and Installation....12182
Overview....12182
RollTek Side Roll Airbag (SRA) – Removal....12184
Unpacking Replacement SRA Unit....12187
Product Identification....12188
RollTek Side Roll Air Bag — Installation....12189
RollTek SRS Module - Removal....12192
RollTek SRS Module - Installation....12198
National Seat with RollTek® Supplemental Restraint System (SRS)....12206
Overview....12206
Drivers....12207
Overview....12207
Passenger....12209
Overview....12209
Removal (Driver and Passenger)....12211
Installation (Driver and Passenger)....12215
8. Torque....12220
Torque Chart....12220
9. HVAC....12223
Front HVAC System Repair....12223
A/C Condenser – Removal....12223
Blend Door Actuator....12224
Removal....12224
Installation....12226
Blend Door Gear Train ....12227
Removal....12227
Installation....12230
Blower Assembly....12231
Removal....12231
Installation....12232
Blower Scroll Housing....12233
Removal....12233
Installation....12235
Compressor / Clutch....12236
Removal....12236
Installation....12237
Evaporator....12238
Removal....12238
Installation....12240
Receiver-Drier....12241
Removal....12241
Installation....12243
Freeze Probe....12244
Removal....12244
Installation....12245
Fresh Air Module....12246
Removal....12246
Installation....12248
Heater Core....12249
Removal....12249
Installation....12251
Heater Hoses / Lines....12252
HVAC Air Filter....12253
Removal....12253
Installation....12254
HVAC Control Panel Assembly....12255
Removal....12255
Installation....12256
Interior Module....12257
Removal....12257
Installation....12264
Interior Module Trim Cover....12266
Removal....12266
Installation....12267
Linear Power Module (LPM)....12268
Removal....12268
Installation....12270
Low Pressure Switch....12271
Removal....12271
Installation....12272
Mode Door Actuator....12273
Removal....12273
Installation....12274
Mode Door Gear Train....12275
Removal....12275
Installation....12278
Pressure Transducer....12279
Removal....12279
Installation....12280
Recirculation Door Actuator....12281
Removal....12281
Installation....12282
Recirculation Door Gear Train....12283
Removal....12283
Installation....12285
Recirculation Filters....12286
Removal....12286
Installation....12288
Recirculation, Mode, and Blend Doors....12289
Refrigerant Line....12290
Removal....12290
Installation....12292
Separating Blower Scroll Housing....12293
Removal....12293
Installation....12295
Separating Front HVAC Module....12296
Removal....12296
Installation....12301
Thermostatic Expansion Valve (TXV)....12302
Removal....12302
Installation....12304
Rear HVAC System Repair....12305
A/C Hose Assembly – Rear HVAC....12305
Removal....12305
Installation....12307
Blend Door – Rear HVAC....12309
Removal....12309
Installation....12313
Blend Door Actuator – Rear HVAC....12314
Removal....12314
Installation....12315
Blower – Rear HVAC....12316
Removal....12316
Installation....12317
Evaporator Core – Rear HVAC....12318
Removal....12318
Installation....12322
Filter Element – Rear HVAC....12324
Removal....12324
Installation....12325
Heater Core – Rear HVAC....12326
Removal....12326
Installation....12330
Heater Hose Assembly – Rear HVAC....12331
Removal....12331
Installation....12333
Linear Power Module (LPM) – Rear HVAC....12334
Removal....12334
Installation....12335
Outlet Duct Temperature Sensor – Rear HVAC....12336
Removal....12336
Installation....12337
Rear HVAC Controls – Removal....12338
Rear HVAC Controls – Removal....12338
Analog Controls – Installation....12339
Digital Controls – Installation....12340
Rear HVAC Unit....12341
Removal....12341
Installation....12343
Sleeper HVAC Module....12345
Removal....12345
Installation....12346
Thermostatic Expansion Valve (TXV) – Rear HVAC....12347
Removal....12347
Installation....12349
No-Idle System....12350
Blend Door....12350
Removal....12350
Installation....12355
Blend Door Actuator....12356
Removal....12356
Installation....12357
Blower Motor....12358
Removal....12358
Installation....12359
Compressor Controller ....12360
Removal....12360
Installation....12362
Condenser Fan....12363
Removal....12363
Installation....12365
Discharge Temperature Sensor....12366
Removal....12366
Installation....12367
Evaporator Inlet Filter....12368
Removal....12368
Installation....12369
Flow Control Valve ....12370
Removal....12370
Installation....12371
Heater Coil ....12372
Removal....12372
Installation....12376
HVAC Drain Tube ....12377
Removal....12377
Installation....12378
Inlet Temperature Sensor....12379
Removal....12379
Installation....12380
Linear Power Module (LPM)....12381
Removal....12381
Installation....12382
No-Idle HVAC Unit....12383
Removal....12383
Installation....12392
Refrigerant Circuit ....12394
Removal....12394
Installation....12396
No-Idle HVAC Module....12397
Removal....12397
Installation....12398
ESPAR Auxiliary Heater....12399
Blower Motor....12399
Removal....12399
Installation....12401
Blower Motor Cover....12402
Removal....12402
Installation....12403
Controller....12404
Removal....12404
Installation....12406
Flame Sensor....12407
Removal....12407
Installation....12408
Fuel Pump....12409
Removal....12409
Installation....12411
Glow Pin Screen....12412
Removal....12412
Installation....12413
Glow Plug....12414
Removal....12414
Installation....12415
Heat Exchanger Cover....12416
Removal....12416
Installation....12417
Overheat / Temperature Sensor Assembly....12418
Removal....12418
Installation....12419
Water Pump....12420
Removal....12420
Installation....12421
Service Procedures....12422
Automatic Mode....12422
Charge A/C System (Charge Mode)....12425
Equipment Conditions....12425
Discharging the System (Recycle Mode)....12427
Evacuate A/C System (Vacuum Mode)....12429
Checking Compressor Oil Level....12431
Overview....12431
Special Tools....12431
Equipment Conditions....12431
Procedure....12431
Follow-On Procedure....12433
Oil Fill Guidelines....12434
Overview....12434
Special Tools....12434
Equipment Conditions....12434
Procedure....12437
Oil separation during refrigerant recovery....12437
Component replacement....12437
Oil loss due to refrigerant leak....12437
Compressor replacement due to internal compressor failure....12437
Compressor replacement due to clutch failure....12437
Follow-On Procedure....12437
Flush and Purge A/C System....12438
Cab Evaporator....12438
Overview....12438
Special Tools....12438
Equipment Conditions....12438
Cab Evaporator Flush and Purge Procedure....12443
Follow-On Procedure....12444
Cab Supply and Return Lines....12445
Overview....12445
Special Tools....12445
Equipment Conditions....12445
Cab Supply and Return Line Flush and Purge Procedure....12445
Follow-On Procedure....12447
Condenser....12448
Overview....12448
Special Tools....12448
Equipment Conditions....12448
Condenser Flush and Purge Procedure....12449
Follow-On Procedure....12452
Sleeper Evaporator....12453
Overview....12453
Special Tools....12453
Equipment Conditions....12453
Sleeper Evaporator Flush and Purge Procedure....12453
Follow-On Procedure....12455
Sleeper Supply and Return Lines....12456
Overview....12456
Special Tools....12456
Equipment Conditions....12456
Sleeper Supply and Return Line Flush and Purge....12456
Follow-On Procedure....12459
Rear Wheels....12461
1. Wheels, Rims and Tires....12463
Wheel Components....12463
Warnings....12467
Service Procedure....12468
Tire Service....12468
Brake Service....12468
Wheel and Wheel Assemblies Removal and Installation....12469
Cast Spoke Wheels....12469
Removal....12469
Installation....12471
Disc Wheels....12472
Tire and Rim - Removal....12472
Tire and Rim - Installation....12475
OSHA Standards....12476
Wall Charts....12477
Care and Maintenance....12478
Wheel Studs and Mounting Nuts....12479
Installation, Tightening, and Alignment (Lateral Run-Out)....12481
Disc Wheels or Cast Spoke Wheels....12481
Cast Spoke Wheels....12482
Disc Wheels with (Ball Seat) Nuts....12484
Disc Wheels with Flange Nuts....12485
Wheel and Tire Balancing....12487
Static Balancing....12487
Dynamic Balancing....12487
Tire Care....12488
Inspection....12488
Inflation....12488
Loads....12488
Tire Matching....12488
Dual Tires....12488
Tandem Drive Axles....12488
Front Wheel Drive, 4x4, 6x6 and 8x6....12489
Radial and Bias Ply Tires....12489
Rotation....12489
Rotation Is Always Advisable:....12489
Rotation May Be Advisable:....12489
Alignment - Front Axle....12489
Alignment - Rear Axle....12490
Tire Wear....12490
Service Load and Inflation Charts....12491
Tire and Rim Combinations....12496
Ply Rating Vs. Load Range....12497
Torque....12498
tables....9619
Torque Specifications....9619
Torque Specifications....9626
Torque Specifications....9634
Torque Specifications....9637
Torque Specifications....9646
Torque Specifications....9648
Torque Specifications....9651
Torque Specifications....9654
Torque Specifications....9656
Torque Specifications....9659
Torque Specifications....9663
Torque Specifications....9669
Torque Specifications....9675
Torque Specifications....9677
Torque Specifications....9680
Torque Specifications....9683
Torque Specifications....9696
Torque Specifications....9703
Torque Specifications....9705
Torque Chart....9708
Torque Specifications....9727
Torque Specifications....9730
Torque Specifications....9733
Torque Specifications....9735
Torque Specifications....9738
Torque Specifications....9740
Torque Specifications....9742
Torque Specifications....9745
Torque Specifications....9746
Torque Specifications....9750
Torque Specifications....9754
Torque Specifications....9756
Torque Chart....9758
Troubleshooting Table....9764
Torque Specifications....9778
Torque Specifications....9789
Torque Specifications....9796
Torque Specifications....9807
Torque Specifications....9812
Torque Specifications....9816
Torque Chart....9818
Torque Specifications....9842
Torque Specifications....9845
Drag Link Nut Torque Chart....9846
Torque Specifications....9847
Dual Steering Gear Drag Link Nut Torque Chart....9848
Master Gear Drag Link Nut Torque Chart....9848
Torque Specifications....9854
Drag Link Torque Chart....9861
Torque Specifications....9888
Specifications....9912
M-Series Torque Chart....9913
All Steering Applications Torque Chart....9913
Special Tools....9914
Driveline Universal Joint Operating Angle Chart....9967
Procedures....9992
Feature Codes....10015
Fault Codes....10015
Symptoms....10016
Torque Chart....10020
Torque Specifications....10027
AC Output Ratings....10045
AC Output Ratings....10053
Feature Code....10076
Diagnostic Trouble Codes....10077
Diagnostic Section....10079
500K Input Diagnostic Section....10106
Battery Type....10124
Description....10124
Battery Chemistry....10124
Description....10124
Battery Type....10129
Description....10129
Battery Chemistry....10130
Description....10130
Individual Battery Test RESULTS....10132
Recommended Action....10132
Starting System RESULTS....10133
Recommended Action....10133
RESULTS....10137
Recommended Action....10137
Service Information....10179
Torque Specifications....10197
Modules on J1939 Public bus....10212
J1939 Public communication faults....10213
System Pressure Test Chart....10474
HVAC Controller Blower Speed Voltage Specifications....10483
Blower Motor Voltage ....10484
Freeze Probe Specifications....10497
R-134a Static Temperature / Pressure Table....10557
Dynamic Refrigerant Pressure Test Specifications....10559
Amperage Draw at 70°F (21°C)....10734
Temperature vs. Resistance....10739
Temperature vs. Resistance....10742
Specification....10818
Specification....10822
Specification....10823
Specification....10827
Specification....10829
Torque Chart....10832
Fuel gauge feature codes....10839
Fuel Gauge Fault Codes....10839
DEF level feature codes....10846
DEF level fault codes....10846
Transmission temperature feature codes....10848
Transmission temperature fault codes....10848
Transmission oil temp sensor resistance specification....10853
Measure resistance of transmission oil temperature circuit at Connector 1702....10853
Measure resistance of transmission oil temperature sensor....10853
Air gauge feature codes....10854
Air 1 gauge fault codes....10855
Check for short to GND in Primary Air Pressure signal circuit....10859
Check for short to GND in Primary Air Pressure signal circuit B40....10860
Check for VREF and GND at Primary Air Pressure Transducer....10860
Check for Open or high resistance in Primary Air Pressure signal circuit....10860
Check for Open or high resistance in Primary Air Pressure signal circuit A40....10860
Check for Open or high resistance in Primary Air Pressure signal circuit B40....10861
Body Controller output test....10861
Air 2 gauge fault codes....10862
Check for short to GND in Secondary Air Pressure signal circuit....10867
Check for short to GND in Secondary Air Pressure signal circuit B40A....10868
Check for VREF and GND at Secondary Air Pressure Transducer....10868
Check for Open or high resistance in Secondary Air Pressure signal circuit....10868
Check for Open or high resistance in Secondary Air Pressure signal circuit A40A....10868
Check for Open or high resistance in Secondary Air Pressure signal circuit B40A....10869
Body Controller output test....10869
Coolant temperature feature codes....10870
Coolant temperature fault codes....10870
Oil pressure feature codes....10871
Oil pressure fault codes....10871
Oil temperature feature codes....10872
Oil temperature fault codes....10872
Engine speed feature codes....10873
Engine speed fault codes....10873
Vehicle speed feature codes....10874
Vehicle speed fault codes....10874
Fault codes....10875
Ambient Air Temperature Sensor Table....10876
Feature Codes....10880
Fog Light Symptom Diagnostics....10880
Fog Light Fault Code Diagnostics....10880
Feature Codes....10918
Low Beam Headlight Diagnostics....10918
High Beam Headlight Diagnostics....10920
Software Feature Codes....10996
Normal Operation....10997
Symptom Diagnostics....10998
Fault Code Diagnostics....10998
Diagnostic Section....11019
Software Feature Codes....11019
Turn Signal Input and Front Turn Lamp Diagnostics....11030
Combined Stop and Turn Lamps....11077
Separate Stop and Turn Lamps....11107
Feature Codes....11132
Park / Marker Lights....11133
Feature Codes....11159
Trailer Lights Symptom Diagnostics....11160
Diagnostics....11213
Feature Codes....11229
Theft Deterrent Diagnostics....11230
Feature Codes....11240
Windshield Wiper Diagnostics....11241
Washer Pump Diagnostics....11242
Windshield Wiper Input Switch....11242
Torque Specifications....11369
Torque Specifications....11371
Torque Specifications....11374
Torque Specifications....11378
Torque Specifications....11381
Fluid Specifications....11387
Torque Specifications....11416
Torque Specifications....11418
Torque Specifications....11421
Torque Specifications....11427
Torque Specifications....11433
Torque Specifications....11437
Torque Specifications....11439
Torque Specifications....11468
Torque Specifications....11470
Torque Chart Navistar® Engines....11592
Torque Chart Cummins® ISX15 Engine....11594
Torque Chart....11768
Torque Chart....11799
Torque Chart....12173
Check Communication....12178
Test 1 – PWR Circuit Check....12178
Test 2– GND Circuit Check....12178
Torque Specifications....12431
Oil Capacity by Component....12434
SERVICE LOAD AND INFLATION CHART (NOT MICHELIN) (For Trucks, Buses and Trailers in Normal Highway Service)....12491
SERVICE LOAD AND INFLATION CHART (NOT MICHELIN) (For Trucks, Buses and Trailers in Normal Highway Service) (Cont.)....12492
SERVICE LOAD AND INFLATION CHART (NOT MICHELIN) (For Trucks, Buses and Trailers in Normal Highway Service) (Cont.)....12493
SERVICE LOAD AND INFLATION CHART (MICHELIN ONLY) (For Trucks, Buses and Trailers in Normal Highway Service)....12494
SERVICE LOAD AND INFLATION CHART (MICHELIN ONLY) (For Trucks, Buses and Trailers in Normal Highway Service) (Cont.)....12494
TIRE AND RIM COMBINATIONS - Tires Designed for Normal Highway Service....12496
Ply Rating vs. Load Range....12497
1087481R1 - 1000 Through 4000, 7000, 8000 Series Electrical Circuit Diagrams CTS-4417....12500
Blank Page....12501
4328434 - New Truck Processing Manual....12670
toc....12672
Table of Contents....12672
Introduction....12674
Safety....12674
UNDECKING AND STORAGE....12675
INTRODUCTION....12675
ASSISTANCE TO DEALER ....12675
DEALER RESPONSIBILITIES FOR UNDECKING EXPENSE....12675
CORRECT UNDECKING FACILITY CONFIGURATION....12675
LOAD LIMIT....12676
NEW VEHICLE RECEIVING PROCEDURES....12677
CARRIER DELIVERY and INSPECTION RESPONSIBILITIES ....12677
DEALER RECEIVING RESPONSIBILITIES ....12677
DEALER DELIVERY and INSPECTION RESPONSIBILITIES ....12677
VEHICLE STORAGE....12678
Storage Duration — Two Months Or Less....12678
Storage Duration — Over Two Months....12680
Storage Facilities....12680
NEW TRUCK RECEIVING AND DAMAGE CLAIM PROCESSING....12681
INTRODUCTION....12681
Exceptions....12681
Concealed Damage:....12681
CARRIER'S UNDECKING RESPONSIBILITIES....12681
VEHICLE RECEIVING / INSPECTION....12682
AFTER-HOURS DELIVERY....12682
DELIVERIES TO BODY COMPANIES OR FLEET LOCATIONS....12683
CONCEALED DAMAGE....12684
CARRIER DELIVERY RECEIPT....12684
Important:....12684
FILLING OUT THE DELIVERY RECEIPT....12684
FILING A DAMAGE AND LOSS CLAIM....12685
Supporting Documents....12686
VEHICLES NOT BUILT TO ORDER....12687
INTRODUCTION....12687
TRUCKS NOT BUILT TO ORDER — U.S. AND CANADA....12687
CHECKING ORDER CONFIRMATION — U.S. and CANADA....12687
CLAIM PROCEDURES (USE “TRUCK NOT BUILT TO ORDER” CLAIM FORM)....12688
U.S. AND CANADA:....12688
CLAIM FORM — TRUCK NOT BUILT TO ORDER....12690
ORDER CONTENT CONFIRMATION REPORT....12691
VEHICLE SAFETY CERTIFICATION....12695
INTRODUCTION....12695
INTERNATIONAL® MODEL LINEUP....12695
PENALTIES FOR VIOLATIONS....12696
CERTIFICATION....12696
PREPARATION AND DELIVERY....12697
INTRODUCTION....12697
NEW VEHICLE PRE-DELIVERY SERVICE ....12697
PREPARATION AND DELIVERY (P&D) REIMBURSEMENT (U.S. ONLY)....12697
NON-REIMBURSEMENT ADDENDUM ....12697
“Will Call”- Truck Specialty Center (TSC)....12698
Vehicle Identification Label....12698
CTS-1122, PRE-DELIVERY SERVICE IDENTIFICATION STICKER ....12698
New Vehicle Processing Documentation....12699
Quality Inspection Report....12699
FINAL DELIVERY GUIDELINES....12700
INTRODUCTION....12700
FINAL DELIVERY GUIDELINES....12700
Introduction....12700
Before Vehicle Pick-Up Or Delivery....12700
During Vehicle Pick-Up Or Delivery....12700
tables....12676
Table 1VEHICLE HOIST REQUIREMENT CHART....12676
CTS-5122K - 2000 , 4000 and 8000 Series September 1993 and Later Electrical Circuit Diagrams....12701
Blank Page....12702
CTS-5122T - 2000, 4000, 8000 Series Built After February 1, 1996 Electrical Circuit Diagrams....12895
S02005R - Rockwell Front Non-Drive Steering Axle, Supersedes CTS-5046R (April 1996) Service Manual....13171
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual....13220
S03002R - Neway Air Suspension, Supersedes CTS-5028R (March 1996) Service Manual....13241
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual....13276
S03011 - Hendrickson HN-460 Suspension, Supersedes CTS-5221 (March 1996) Service Manual....13290
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual....13323
S03015 - 2007 MY ProStar _ LoneStar MAXXPOWER Front Air Suspension (Oct 2009) Service Manual....13364
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual....13412
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual....13446
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual....13490
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual....13495
S04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual....13518
S04014 - Air Compressor_ Holset SS 296 and QE 296_338, Supersedes CTS-5197 (March 1996) Service Manual....13549
S04019 - Double Diaphragm Anchorlok Spring Brake, Supersedes CTS-5074 (March 1996) Service Manual....13625
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual....13648
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual....13674
S04033 - Antilock Brakes_Traction Control_ Bendix - Troubleshooting, Supersedes CTS-5250 (June 1996) Service Manual....13700
S04038 EC-17 - Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Service Manual....13744
S04053 - ECE-13 Brake System (2010) Service Manual....13813
S04055 - MCAC 465 Air Compressor (Dec 2010) Service Manual....13849
toc....13851
Table of Contents....13851
1. DESCRIPTION....13853
1.1. Components....13854
Cylinder Head....13854
Crankcase....13855
1.2. Name Plate....13855
2. Compressor Maintenance....13856
3. Remove and Install Procedures....13857
3.1. MCAC 476 Air Compressor....13858
MCAC 476 Air Compressor – Removal....13858
MCAC 476 Air Compressor – Installation....13859
3.2. MCAC 476 Air Compressor Disassembly....13860
Cylinder Head Disassembly....13860
Crankcase Disassembly....13862
Drive Gear Removal....13863
Air Cylinder Cover Removal....13864
Crankcase Removal....13865
Air Cylinder Removal....13866
Air Cylinder Disassembly....13867
Clutch Housing Disassembly....13868
Piston Removal....13869
3.3. MCAC 476 Air Compressor – Assembly....13870
Crankcase Assembly....13870
Clutch Housing Assembly....13871
Air Cylinder Assembly....13872
Air Cylinder Installation....13873
Crankshaft Installation....13874
Air Cylinder Cover Installation....13875
Center Shaft Installation....13876
Center Shaft Nut Installation....13877
Cylinder Head Assembly (Lower)....13878
Cylinder Head Assembly (Upper)....13879
4. Troubleshooting....13880
4.1. Troubleshooting Table....13880
4.2. Tests....13884
Oil Leakage at the Head Gasket Test....13884
Air Brake System and Accessory Leakage Test....13884
Air Compressor Discharge Temperature and Air Dryer Inlet Tempera....13885
Governor Malfunction Test....13886
Governor Control Line Test....13886
Compressor Clutch Operation - No Air Charging Test....13886
Compressor Clutch Operation - Continuous Air Charging Test....13886
tables....13887
Table 3Torque Chart....13887
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual....13888
S05012 - Steering Column Assembly, Tilt_Telescoping Supersedes CTS-5167 (May 1996) Service Manual....13965
S05013 - Steering Column Assembly, Standard and Tilt, Supersedes CTS-5168 (April 1996) Service Manual....13979
S05015Y - Power Steering Gear_ Sheppard M-Series, Supersedes CTS-5262 (Sept 2000) Service Manual....13994
S05016 - Steering Wheel Removal and Installation (Sept 2010) Service Manual....14089
S05018 - LoneStar Steering Column Assembly, Tilt _ Telescoping (Oct 2011) Service Manual....14102
S05021 - Steering Wheel and Steering Column Assembly (July 2012)Manual - Truck3_10_2016 12_00_00 AM....14130
toc....14132
Table of Contents....14132
1. DESCRIPTION....14134
1.1. STEERING WHEEL....14134
1.2. CLOCK SPRING....14134
1.3. STEERING COLUMN....14135
2. REMOVE AND INSTALL PROCEDURES....14136
2.1. STEERING WHEEL....14137
Steering Wheel – Removal....14137
Steering Wheel – Installation....14140
2.2. CLOCK SPRING....14141
Clock Spring – Removal....14141
Clock Spring – Installation....14143
2.3. STEERING COLUMN....14145
Steering Column – Removal....14145
Steering Column – Installation....14147
3. CHECKS AND ADJUSTMENTS....14148
3.1. STEERING WHEEL....14148
Steering Wheel – Check....14148
Steering Wheel – Adjust....14148
tables....14149
Table 1Torque Chart....14149
S05025 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual....14150
toc....14152
tables....14169
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual....14170
S08003 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual....14251
S08018 - 9100, 9200, 9300, 9400, 9600, 9700, and 9800 Model Alternator (Delco-Remy 26-SI Series), Supersedes CTS-5077 (March 1996) Service Manual....14363
S08034X - Instruments, Supersedes CTS-5088K (Oct 1999) Service Manual....14384
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual....14422
S08154X - Speedometer _ Tachometer Diagnostics and Service, Supersedes CTS-5257 (Oct 1999) Service Manual....14451
S08155X - Instruments (New Data Link Driven Instrument Cluster), Supersedes CTS-5228 (Oct 1999) Service Manual....14540
S08186 - 2000, 4000, 8000 Models Built October 1, 1998 To September 30, 1999 Electrical Circuit Diagrams....14664
toc....14666
Table of Contents....14666
INSTRUCTIONS AND CHARTS (Chapter 1)....14674
1.1. Circuit Identification Chart, P. 1....14674
1.2. Circuit Identification Chart, P. 2....14675
1.3. Circuit Identification Chart, P. 3....14676
1.4. Circuit Diagram Instructions, P. 4....14677
1.5. Circuit Diagram Instructions, P. 5....14678
1.6. Schematic Symbols, P. 6....14679
1.7. Relay Function/Bus Bar Configuration (Fuse Block Connector)....14680
1.8. Fuse Block Connector/Connection Tables, P. 8....14681
1.9. Lamp Bulb Chart, P. 9....14682
1.10. Fuse/Circuit Breaker Chart/Labels, P. 10....14683
1.11. Relay Mounting Locations/Labels, P. 11....14684
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....14685
2.1. Accessory, P. 1....14685
2.2. Accessory (Cont.), P. 2....14686
2.3. Battery, P. 3....14687
2.4. Battery (Cont.), P. 4....14688
2.5. Ignition, P. 5....14689
2.6. Ignition (Cont.), P. 6....14690
2.7. Ignition (Cont.), P. 7....14691
2.8. Ground, P. 8....14692
2.9. Ground (Cont.), P. 9....14693
CAB ACCESSORIES (Chapter 3)....14694
3.1. Power Window, P. 1....14694
3.2. Horn, Single & Dual, P. 2....14695
3.3. Mirrors, Heated W/Power Mirror, P. 3....14696
3.4. Mirrors, Lighted, P. 4....14697
3.5. Owner/Operator Connections — Rear Cab Junction Block, Acces....14698
3.6. Radio, Cab, 2 Speakers, AM-FM Cassette Radio & CB Radio 2–W....14699
3.7. Radio, Cab, 4 Speakers, AM-FM Cassette Premium Radio, P. 7....14700
3.8. Radio, Sleeper, AM-FM Cassette Radio W/Sleeper Speakers, P.....14701
3.9. Cigar Lighter, Power Seat, P. 9....14702
3.10. Radio, Sleeper, AM-FM Cassette Premium Radio W/Sleeper Spe....14703
3.11. Sleeper Cab, 42 Inch, P. 11....14704
3.12. Sleeper Cab, 42 Inch (Cont.), P. 12....14705
3.13. Turn Signals W/International T/S Switch W/Tractor & N/Pede....14706
3.14. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14707
3.15. Turn Signals W/International T/S Switch W/Tractor/Truck & ....14708
3.16. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14709
3.17. Turn Signals W/Sig-Stat 910/915 T/S Switch W/ & N/Pedestal....14710
3.18. Windshield Wiper & Washer (Elect) W/International T/S Swit....14711
3.19. Windshield Washer (Elect) W/Air Wipers & W/International T....14712
3.20. Windshield Washer (Elect) W/Air Wipers & W/Sig–Stat T/S Sw....14713
3.21. Windshield Wiper W/Intermittent Wiper/Washer W/Sig–Stat T/....14714
12V CHARGING + CRANKING SYSTEM (Chapter 4)....14715
4.1. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/I....14715
4.2. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/N....14716
4.3. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/C....14717
4.4. Charging System (12V) Delco (90 AMP) CS-130 & 21SI (65, 100....14718
4.5. Cranking System (12V) (8100) W/ISM, P. 5....14719
4.6. Cranking System (12V) (8100) C-10, C-12, P. 6....14720
4.7. Cranking System (12V) (2500, 2600) W/ISM, N14E PLUS, P. 7....14721
4.8. Cranking System (12V) (2500, 2600) W/C-10, C-12, P. 8....14722
4.9. Cranking System (12V) W/T 444E, I6 HEUI, P. 9....14723
4.10. Ether Start W/ISM, C-10, C-12, I6 HEUI, P. 10....14724
FANS (Chapter 5)....14725
5.1. Horton Engine Fan With Cummins N14E PLUS W/ & N/Air Conditi....14725
5.2. Horton Engine Fan With Cummins ISM Engine W/ & N/Air Condit....14726
5.3. Radiator Shutter W/ISM, N14E PLUS, P 3....14727
5.4. Horton Engine Fan With Cat. C-10, C-12 W/ & N/Air Condition....14728
5.5. Shutter & Fan Wiring W/I6 HEUI, T 444E, P. 5....14729
ELECTRONIC ENGINES (Chapter 6)....14730
6.1. Engine Controls, Cummins N14E PLUS, P. 1....14730
6.2. Engine Controls, Cummins N14E PLUS (Cont.), P. 2....14731
6.3. Engine Controls, Cummins ISM Engine, P. 3....14732
6.4. Engine Controls, Cummins ISM Engine (Cont.), P. 4....14733
6.5. Engine Controls, Cummins ISM Engine (Cont.), P. 5....14734
6.6. Engine Brake N/Electronic Transmission, Cummins N14E PLUS, ....14735
6.7. Engine Brake N/Electronic Transmission, Cummins ISM, P. 7....14736
6.8. Engine Brake, Caterpillar C-10, C-12, P. 8....14737
6.9. Cruise Control, Caterpillar C-10, C-12, P. 9....14738
6.10. Engine Controls, Caterpillar C-10, C-12, P. 10....14739
6.11. Engine Shutdown Warning Lights, Low Coolant Switch, Caterp....14740
6.12. Low Air Pressure (Brake) Alarm & Brake Systems Warning Lig....14741
6.13. Module Power & Ground System W/T 444E, I6 HEUI, P. 13....14742
6.14. Accelerator, BAP & Ambient Air Systems W/T 444E & I6 HEUI ....14743
6.15. Accelerator, BAP & Ambient Air Temp. Sensor W/T 444E & I6 ....14744
6.16. Cruise Control, Body Builder Connections W/T 444E, I6 HEUI....14745
GAUGES (Chapter 7)....14746
7.1. Oil Temperature Gauges — Fwd/RR & RR/RR Axles W/6x4, Rear A....14746
7.2. Engine Oil W/ISM Engine & Transmission Oil Temperature Gaug....14747
7.3. Engine Oil Temperature Gauge W/N14E PLUS Engine, P. 3....14748
7.4. Engine Oil Temperature Gauge W/C-10, C-12, P. 4....14749
7.5. Engine Water Temp., Tach, Gauge, Left Turn, HI Beam Ind. W/....14750
7.6. Ammeter Wiring, P. 6....14751
7.7. Fuel Gauge, Speedometer (N/T 444E), Voltmeter, Right Turn I....14752
7.8. Speedometer, Tachometer, HI Beam, Right & Left T/S Ind. Lig....14753
7.9. Pyrometer Gauge N/T 444E, I6 HEUI, P. 9....14754
WARNING LIGHTS (Chapter 8)....14755
8.1. Windshield Washer Low Fluid Warning Light, Power Divider Lo....14755
8.2. Fuel Filter Wiring System W/T 444E, I6 HEUI, P. 2....14756
8.3. Diagnostic/Programmable Conn., W/T 444E, I6 HEUI, P. 3....14757
8.4. Surge Tank W/T 444E & I6 HEUI (Plastic or Metal Tanks), P. ....14758
8.5. Engine Warning Lights/Alarm & Test Switch W/T 444E & I6 HEU....14759
CHASSIS ACCESSORIES (Chapter 9)....14760
9.1. Air Suspension W/Air Hydraulic Brakes, P. 1....14760
9.2. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....14761
9.3. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....14762
9.4. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....14763
9.5. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....14764
9.6. Allison Automatic (Electronic) Transmission W/I6 or V8, P. ....14765
9.7. Allison Automatic (Electronic) Transmission Retarder Contro....14766
9.8. Allison Automatic (Electronic) Transmission Retarder Contro....14767
9.9. Allison Automatic (Electronic) Transmission Retarder, P. 9....14768
9.10. Auto Neutral, P. 10....14769
9.11. Allison Automatic (Electronic) Transmission WTEC III HD, P....14770
9.12. Allison Automatic (Electronic) Transmission WTEC III HD (C....14771
9.13. Allison Automatic (Electronic) Transmission WTEC III HD (C....14772
9.14. Allison Automatic (Electronic) Transmission WTEC III HD (C....14773
9.15. Exhaust Brake, I6 HEUI W/Air ABS, W/Allison WT Transmissio....14774
9.16. Exhaust Brake, I6 HEUI W/Air ABS, N/Allison WT Transmissio....14775
9.17. Exhaust Brake W/Hyd. Brakes N/AT-MT Retarders or MD Transm....14776
9.18. Exhaust Brake Solenoid, I6 HEUI, N/ABS, N/Allison WT Trans....14777
9.19. Allison Automatic Transmission System W/I6 HEUI, T 444E, P....14778
9.20. Axle, Two Speed, Wiring (Air) W/Allison (Elect.) Auto Tran....14779
9.21. Axle, Two Speed, Wiring (Hyd.) W/Allison (Elect.) Auto Tra....14780
9.22. Axle, Two Speed, Electric W/T 444E & I6 HEUI, P. 22....14781
9.23. Axle, Two Speed, Electric (Air) & Air Dryer W/Auto or Manu....14782
9.24. Axle, Two Speed, Electric (Hydraulic) W/Auto or Manual Tra....14783
9.25. Brake System, Hydraulic, P. 25....14784
9.26. Bendix Automatic Drain Valve (DV-2) W/Heater W/ & N/Exhaus....14785
9.27. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Air ABS, ....14786
9.28. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Hyd. ABS,....14787
9.29. Locking Differential W/Allison WT Transmission, P. 29....14788
9.30. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14789
9.31. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14790
9.32. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14791
9.33. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....14792
9.34. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....14793
9.35. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....14794
9.36. Brake System, Hydraulic W/4000 & W/ or N/ABS, P. 36....14795
9.37. Antilock Hydraulic Brakes (4 Channel) W/4000, P. 37....14796
9.38. Antilock Hydraulic Brakes (4 Channel) W/4000 (Cont.), P. 3....14797
9.39. Transfer Case Shift System Front Axle Warning Light, P. 39....14798
9.40. Trailer Connection W/Regular Cab & W/Sleeper Box, P. 40....14799
9.41. Trailer Connection W/Frame Mounted 7–Way & W/Tractor, P. 4....14800
9.42. Trailer Connection W/Frame Mounted 7–Way & W/Truck & W/Air....14801
9.43. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco, P. 43....14802
9.44. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco (Cont.), ....14803
9.45. Air Suspension, Main Cab Overlay Control Harness, P. 45....14804
9.46. Meritor G Series Transmission, P. 46....14805
LIGHT SYSTEMS (Chapter 10)....14806
10.1. Back-Up Lights, P. 1....14806
10.2. Clearance, Marker & Tail Lights W/Tractor N/T 444E, I6 HEU....14807
10.3. Clearance, Marker & Tail Lights W/Truck N/T 444E, I6 HEUI,....14808
10.4. Clearance, Marker & Tail Lights W/Tractor W/T 444E, I6 HEU....14809
10.5. Clearance, Marker & Tail Lights W/Truck W/T 444E, I6 HEUI,....14810
10.6. Cab Dome and Courtesy Lights, P. 6....14811
10.7. Work Light W/Tractor & W/Reg. Cab, Sleeper Cab, P. 7....14812
10.8. Work Light W/Truck, P. 8....14813
10.9. Fog Light System W/ & N/DRL (USA) & N/T 444E, I6 HEUI, P. ....14814
10.10. Fog Light System W/ & N/DRL (Canada) & N/T 444E, I6 HEUI,....14815
10.11. Fog Light System W/ & N/DRL (USA) & W/T 444E, I6 HEUI, P.....14816
10.12. Fog Light System W/DRL (Canada) & W/T 444E, I6 HEUI, P. 1....14817
10.13. Headlight System N/DRL W/International Turn Signal Switch....14818
10.14. Headlight System N/DRL W/International Turn Signal Switch....14819
10.15. Headlight System N/DRL W/Sig-Stat 910 T/S Sw. W/Flr. Mtd.....14820
10.16. Headlight System N/DRL W/Sig-Stat 915 T/S Sw. W/Push Btn.....14821
10.17. Headlight System W/DRL (Canada) W/Sig-Stat 910 T/S Sw. W/....14822
10.18. Headlight System W/DRL (Canada) W/Sig-Stat 915 T/S Sw. W/....14823
10.19. Headlight System W/DRL (USA) W/Sig-Stat 910 T/S Sw. W/Air....14824
10.20. Headlight System W/DRL (USA) W/Sig-Stat 915 T/S Sw. W/Air....14825
10.21. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Hyd. Br....14826
10.22. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Hyd. Brake....14827
10.23. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14828
10.24. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14829
10.25. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....14830
10.26. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....14831
10.27. Additional Headlight Wiring W/Dual Drive Cab, P. 27....14832
10.28. Hydraulic Park Brake Ind. Light W/Key Sw. or Push Button ....14833
10.29. Panel Lights, P. 29....14834
10.30. Stop Light Switch W/T 444E & I6 HEUI W/Air Brakes, P. 30....14835
10.31. Stop Light Switch Truck W/Standard Air Brakes W/Internati....14836
10.32. Stop Light Switch Truck W/Standard Air Brakes W/Sig-Stat ....14837
10.33. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14838
10.34. Stop Light Switch W/Tractor, Truck W/Tractor Application,....14839
HEATER AND AIR CONDITIONER (Chapter 11)....14840
11.1. Heater / Air Conditioner, P. 1....14840
11.2. Heater Only, P. 2....14841
CONNECTOR COMPOSITES (Chapter 12)....14842
12.1. Dash Connector (2) (N/T 444E or I6 HEUI), P. 1....14842
12.2. Dash Connector (2) (W/T 444E or I6 HEUI), P. 2....14843
12.3. Dash Connector Engine Connections (2A) (N/T 444E or I6 HEU....14844
12.4. Dash Connector Engine Connections (2A) (W/T 444E or I6 HEU....14845
12.5. Connector Composites (3 & 3A), P. 5....14846
12.6. Connector Composite (3J), P. 6....14847
12.7. Connector Composites (11), (12), (13), P. 7....14848
12.8. Connector Composites (14), (14A), (15), (16), (17), (18), ....14849
12.9. Connector Composites (20), (21), P. 9....14850
12.10. Connector Composites (23), (24), (26), P. 10....14851
12.11. Connector Composites (27), (28), (29), (30), (31), (32), ....14852
12.12. Connector Composites (33), (34), (35), (36), (37), (38), ....14853
12.13. Connector Composites (44), (46), (47 & 48), (49), (50), (....14854
12.14. Connector Composites (53), (54), (55), (56), (57), (58), ....14855
12.15. Connector Composites (66), (67), (69), (70), (71), P. 15....14856
12.16. Connector Composites (72), (73), (74), (75), (76), (77), ....14857
12.17. Connector Composites (80), (83), (84 & 85), (86), (90), (....14858
12.18. Connector Composites (98), (99), (100), (101), (102), (10....14859
12.19. Connector Composites (105), (106), (107), (108), (109), (....14860
12.20. Connector Composites (117), (119), (121), (122), (123), (....14861
12.21. Connector Composites (132), (133), (135), (136), P. 21....14862
12.22. Connector Composites (137), (141), (142), (143), (144), (....14863
12.23. Connector Composites (147), (148), (149), (153), P. 23....14864
12.24. Connector Composites (153), (154), (156), (157), (158), (....14865
12.25. Connector Composites (160), (161), (162), (163), (164), (....14866
12.26. Connector Composites (169), (170), (171), (172), (173), (....14867
12.27. Connector Composites (179), (180), (181), (182), (183), (....14868
12.28. Connector Composites (194A), (199), (203), (210), (212), ....14869
12.29. Connector Composites (214M), (218), (219), (220), (221), ....14870
12.30. Connector Composites (223), (225), (226), (237), P. 30....14871
12.31. Connector Composites (252), (257), (258), (259), (260), (....14872
12.32. Connector Composites (270), (271), (272), (273), (274A), ....14873
12.33. Connector Composites (274), (275), (276), (277), (279), P....14874
12.34. Connector Composites (280), (284), (286), (287), P. 34....14875
12.35. Connector Composites (288), (289), (290), (291), (292), (....14876
12.36. Connector Composites (294), (295), (296), (297), (298), (....14877
12.37. Connector Composites (304), (305), (306), (309), (310), (....14878
12.38. Connector Composites (311), (312), (313), (314), (315), (....14879
12.39. Connector Composites (320), (323), (325), P. 39....14880
12.40. Connector Composites (325), (326), (327), (328), (329), (....14881
12.41. Connector Composites (332), (333), (335), (336), (337), P....14882
12.42. Connector Composites (338), (339), (340), (341), (342), (....14883
12.43. Connector Composites (345), (346), (347), (348), (349), (....14884
12.44. Connector Composites (355), (356), (357), (358), (359), (....14885
12.45. Connector Composites (367), (368), (369), (370), (372), (....14886
12.46. Connector Composites (377), (377A), (377B), P. 46....14887
12.47. Connector Composites (379), (382), (382A), P. 47....14888
12.48. Connector Composites (383), (384), (386), (387), (389), (....14889
12.49. Connector Composites (391), (392), P. 49....14890
12.50. Connector Composites (396), (399), (400), (401), P. 50....14891
12.51. Connector Composites (402), (403), (404), P. 51....14892
12.52. Connector Composites (406), (413), (417), P. 52....14893
12.53. Connector Composite (418), P. 53....14894
12.54. Connector Composites (419), (420), (421), (422), P. 54....14895
12.55. Connector Composites (423), (425), (426), (427), (428), P....14896
12.56. Connector Composites (430), (431), (432), (433), (434), (....14897
12.57. Connector Composites (447), (449), (457), P. 57....14898
12.58. Connector Composites (458), (459), (460), (463), (465), (....14899
12.59. Connector Composites (467), (468), (469), (473), (480), (....14900
12.60. Connector Composites (492), (493), (494), (495), P. 60....14901
12.61. Connector Composites (499), (500), (501), (502), (503), (....14902
12.62. Connector Composites (506), (507), (508), (510), (511), (....14903
12.63. Connector Composites (555), (557), (558), (569), (570), (....14904
12.64. Connector Composite (615), P. 64....14905
12.65. Connector Composites (631), (632), P. 65....14906
12.66. Connector Composites (633), (634), P. 66....14907
12.67. Connector Composites (636), (637), (639), P. 67....14908
12.68. Connector Composites (646), (646A), (647), (648), (649), ....14909
12.69. Connector Composites (661), (662), (667), (675), (683), (....14910
12.70. Connector Composites (700), (701), (702), (703), (707), P....14911
12.71. Connector Composites (708), (734), (758), (759), (760), (....14912
12.72. Connector Composites (766), (767), (768), (769), (770), (....14913
12.73. Connector Composites (775), (776), (777), (778), (789), (....14914
12.74. Connector Composites (791), (792), (807), (917), (918), (....14915
12.75. Connector Composites (926), (958), (959), (960), (960A), ....14916
12.76. Connector Composites (1000), (1001), (1002), (1003), (100....14917
12.77. Connector Composites (1014), (1015), P. 77....14918
12.78. Connector Composites (1016), (1017), (1091), P. 78....14919
12.79. Connector Composites (1093), (1094), (1095), (1097), (109....14920
12.80. Connector Composites (1110M), (1113F), (1117), (1119), (1....14921
12.81. Connector Composites (1125), (1126), (1128), (1129), (113....14922
12.82. Connector Composites (1132), (1133), (1134), (1135), (302....14923
S08186X - 2000, 4000, 8000 Models Built October 1, 1999 and After Electrical Circuit Diagrams....14924
toc....14926
Table of Contents....14926
INSTRUCTIONS AND CHARTS (Chapter 1)....14934
1.1. Circuit Identification Chart, p. 1....14934
1.2. Circuit Identification Chart, p. 2....14935
1.3. Circuit Identification Chart, p. 3....14936
1.4. Circuit Diagram Instructions, p. 4....14937
1.5. Circuit Diagram Instructions, p. 5....14938
1.6. Schematic Symbols, p. 6....14939
1.7. Relay Function/Bus Bar Configuration (Fuse Block Connector)....14940
1.8. Fuse Block Connector/Connection Tables, p. 8....14941
1.9. Lamp Bulb Chart, p. 9....14942
1.10. Fuse/Circuit Breaker Chart/Labels, p. 10....14943
1.11. Relay Mounting Locations/Labels, p. 11....14944
12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (Chapter 2)....14945
2.1. Accessory, p. 1....14945
2.2. Accessory (Cont.), p. 2....14946
2.3. Battery, p. 3....14947
2.4. Battery (Cont.), p. 4....14948
2.5. Ignition, p. 5....14949
2.6. Ignition (Cont.), p. 6....14950
2.7. Ignition (Cont.), p. 7....14951
2.8. Ground, p. 8....14952
2.9. Ground (Cont.), p. 9....14953
CAB ACCESSORIES (Chapter 3)....14954
3.1. Power Window, p. 1....14954
3.2. Horn, Single & Dual, p. 2....14955
3.3. Mirrors, Heated W/Power Mirror, p. 3....14956
3.4. Mirrors, Lighted, p. 4....14957
3.5. Owner/Operator Connections — Rear Cab Junction Block, Acces....14958
3.6. Radio, Cab, 2 Speakers, AM-FM Cassette Radio & CB Radio 2–W....14959
3.7. Radio, Cab, 4 Speakers, AM-FM Cassette Premium Radio, p. 7....14960
3.8. Radio, Sleeper, AM-FM Cassette Radio W/Sleeper Speakers, p.....14961
3.9. Cigar Lighter, Power Seat, p. 9....14962
3.10. Radio, Sleeper, AM-FM Cassette Premium Radio W/Sleeper Spe....14963
3.11. Sleeper Cab, 42 Inch, p. 11....14964
3.12. Sleeper Cab, 42 Inch (Cont.), p. 12....14965
3.13. Turn Signals W/International T/S Switch W/Tractor & N/Pede....14966
3.14. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14967
3.15. Turn Signals W/International T/S Switch W/Tractor/Truck & ....14968
3.16. Turn Signals W/International T/S Switch W/Truck & N/Trlr C....14969
3.17. Turn Signals W/Sig-Stat 910/915 T/S Switch W/ & N/Pedestal....14970
3.18. Windshield Wiper & Washer (Elect) W/International T/S Swit....14971
3.19. Windshield Washer (Elect) W/Air Wipers & W/International T....14972
3.20. Windshield Washer (Elect) W/Air Wipers & W/Sig–Stat T/S Sw....14973
3.21. Windshield Wiper W/Intermittent Wiper/Washer W/Sig–Stat T/....14974
12V CHARGING + CRANKING SYSTEM (Chapter 4)....14975
4.1. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/I....14975
4.2. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/N....14976
4.3. Charging System (12V) Delco (65, 85, 100, 105, 115 AMP) W/C....14977
4.4. Charging System (12V) Delco (90 AMP) CS-130 & 21SI (65, 100....14978
4.5. Cranking System (12V) (8100) W/ISM, p. 5....14979
4.6. Cranking System (12V) (8100) C-10, C-12, p. 6....14980
4.7. Cranking System (12V) (2500, 2600) W/ISM, N14E PLUS, p. 7....14981
4.8. Cranking System (12V) (2500, 2600) W/C-10, C-12, p. 8....14982
4.9. Cranking System (12V) W/T 444E, I6 HEUI, p. 9....14983
4.10. Ether Start W/ISM, C-10, C-12, I6 HEUI, p. 10....14984
4.11. Auto Neutral (813AAS), p. 11....14985
FANS (Chapter 5)....14986
5.1. Horton Engine Fan With Cummins N14E PLUS W/ & N/Air Conditi....14986
5.2. Horton Engine Fan With Cummins ISM Engine W/ & N/Air Condit....14987
5.3. Radiator Shutter W/ISM, N14E PLUS, p. 3....14988
5.4. Horton Engine Fan With Cat. C-10, C-12 W/ & N/Air Condition....14989
5.5. Shutter & Fan Wiring W/I6 HEUI, T 444E, p. 5....14990
ELECTRONIC ENGINES (Chapter 6)....14991
6.1. Engine Controls, Cummins N14E PLUS, p. 1....14991
6.2. Engine Controls, Cummins N14E PLUS (Cont.), p. 2....14992
6.3. Engine Controls, Cummins ISM Engine, p. 3....14993
6.4. Engine Controls, Cummins ISM Engine (Cont.), p. 4....14994
6.5. Engine Controls, Cummins ISM Engine (Cont.), p. 5....14995
6.6. Engine Brake N/Electronic Transmission, Cummins N14E PLUS, ....14996
6.7. Engine Brake N/Electronic Transmission, Cummins ISM, p. 7....14997
6.8. Engine Brake, Caterpillar C-10, C-12, p. 8....14998
6.9. Cruise Control, Caterpillar C-10, C-12, p. 9....14999
6.10. Engine Controls, Caterpillar C-10, C-12, p. 10....15000
6.11. Engine Shutdown Warning Lights, Low Coolant Switch, Caterp....15001
6.12. Low Air Pressure (Brake) Alarm & Brake Systems Warning Lig....15002
6.13. Module Power & Ground System W/T 444E, I6 HEUI, p. 13....15003
6.14. Accelerator, BAP & Ambient Air Systems W/T 444E & I6 HEUI ....15004
6.15. Accelerator, BAP & Ambient Air Temp. Sensor W/T 444E & I6 ....15005
6.16. Cruise Control, Body Builder Connections W/T 444E, I6 HEUI....15006
GAUGES (Chapter 7)....15007
7.1. Oil Temperature Gauges — Fwd/RR & RR/RR Axles W/6x4, Rear A....15007
7.2. Engine Oil W/ISM Engine & Transmission Oil Temperature Gaug....15008
7.3. Engine Oil Temperature Gauge W/N14E PLUS Engine, p. 3....15009
7.4. Engine Oil Temperature Gauge W/C-10, C-12, p. 4....15010
7.5. Engine Water Temp., Tach, Gauge, Left Turn, HI Beam Ind. W/....15011
7.6. Ammeter Wiring, p. 6....15012
7.7. Fuel Gauge, Speedometer (N/T 444E), Voltmeter, Right Turn I....15013
7.8. Speedometer, Tachometer, HI Beam, Right & Left T/S Ind. Lig....15014
7.9. Pyrometer Gauge N/T 444E, I6 HEUI, p. 9....15015
WARNING LIGHTS (Chapter 8)....15016
8.1. Windshield Washer Low Fluid Warning Light, Power Divider Lo....15016
8.2. Fuel Filter Wiring System W/T 444E, I6 HEUI, p. 2....15017
8.3. Diagnostic/Programmable Conn., W/T 444E, I6 HEUI, p. 3....15018
8.4. Surge Tank W/T 444E & I6 HEUI (Plastic or Metal Tanks), p. ....15019
8.5. Engine Warning Lights/Alarm & Test Switch W/T 444E & I6 HEU....15020
8.6. Air Actuated and Hydraulic Actuated Park Brake With Hydraul....15021
CHASSIS ACCESSORIES (Chapter 9)....15022
9.1. Air Suspension W/Air Hydraulic Brakes, p. 1....15022
9.2. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....15023
9.3. Allison Automatic (Electronic) Transmission Spare I/O W/I6 ....15024
9.4. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....15025
9.5. Allison Automatic (Electronic) Transmission W/I6 HEUI & T 4....15026
9.6. Allison Automatic (Electronic) Transmission W/I6 or V8, p. ....15027
9.7. Allison Automatic (Electronic) Transmission Retarder Contro....15028
9.8. Allison Automatic (Electronic) Transmission Retarder Contro....15029
9.9. Allison Automatic (Electronic) Transmission Retarder, p. 9....15030
9.10. Auto Neutral, p. 10....15031
9.11. Allison Automatic (Electronic) Transmission WTEC III HD, p....15032
9.12. Allison Automatic (Electronic) Transmission WTEC III HD (C....15033
9.13. Allison Automatic (Electronic) Transmission WTEC III HD (C....15034
9.14. Allison Automatic (Electronic) Transmission WTEC III HD (C....15035
9.15. Exhaust Brake, I6 HEUI W/Air ABS, W/Allison WT Transmissio....15036
9.16. Exhaust Brake, I6 HEUI W/Air ABS, N/Allison WT Transmissio....15037
9.17. Exhaust Brake W/Hyd. Brakes N/AT-MT Retarders or MD Transm....15038
9.18. Exhaust Brake Solenoid, I6 HEUI, N/ABS, N/Allison WT Trans....15039
9.19. Allison Automatic Transmission System W/I6 HEUI, T 444E, p....15040
9.20. Axle, Two Speed, Wiring (Air) W/Allison (Elect.) Auto Tran....15041
9.21. Axle, Two Speed, Wiring (Hyd.) W/Allison (Elect.) Auto Tra....15042
9.22. Axle, Two Speed, Electric W/T 444E & I6 HEUI, p. 22....15043
9.23. Axle, Two Speed, Electric (Air) & Air Dryer W/Auto or Manu....15044
9.24. Axle, Two Speed, Electric (Hydraulic) W/Auto or Manual Tra....15045
9.25. Brake System, Hydraulic, p. 25....15046
9.26. Bendix Automatic Drain Valve (DV-2) W/Heater W/ & N/Exhaus....15047
9.27. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Air ABS, ....15048
9.28. Allison AT Retarder W/4000, W/I6 HEUI, T 444E, W/Hyd. ABS,....15049
9.29. Locking Differential W/Allison WT Transmission, p. 29....15050
9.30. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....15051
9.31. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....15052
9.32. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....15053
9.33. Antilock Air Brakes (4 Channel) W/Electronic Engines & W/ ....15054
9.34. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....15055
9.35. Antilock Air Brakes (4 Channel) W/I6 HEUI, T 444E & W/Alli....15056
9.36. Brake System, Hydraulic W/4000 & W/ or N/ABS, p. 36....15057
9.37. Antilock Hydraulic Brakes (4 Channel) W/4000, p. 37....15058
9.38. Antilock Hydraulic Brakes (4 Channel) W/4000 (Cont.), p. 3....15059
9.39. Transfer Case Shift System Front Axle Warning Light, p. 39....15060
9.40. Trailer Connection W/Regular Cab & W/Sleeper Box, p. 40....15061
9.41. Trailer Connection W/Frame Mounted 7–Way & W/Tractor, p. 4....15062
9.42. Trailer Connection W/Frame Mounted 7–Way & W/Truck & W/Air....15063
9.43. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco, p. 43....15064
9.44. Antilock Brakes (4 Channel) W/8000 & W/ATC-Wabco (Cont.), ....15065
9.45. Air Suspension, Main Cab Overlay Control Harness, p. 45....15066
9.46. Meritor G Series Transmission, p. 46....15067
9.47. Allison LCT With Hydraulic Brakes, p. 47....15068
9.48. Allison LCT With Hydraulic Brakes (Cont.), p. 48....15069
9.49. Allison LCT With Hydraulic Brakes (Cont.), p. 49....15070
9.50. Allison LCT With Hydraulic Brakes (Cont.), p. 50....15071
9.51. Allison LCT With Hydraulic Brakes (Cont.), p. 51....15072
9.52. Allison LCT With Hydraulic Brakes (Cont.), p. 52....15073
9.53. Allison LCT With Hydraulic Brakes (Cont.), p. 53....15074
9.54. Dual Neutral, p. 54....15075
LIGHT SYSTEMS (Chapter 10)....15076
10.1. Back-Up Lights, p. 1....15076
10.2. Clearance, Marker & Tail Lights W/Tractor N/T 444E, I6 HEU....15077
10.3. Clearance, Marker & Tail Lights W/Truck N/T 444E, I6 HEUI,....15078
10.4. Clearance, Marker & Tail Lights W/Tractor W/T 444E, I6 HEU....15079
10.5. Clearance, Marker & Tail Lights W/Truck W/T 444E, I6 HEUI,....15080
10.6. Cab Dome and Courtesy Lights, p. 6....15081
10.7. Work Light W/Tractor & W/Reg. Cab, Sleeper Cab, p. 7....15082
10.8. Work Light W/Truck, p. 8....15083
10.9. Fog Light System W/ & N/DRL (USA) & N/T 444E, I6 HEUI, p. ....15084
10.10. Fog Light System W/ & N/DRL (Canada) & N/T 444E, I6 HEUI,....15085
10.11. Fog Light System W/ & N/DRL (USA) & W/T 444E, I6 HEUI, p.....15086
10.12. Fog Light System W/DRL (Canada) & W/T 444E, I6 HEUI, p. 1....15087
10.13. Headlight System N/DRL W/International Turn Signal Switch....15088
10.14. Headlight System N/DRL W/International Turn Signal Switch....15089
10.15. Headlight System N/DRL W/Sig-Stat 910 T/S Sw. W/Flr. Mtd.....15090
10.16. Headlight System N/DRL W/Sig-Stat 915 T/S Sw. W/Push Btn.....15091
10.17. Headlight System W/DRL (Canada) W/Sig-Stat 910 T/S Sw. W/....15092
10.18. Headlight System W/DRL (Canada) W/Sig-Stat 915 T/S Sw. W/....15093
10.19. Headlight System W/DRL (USA) W/Sig-Stat 910 T/S Sw. W/Air....15094
10.20. Headlight System W/DRL (USA) W/Sig-Stat 915 T/S Sw. W/Air....15095
10.21. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Hyd. Br....15096
10.22. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Hyd. Brake....15097
10.23. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....15098
10.24. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....15099
10.25. Headlight System W/DRL (Canada) W/Int'l T/S Sw. W/Air Bra....15100
10.26. Headlight System W/DRL (USA) W/Int'l T/S Sw. W/Air Brakes....15101
10.27. Additional Headlight Wiring W/Dual Drive Cab, p. 27....15102
10.28. Hydraulic Park Brake Ind. Light W/Key Sw. or Push Button ....15103
10.29. Panel Lights, p. 29....15104
10.30. Stop Light Switch W/T 444E & I6 HEUI W/Air Brakes, p. 30....15105
10.31. Stop Light Switch Truck W/Standard Air Brakes W/Internati....15106
10.32. Stop Light Switch Truck W/Standard Air Brakes W/Sig-Stat ....15107
10.33. Stop Light Switch W/Tractor, Truck W/Tractor Application,....15108
10.34. Stop Light Switch W/Tractor, Truck W/Tractor Application,....15109
HEATER AND AIR CONDITIONER (Chapter 11)....15110
11.1. Heater/Air Conditioner, p. 1....15110
11.2. Heater Only, p. 2....15111
CONNECTOR COMPOSITES (Chapter 12)....15112
12.1. Dash Connector (2) (N/T 444E or I6 HEUI)....15112
12.2. Dash Connector (2) (W/T 444E or I6 HEUI)....15113
12.3. Dash Connector Engine Connections (2A) (N/T 444E or I6 HEU....15114
12.4. Dash Connector Engine Connections (2A) (W/T 444E or I6 HEU....15115
12.5. Connector Composites (3 & 3A)....15116
12.6. Connector Composite (3J)....15117
12.7. Connector Composites (11), (12), (13)....15118
12.8. Connector Composites (14), (14A), (15), (16), (17), (18), ....15119
12.9. Connector Composites (20), (21)....15120
12.10. Connector Composites (23), (24), (26)....15121
12.11. Connector Composites (27), (28), (29), (30), (31), (32)....15122
12.12. Connector Composites (33), (34), (35), (36), (37), (38), ....15123
12.13. Connector Composites (47 & 48), (47A), (47B), (49), (50),....15124
12.14. Connector Composites (53), (54), (55), (56), (57), (58), ....15125
12.15. Connector Composites (66), (67), (69), (70), (71)....15126
12.16. Connector Composites (72), (73), (74), (75), (76), (77), ....15127
12.17. Connector Composites (80), (83), (84 & 85), (86), (90), (....15128
12.18. Connector Composites (98), (99), (100), (101), (102), (10....15129
12.19. Connector Composites (105), (106), (107), (108), (109), (....15130
12.20. Connector Composites (117), (119), (121), (122), (123), (....15131
12.21. Connector Composites (132), (133), (135), (136)....15132
12.22. Connector Composites (137), (141), (142), (143), (144), (....15133
12.23. Connector Composites (147), (148), (149), (153)....15134
12.24. Connector Composites (153), (154), (156), (157), (158), (....15135
12.25. Connector Composites (160), (161), (162), (163), (164), (....15136
12.26. Connector Composites (169), (170), (171), (172), (173), (....15137
12.27. Connector Composites (179), (180), (181), (182), (183), (....15138
12.28. Connector Composites (194A), (199), (203), (210), (212), ....15139
12.29. Connector Composites (214M), (218), (219), (220), (221), ....15140
12.30. Connector Composites (223), (225), (226), (231), (232M), ....15141
12.31. Connector Composites (252), (257), (258), (259), (260), (....15142
12.32. Connector Composites (270), (271), (272), (273), (274A), ....15143
12.33. Connector Composites (274), (275), (276), (277), (279)....15144
12.34. Connector Composites (280), (284), (286), (287)....15145
12.35. Connector Composites (288), (289), (290), (291), (292), (....15146
12.36. Connector Composites (294), (295), (296), (297), (298), (....15147
12.37. Connector Composites (304), (305), (306), (309), (310), (....15148
12.38. Connector Composites (311), (312), (313), (314), (315), (....15149
12.39. Connector Composites (320), (323), (325)....15150
12.40. Connector Composites (325), (326), (327), (328), (329), (....15151
12.41. Connector Composites (332), (333), (335), (336), (337)....15152
12.42. Connector Composites (338), (339), (340), (341), (342), (....15153
12.43. Connector Composites (345), (346), (347), (348), (349), (....15154
12.44. Connector Composites (355), (356), (357), (358), (359), (....15155
12.45. Connector Composites (367), (368), (369), (370), (372), (....15156
12.46. Connector Composites (377), (377A), (377B)....15157
12.47. Connector Composites (379), (382), (382A)....15158
12.48. Connector Composites (383), (384), (386), (386A), (386B)....15159
12.49. Connector Composites (387), (389), (390), (391), (392)....15160
12.50. Connector Composites (396), (399), (400), (401)....15161
12.51. Connector Composites (402), (403), (404)....15162
12.52. Connector Composites (406), (413), (417)....15163
12.53. Connector Composite (418)....15164
12.54. Connector Composites (420), (421), (422)....15165
12.55. Connector Composites (423), (425), (426), (427), (428)....15166
12.56. Connector Composites (430), (431), (432), (433), (434), (....15167
12.57. Connector Composites (447), (449), (457)....15168
12.58. Connector Composites (458), (459), (460), (463), (465), (....15169
12.59. Connector Composites (467), (468), (469), (473), (480), (....15170
12.60. Connector Composites (492), (493), (494), (495)....15171
12.61. Connector Composites (499), (500), (501), (502), (503), (....15172
12.62. Connector Composites (506), (507), (508), (510), (511), (....15173
12.63. Connector Composites (555), (557), (558), (569), (570), (....15174
12.64. Connector Composite (615)....15175
12.65. Connector Composites (631), (632)....15176
12.66. Connector Composites (633), (634)....15177
12.67. Connector Composites (636), (637), (639)....15178
12.68. Connector Composites (646), (646A), (647), (648), (649), ....15179
12.69. Connector Composites (661), (662), (667), (675), (683), (....15180
12.70. Connector Composites (700), (701), (702), (703), (707)....15181
12.71. Connector Composites (708), (734), (758), (759), (760), (....15182
12.72. Connector Composites (766), (767), (768), (769), (770), (....15183
12.73. Connector Composites (775), (776), (777), (778), (789), (....15184
12.74. Connector Composites (792), (807), (830A), (830B), (917),....15185
12.75. Connector Composites (926), (958), (959), (960), (960A), ....15186
12.76. Connector Composites (995), (996), (1000), (1001), (1002)....15187
12.77. Connector Composites (1014), (1015)....15188
12.78. Connector Composites (1016), (1017), (1091)....15189
12.79. Connector Composites (1093), (1094), (1095), (1097), (109....15190
12.80. Connector Composites (1110M), (1113F), (1117), (1119), (1....15191
12.81. Connector Composites (1125), (1126), (1128), (1129), (113....15192
12.82. Connector Composites (1132), (1133), (1134), (1135), (302....15193
12.83. Connector Composites (3024), (3025), (3026), (3027), (302....15194
12.84. Connector Composites (3031), (3032), (3033), (3034)....15195
12.85. Connector Composites (3035), (3038), (3039), (3040)....15196
12.86. Connector Composites (3043), (3044), (3047), (3084), (308....15197
S08230- Electrical System Troubleshooting Guide, Supersedes CTS-5300 (July 1999) Service Manual....15198
S082503 - Electrical System Troubleshooting Guide Models Built 10_16_2000 to 05_20_2003 (Jan 2008) Service Manual....15910
S082503Z....15910
S082503B....16050
S082503C....16240
S082503D....16342
S082503E....16524
S082503F....16720
S082503G....16854
S082503 - TRUCK SERVICE MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Before 05_20_2003....17062
S082503Z.PDF (p.1-140)....17062
3200 4000 7000 8000 (May 2003) Electrical Troubleshooting (S082503A).pdf (p.141-1320)....17202
S082503AA.PDF (p.1-140)....17202
S082503AB.PDF (p.141-340)....17342
S082503AC.PDF (p.341-444)....17542
S082503AD.PDF (p.445-628)....17646
S082503AE.PDF (p.629-830)....17830
S082503AF.PDF (p.831-964)....18032
S082503AG.PDF (p.965-1180)....18166
S082503B.PDF (p.1321-1510)....18382
S082503C.PDF (p.1511-1612)....18572
S082503D.PDF (p.1613-1794)....18674
S082503E.PDF (p.1795-1990)....18856
S082503F.PDF (p.1991-2124)....19052
S082503G.PDF (p.2125-2332)....19186
S082503A - Electrical System Troubleshooting Guide Models Built After 05_20_2003 (Apr 2004) Service Manual....19394
S082503AA....19394
S082503AB....19534
S082503AC....19734
S082503AD....19838
S082503AE....20022
S082503AF....20224
S082503AG....20358
S082504 - 3200, 4100, 4200,4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models (May 2003 to Feb 2007) Electrical Troubleshooting....20574
S082504Z.PDF (p.1-332)....20574
S082504B.PDF (p.333-620)....20906
S082504C.PDF (p.621-824)....21194
S082504D.PDF (p.825-1172)....21398
S082504 - Electrical System Troubleshooting Guide Models Built 05_20_2003 to 02_28_2007 (Jan 2008) Service Manual....21746
S082504Z....21746
S082504B....22078
S082504C....22366
S082504D....22570
S082852 - 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600 Models Built January 1, 2002 To September 30, 2002 Electrical Circuit Diagrams (Jan 2002)Circuit Diagrams3_30_2016 12_00_00 AM....22918
S082852Z....22918
S082852B....22981
S082852C....23037
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)Circuit Diagrams3_30_2016 12_00_00 AM....23101
S082852AA....23101
S082852AB....23166
S082852AC....23224
S082853 - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built September 16, 2003 to March 10, 2004 Electrical Circuit Diagrams....23288
S082853Z....23288
S082853B....23357
S082853C....23431
S082854 - Wiring Diagrams (2004 to 2005)....23496
S08287 - 1000-4000, 7000, 8000 Fuses and Circuit Breakers Supersedes CTS-4410 (June 2001) Service Manual....23711
S08300 - Body Builder Electrical Data Book for Models Built January 2001 to February 28, 2007 Supersedes PBB-73000B (Aug 2008) Service Manual....23720
S08300z0805....23720
S08300b0805....23847
S08300c0805....24004
S08300, Formerly PBB-73000B - 3200 4000 7000 8000 - Body Builder Data Book....24156
01 - (2005) 3200 4000 7000 8000 - Body Builder Data Book.pdf (p.1-127)....24156
S08300b0805.pdf (p.128-284)....24283
S08300c0805.pdf (p.285-436)....24440
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes (June 2005) Service Manual....24592
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....24603
S08322 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600, RXT Models Built March 1, 2007 to March 18, 2008 Electrical Circuit Diagrams....24892
S08322a....24892
S08322b....25006
S08322c....25114
S08322 - 3200, 4100, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, RXTModels Built March 1, 2007 to March 18, 2008 Wiring Diagrams....25243
3200 RXT 4000 7000 8000 (March 2007 to March 2008) Wiring Diagrams (S08322a).pdf (p.1-114)....25243
S08322b.pdf (p.115-222)....25357
S08322c.pdf (p.223-351)....25465
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 GuideDiagnostic Trouble Codes....25594
toc....25598
SAFETY INFORMATION....25598
INTRODUCTION....25600
1. MANUAL INTRODUCTION....25602
Electronic Gauge Cluster....25604
1. Description And Operation....25606
1.1. Overview....25606
1.2. Operation....25606
1.3. EGC Diagram....25607
1.4. Data Link Communication....25607
2. Feature Codes....25607
3. Cluster Features....25608
3.1. Gauges....25608
3.2. Warning and Indicator Lamps....25614
Flashing of Diagnostic Lamps ....25614
Individual Warning Lamps....25614
In-Gauge Warning Lamps....25631
Direct Drive Warning Lamps....25631
3.3. Digital Display....25632
Display Control....25632
Display Lighting....25632
Initial Display Mode....25633
Informational Display Screens (Quadrant 1)....25633
Standard Selections....25633
Optional Selections....25633
Odometer/Trip Functions....25633
Hours Functions....25634
Fuel Economy....25634
Fuel Used (2010 and beyond Clusters)....25635
Compass/Outside Temperature (Quadrant 3)....25635
General Text and Warning Messages (Quadrant 2)....25636
HVAC Graphics....25640
Transmission Gear Displays (Quadrant 4)....25640
3.4. Audible Alarm....25641
One-time Five-short-beeps Alarm....25641
Repetitive One-short-beep Alarm....25641
One-time Ten-short-beeps Alarm ....25642
One-time Three-long-beeps Alarm....25642
Repetitive Short Duration Blips ....25642
3.5. Switches....25642
Headlight/Park Light Switch....25643
Panel Dimmer Switch....25643
Right Side Optional Switches....25643
Left Side Optional Switches....25643
3.6. Analog Inputs....25643
Pressure Sensors....25643
Outside Temperature....25644
3.7. Outputs....25644
Headlight Enable....25644
3.8. Digital Inputs....25644
3.9. Panel Dimming and Gauge Backlighting....25644
Panel Lighting....25644
3.10. Error Operation....25645
Lost Communication....25645
EGC Internal Failure....25645
Gauge Faults....25645
Digital Display....25646
3.11. Full Power, Low Power, and Standby Modes....25646
4. Cluster Programming....25648
5. User Programmable Parameters....25648
6. Caution — Handling the EGC....25649
7. Diagnostics....25649
7.1. Gauge Sweep....25649
7.2. On-Board Diagnostics....25649
7.3. Off-Board Diagnostics....25649
7.4. Diamond Logic Builder (DLB)....25650
7.5. Diagnostic Trouble Codes....25650
7.6. Displaying Fault Codes....25654
Definitions:....25655
Failure Mode Indicators (FMI):....25656
Source Addresses (SA)....25657
7.7. Clearing Fault Codes....25658
8. Troubleshooting....25658
8.1. EGC Preliminary System Check....25658
8.2. EGC Power and Data Link Voltage Checks....25660
8.3. Gauge Troubleshooting....25660
Gauge Troubleshooting Procedure....25660
Diagnostic Trouble Codes and Related Voltage Checks for the Sens....25664
8.4. Warning Lamp Troubleshooting Procedure....25677
8.5. In-Gauge Warning Lamps....25679
8.6. Direct Drive Warning Lamps....25680
Direct Drive Warning Lamp Troubleshooting:....25681
8.7. EGC Backlighting Inoperative....25681
8.8. EGC Switches....25682
Push Button Switch Troubleshooting....25682
Rocker Switch Troubleshooting....25682
8.9. Digital Display....25682
Display Control....25683
8.10. Audible Alarm....25683
8.11. Outside Temperature Display Malfunction....25684
8.12. Lost SAE J1939 Data Link Communication....25685
9. Body Controller Signals....25686
Lighting Systems....25688
1. snowplow auxiliary lighting....25692
1.1. system description....25692
Overview....25692
Operation....25692
1.2. feature codes....25692
1.3. user programmable parameters....25693
1.4. diagnostic trouble codes....25694
1.5. troubleshooting....25695
Snow plow lighting preliminary checks....25696
Auxiliary Lights Relay Tests....25697
2. back up lights....25698
2.1. system description....25698
Overview....25698
Operation....25698
2.2. feature code....25699
2.3. user programmable parameters....25699
2.4. diagnostic trouble codes....25699
2.5. troubleshooting....25700
Back Up Lights Preliminary Checks....25700
Back Up Lights Test....25701
Backup Light Relay Tests....25702
Backup Light Ball Switch Tests....25702
3. Dome and courtesy lights....25702
3.1. system description....25702
Overview....25702
Operation....25703
3.2. feature code....25703
3.3. USER PROGRAMMABLE PARAMETERS....25703
3.4. diagnostic trouble codes....25704
3.5. troubleshooting....25705
Dome and Courtesy Lights Preliminary Checks....25705
Door Switch Circuit Tests....25706
Dome Light Circuit Tests....25707
4. fog lights....25708
4.1. system description....25708
Overview....25708
Operation....25709
4.2. feature codes....25709
4.3. user programmable parameters....25709
4.4. diagnostic trouble codes....25709
4.5. troubleshooting....25710
Fog Light System Preliminary Checks....25711
Fog Light Switch Test....25711
Fog Light Open Circuit Test....25712
Fog Light Short Circuit Test....25713
5. Headlights and DTRL....25713
5.1. system description....25713
Overview....25713
Operation....25713
5.2. feature codes....25714
5.3. user programmable parameters....25714
5.4. diagnostic trouble codes....25715
5.5. troubleshooting....25716
Headlight System Preliminary Checks....25717
Headlight Switch and Headlight Dimmer Tests....25718
Headlight Open Circuit Test....25719
Headlight Short Circuit Test....25720
6. STOP, TURN, AND HAZARDS....25720
6.1. system description....25720
Overview....25720
Operation....25720
6.2. feature codes....25720
6.3. user programmable parameters....25722
6.4. diagnostic trouble codes....25722
6.5. troubleshooting....25724
Stop, Turn, and Hazards System Preliminary Checks....25724
Turn Signal Switch Test....25726
Hazard Switch Test....25726
Brake Switch Test....25727
Output Open Circuit Test....25727
Output Short Circuit Test....25728
7. TAIL, MARKER, PARK, AND CLEARANCE LIGHTING....25728
7.1. system description....25728
Overview....25728
Operation....25729
7.2. feature codes....25729
7.3. user programmable parameters....25730
7.4. diagnostic trouble codes....25730
7.5. troubleshooting....25731
Tail, Marker, Park, and Clearance Lighting Preliminary Checks....25732
Headlight Switch Tests....25732
Interrupt Switch Tests....25733
Park Light Open Circuit Tests....25734
Park Light Short Circuit Tests....25734
8. work lights....25734
8.1. system description....25734
Overview....25734
Operation....25735
8.2. feature codes....25735
8.3. user programmable parameters....25736
8.4. diagnostic trouble codes....25736
8.5. troubleshooting....25737
Work Light System Preliminary Checks....25737
Work Light Switch Test....25738
Work Light Open Circuit Test....25738
Work Light Short Circuit Test....25739
Auxiliary Gauge Switch Pack....25740
1. Description And Operation....25742
1.1. Overview....25742
1.2. Operation....25742
1.3. AGSP Diagram....25742
1.4. Data Link Communication....25742
2. Feature Codes....25743
3. Features....25743
3.1. Gauges....25743
3.2. In-Gauge Warning Lamps....25744
3.3. Hybrid Display....25744
3.4. Switches....25745
3.5. Panel Dimming and Gauge Backlighting....25745
3.6. Error Operation....25745
Lost Communication....25746
Gauge Faults....25746
4. AGSP Programming....25747
5. User Programmable Parameters....25747
6. Caution — Handling the AGSP....25747
7. Diagnostics....25747
7.1. Gauge Sweep....25747
7.2. On-Board Diagnostics....25748
7.3. Off-Board Diagnostics....25748
7.4. Diamond Logic Builder (DLB)....25748
7.5. Diagnostic Trouble Codes....25748
8. Troubleshooting....25751
8.1. AGSP Preliminary System Check....25751
8.2. AGSP Power and Data Link Voltage Checks....25752
8.3. Gauge Troubleshooting Procedure....25752
8.4. Troubleshooting Specific Gauges....25754
8.5. In-Gauge Warning Lamps....25761
8.6. Panel Dimming and Gauge Backlighting....25762
8.7. AGSP Switches....25762
8.8. Lost SAE J1939 Data Link Communication....25762
9.1. Body Controller Signals....25762
Cab Features....25764
1. cigar lighter and power feed....25770
1.1. System description....25770
Overview....25770
Cigar Lighter Operation....25770
Cigar Lighter Power Source and Two Post Power Source Operation....25770
1.2. feature codes....25770
1.3. user programmable parameters....25770
1.4. diagnostic trouble codes....25770
1.5. diagnostics....25770
Cigar Lighter and Power Feed Preliminary Check....25770
Cigar Lighter Tests....25771
Cigar Lighter Power Source Test....25772
Two Post Power Source Test....25772
2. C.b. Power radio....25774
2.1. system description....25774
Overview....25774
Operation....25774
2.2. feature codes....25774
2.3. user programmable parameters....25774
2.4. diagnostic trouble codes....25774
2.5. diagnostics....25774
C.B. Radio Power Source Preliminary Check....25774
C.B. Power Connector Tests....25775
3. compass and temperature display....25777
3.1. system description....25777
Overview....25777
Temperature Display Operation....25777
Compass Display Operation....25777
3.2. feature codes....25777
3.3. USER PROGRAMMABLE PARAMETERS....25777
3.4. Diagnostic Trouble Codes....25777
3.5. diagnostics....25778
Compass/Temperature Display Preliminary Check....25779
Compass/Temperature Display Voltage Checks....25779
4. power windows and locks....25780
4.1. system description....25780
Overview....25780
Power Window Operation....25780
Power Door Lock Operation....25780
4.2. feature codes....25781
4.3. user programmable parameters....25783
4.4. diagnostic trouble codes....25783
4.5. Troubleshooting....25786
Power Window and Lock Preliminary Check....25787
Power Door Lock Tests....25788
Power Window Test....25789
5. cruise control....25790
5.1. system description....25790
Overview....25790
Operation....25790
5.2. feature codes....25790
5.3. user programmable parameters....25791
5.4. diagnostic trouble codes....25791
5.5. Troubleshooting....25792
Cruise Control Preliminary Check....25793
Cruise Control Switch Tests....25794
6. Theft deterrent....25796
6.1. system description....25796
Overview....25796
Operation....25796
6.2. feature codes....25797
6.3. User programmable parameters....25798
6.4. diagnostic trouble codes....25799
6.5. troubleshooting....25800
Theft Deterrent Preliminary Check....25800
Theft Deterrent System Test....25800
7. electric horn....25802
7.1. system description....25802
Overview....25802
Operation....25802
7.2. feature codes....25802
7.3. User programmable parameters....25802
7.4. diagnostic trouble codes....25803
7.5. troubleshooting....25804
Electric Horn Preliminary Check....25804
Electric Horn Test....25805
8. air horn....25807
8.1. system description....25807
Overview....25807
Operation....25807
8.2. feature codes....25807
8.3. User programmable parameters....25807
8.4. diagnostic trouble codes....25807
8.5. troubleshooting....25808
Air Horns Preliminary Check....25808
Air Horn Test....25809
9. power mirrors....25810
9.1. system description....25810
Overview....25810
Operation....25810
9.2. feature codes....25810
9.3. User programmable parameters....25810
9.4. diagnostic trouble codes....25810
9.5. troubleshooting....25810
Power Mirror Preliminary Check....25811
Power Mirror Test....25812
10. Heated Mirror....25814
10.1. system description....25814
Overview....25814
Operation....25814
10.2. feature codes....25814
10.3. User programmable parameters....25816
10.4. diagnostic trouble codes....25816
10.5. troubleshooting....25817
Heated Mirror Preliminary Check....25817
Heated Mirrors Test....25818
Left Heated Mirror Test....25818
Right Heated Mirror Test....25819
11. radio (entertainment), speakers....25820
11.1. system description....25820
Overview....25820
Operation....25820
11.2. feature codes....25820
11.3. User programmable parameters....25820
11.4. diagnostic trouble codes....25820
11.5. troubleshooting....25820
Radio Preliminary Check....25821
Radio Test....25821
12. Two-way radio....25823
12.1. system description....25823
Overview....25823
Operation....25823
12.2. feature codes....25823
12.3. User programmable parameters....25823
12.4. diagnostic trouble codes....25823
12.5. troubleshooting....25823
Two-Way Radio Circuit Tests....25823
13. Windshield wiper and washer pump....25825
13.1. system description....25825
Overview....25825
Wiper Operation....25825
Park Operation....25825
Washer Operation....25825
13.2. feature codes....25825
13.3. User programmable parameters....25826
13.4. diagnostic trouble codes....25827
NO TITLE....25829
13.5. troubleshooting....25829
Wiper and Washer Preliminary Check....25829
Washer Test....25831
Wiper Park Test....25831
Wiper Switch Test....25832
Wiper Motor Test....25833
14. Roof auxiliary load and air shield light....25835
14.1. system description....25835
Overview....25835
Roof Auxiliary Load Operation....25835
Air Shield Light Operation....25835
14.2. Feature codes....25835
14.3. User programmable parameters....25835
14.4. diagnostic trouble code....25835
Roof Auxiliary Load Feature....25835
Lighted Air Shield....25836
14.5. troubleshooting....25836
Roof Auxiliary Load Preliminary Check....25836
Roof Auxiliary Load Test....25837
IP Mounted Roof Auxiliary Load Switch Test....25837
Lighted Air Shield Preliminary Check....25838
Lighted Air Shield Test....25839
15. self contained air seat....25840
15.1. system description....25840
Overview....25840
Operation....25840
15.2. Feature codes....25840
15.3. User programmable parameters....25840
15.4. diagnostic trouble code....25840
15.5. troubleshooting....25840
Self Contained Air Seats Preliminary Check....25840
Self Contained Air Seat Test....25841
16. Heated seats....25842
16.1. system description....25842
Overview....25842
Operation....25842
16.2. Feature codes....25842
16.3. User programmable parameters....25842
16.4. diagnostic trouble code....25842
16.5. troubleshooting....25842
Heated Seats Preliminary Check....25842
Heated Seat Test....25843
17. seat belt and seat sensor....25844
17.1. system description....25844
Overview....25844
Operation....25844
17.2. feature codes....25844
17.3. User programmable parameters....25844
17.4. diagnostic trouble code....25845
17.5. troubleshooting....25845
Seat Belt Preliminary Check....25845
Seat Belt Test....25846
18. brake light switch....25847
18.1. system description....25847
Overview....25847
Operation....25847
18.2. Feature codes....25847
18.3. User programmable parameters....25847
18.4. diagnostic trouble code....25847
18.5. troubleshooting....25849
Brake Switch Preliminary Check....25849
Brake Switch Test....25850
19. Clutch switch....25851
19.1. system description....25851
Overview....25851
Operation....25851
19.2. Feature codes....25851
19.3. User programmable parameters....25851
19.4. diagnostic trouble code....25851
19.5. troubleshooting....25852
Clutch Switch Preliminary Checks....25853
No Engine Crank Clutch Switch Test....25854
Cruise Control Clutch Switch Test....25854
20. load shedding....25855
20.1. system description....25855
Overview....25855
Operation....25855
20.2. Feature codes....25855
20.3. User programmable parameters....25855
20.4. diagnostic trouble code....25855
20.5. troubleshooting....25856
Latching Relay Diagnostics....25857
Chassis Features....25858
1. trailer turn signal relays....25864
1.1. System description....25864
Overview....25864
Operation....25864
1.2. feature codes....25864
1.3. user programmable parameters....25864
1.4. diagnostic trouble codes....25864
1.5. troubleshooting....25865
Trailer Turn Signal Relay System Preliminary Checks....25866
Left Trailer Turn Signal Inop Test....25867
Right Trailer Turn Signal Inop Test....25868
2. trailer auxiliary power circuit....25869
2.1. System description....25869
Overview....25869
Operation....25869
2.2. feature codes....25869
2.3. user programmable parameters....25869
2.4. diagnostic trouble codes....25869
2.5. troubleshooting....25870
Trailer Auxiliary Power Circuit Preliminary Checks....25870
Trailer Auxiliary Circuit Tests....25870
3. Auto Neutral (Feature Code 0595AYP)....25872
3.1. Description And Operation....25872
Overview....25872
Operation....25872
3.2. Feature Codes....25873
3.3. User Programmable Parameters....25873
3.4. Diagnostics....25874
Diamond Logic Builder (DLB)....25874
Diagnostic Trouble Codes....25874
Displaying Diagnostic Trouble Codes....25875
3.5. Troubleshooting....25875
Auto Neutral Preliminary System Check....25875
Auto Neutral Does Not Engage....25876
Auto Neutral Does Not Disengage....25877
Auto Neutral Warning Lamp Inoperative....25878
3.6. Body Controller Signals....25878
3.7. Body Controller Functions....25879
Activate Auto Neutral....25879
Error Operation....25880
4. Axle Load Monitor....25881
4.1. Description And Operation....25881
Overview....25881
Operation....25881
4.2. Feature Codes....25881
4.3. User Programmable Parameters....25882
4.4. Diagnostics....25883
Diamond Logic Builder (DLB)....25883
Diagnostic Trouble Codes....25883
Displaying Diagnostic Trouble Codes....25885
4.5. Troubleshooting....25885
Axle Load Monitor Preliminary Check....25885
Axle Pressure Transducer Voltage Checks....25886
4.6. Body Controller Signals....25886
4.7. Body Controller Functions....25887
To activate the axle load monitor feature, the following conditi....25887
5. REMOTE POWER MODULE....25888
5.1. Description and Operation....25888
Overview....25888
Operation....25888
RPM Addressing....25889
5.2. Feature Codes....25889
5.3. User Programmable Parameters....25889
5.4. Diagnostics....25890
Diamond Logic Builder (DLB)....25890
Diagnostic Trouble Codes....25890
Displaying Diagnostic Trouble Codes....25893
5.5. Troubleshooting....25893
Remote Power Module Preliminary Check....25893
RPM Power, Ground and Data Link Circuits....25894
5.6. Body Controller Signals....25895
5.7. Body Controller Functions....25895
6. auxiliary power source....25896
6.1. System description....25896
Overview....25896
Operation....25896
6.2. feature codes....25896
6.3. user programmable parameters....25896
6.4. diagnostic trouble codes....25896
6.5. troubleshooting....25896
Auxiliary Power Source Preliminary Check....25897
Aux Power Source Tests....25897
7. Two-speed axle switch....25899
7.1. System description....25899
Overview....25899
Operation....25899
7.2. feature codes....25899
7.3. user programmable parameters....25899
7.4. diagnostic trouble codes....25899
7.5. troubleshooting....25900
Two-Speed Switch Preliminary Check....25900
Two-Speed Switch Test....25900
8. Air Dryer and heated drain valve....25901
8.1. System description....25901
Overview....25901
Operation....25901
8.2. feature codes....25901
8.3. user programmable parameters....25901
8.4. diagnostic trouble codes....25901
8.5. troubleshooting....25901
Air Dryer and Heated Drain Valve Preliminary Check....25901
Heated Drain Valve Test....25902
Air Dryer Test....25902
9. fuel transfer pump....25904
9.1. System description....25904
Overview....25904
Operation....25904
9.2. feature codes....25904
9.3. user programmable parameters....25904
9.4. diagnostic trouble codes....25906
9.5. troubleshooting....25906
Fuel Transfer Pump Preliminary Check....25907
Fuel Transfer Pump Won’t Run Test....25907
Fuel Transfer Pump Continuously Runs Test....25909
10. water in fuel monitor....25910
10.1. System description....25910
Overview....25910
Operation....25910
10.2. feature codes....25910
10.3. user programmable parameters....25910
10.4. diagnostic trouble codes....25910
10.5. troubleshooting....25911
Water in Fuel Preliminary Check....25911
Water Probe Test....25912
11. electric trailer brake....25913
11.1. System description....25913
Overview....25913
Operation....25913
11.2. feature codes....25913
11.3. user programmable parameters....25913
11.4. diagnostic trouble codes....25913
11.5. troubleshooting....25914
Electric Trailer Brake Preliminary Check....25914
Electric Trailer Brake Test....25915
12. air solenoid....25917
12.1. System description....25917
Overview....25917
Operation....25917
12.2. feature codes....25917
12.3. user programmable parameters....25918
12.4. diagnostic trouble codes....25919
12.5. Troubleshooting....25927
Air Solenoid Preliminary Check....25927
Air Solenoid Diagnosis....25927
13. Suspension dump....25929
13.1. System description....25929
Overview....25929
Operation....25929
13.2. feature code....25929
13.3. user programmable parameters....25929
13.4. diagnostic trouble codes....25930
13.5. Troubleshooting....25931
Suspension Dump Test....25932
14. Customer Installed Lift Gate Power Source....25934
14.1. System description....25934
Overview....25934
Operation....25934
14.2. feature code....25934
14.3. user programmable parameters....25934
14.4. diagnostic trouble codes....25935
14.5. Troubleshooting....25935
Lift Gate Test....25936
15. Fifth Wheel Slide, Air Controlled....25937
15.1. System description....25937
Overview....25937
Operation....25937
15.2. FEATURE CODE....25937
15.3. user programmable parameters....25937
15.4. diagnostic trouble codes....25938
15.5. Troubleshooting....25938
Fifth Wheel Slide Preliminary Check....25939
Fifth Wheel Slide Test....25939
16. Differential Lock Air controlled....25940
16.1. System description....25940
Overview....25940
Operation....25940
16.2. FEATURE CODE....25941
16.3. user programmable parameters....25941
16.4. diagnostic trouble codes....25942
16.5. Troubleshooting....25943
Differential Lock Preliminary Check....25944
(0595ACT) Differential Lock Test....25944
(0595ACU) Differential Lock Test....25945
17. Power Divider Lock (PDL) Air Controlled....25946
17.1. System description....25946
Overview....25946
Operation....25946
17.2. FEATURE CODE....25946
17.3. user programmable parameters....25947
17.4. diagnostic trouble codes....25948
17.5. Troubleshooting....25948
Power Divider Lock Preliminary Check....25949
Power Divider Lock Test....25949
18. Remote start/stop....25950
18.1. System Description....25950
Overview....25950
Operation....25950
18.2. FEATURE CODE....25950
18.3. user programmable parameters....25951
18.4. Diagnostic Trouble Codes....25951
18.5. Troubleshooting....25952
Remote Start/Stop Preliminary Check....25952
Remote Start/Stop System Tests....25954
19. Power Take Off (PTO)....25956
19.1. Description and Operation....25956
Overview....25956
Operation....25956
19.2. Feature Codes....25957
19.3. User Programmable Parameters....25965
19.4. Diagnostics....25966
Diamond Logic Builder (DLB)....25966
Diagnostic Trouble Codes....25966
Displaying Diagnostic Trouble Codes....25977
19.5. Troubleshooting....25977
Power Take Off (PTO) Preliminary Check....25977
19.6. Body Controller Signals....25979
19.7. Body Controller Functions....25981
20. Wheelchair Lift Interlock....25982
20.1. Description And Operation....25982
Overview....25982
Operation....25982
20.2. Feature Codes....25983
20.3. User Programmable Parameters....25983
20.4. Diagnostics....25983
Diamond Logic Builder (DLB)....25983
Diagnostic Trouble Codes....25983
Displaying Diagnostic Trouble Codes....25984
20.5. Troubleshooting....25984
Wheelchair Lift Interlock Preliminary System Check....25984
20.6. Body Controller Signals....25987
20.7. Body Controller Functions....25988
Activate Wheelchair Lift Solenoid....25988
Activate Audible Alarm....25989
TRANSMISSIONS....25990
1. Description and Operation....25992
1.1. Overview....25992
1.2. Operation....25992
2. Feature Codes....25994
2.1. Available Body Controller Configurations....25994
2.2. User Programmable Parameters....25996
3. Diagnostics....25997
3.1. Diamond Logic Builder (DLB)....25997
3.2. Diagnostic Trouble Codes....25997
3.3. Displaying Diagnostic Trouble Codes....25998
4. Troubleshooting....25999
4.1. Preliminary System Check — All Transmissions....25999
4.2. Park Position Unlock Solenoid Checks — Eaton T-Handle & All....26004
4.3. LCT Column Shifter Interlock Checks....26005
4.4. TCM Power, Ground and Data Link Circuit Checks....26005
4.5. Shift Selector Power and Ground Circuit Checks....26006
4.6. Body Controller Signals....26006
4.7. Body Controller Functions....26007
Park Position Unlock Solenoid (Park_Pos_Unlock_Solenoid_Cmd)....26007
PRNDL Display Interlock (PRNDL_Trans_Pseudo_Ignition_Cmd)....26007
Multiplexing (Data Links)....26008
1. multiplexing (data links)....26010
1.1. Description....26010
Overview....26010
Operation....26010
1.2. troubleshooting....26012
J1939 Data Link Terminating Resistors....26012
Body Controller....26013
Electronic Engines....26014
1. REMOTE ENGINE SPEED CONTROL MODULE (RESCM)....26016
1.1. Description and Operation....26016
Overview....26016
Operation....26016
1.2. Feature Codes....26017
1.3. User Programmable Parameters....26017
1.4. Diagnostics....26017
Diamond Logic Builder (DLB)....26017
Diagnostic Trouble Codes....26017
Displaying Diagnostic Trouble Codes....26022
1.5. Troubleshooting....26022
RESCM Preliminary Check....26022
RESCM Power, Ground and Data Link Circuits....26023
1.6. Body Controller Signals....26024
1.7. Body Controller Functions....26025
2. Aftertreatment....26026
2.1. Description And Operation....26026
Overview....26026
Operation....26026
2.2. Aftertreatment Definitions....26027
2.3. Soot Accumulation Level Indications....26027
2.4. Feature Related Text Messages in the Gauge Cluster....26028
2.5. Feature Codes....26029
2.6. User Programmable Parameters....26030
2.7. Diagnostics....26030
Diamond Logic Builder (DLB)....26031
Diagnostic Trouble Codes....26031
Displaying Diagnostic Trouble Codes....26034
2.8. Troubleshooting....26034
Preliminary System Check — Aftertreatment....26034
Parked Regeneration Switch Test....26035
Parked Regeneration Switch Indicator Test....26036
Inhibit Regeneration Switch Test....26036
Inhibit Regeneration Switch Indicator Test....26037
DPF Status Warning Lamp Test....26037
HEST Warning Lamp Test....26037
Lamp Check....26038
Lost Communication and Warning Lamp Diagnostics....26038
2.9. Body Controller Signals....26038
2.10. Body Controller Functions....26040
Parked Regeneration....26040
Inhibit Regeneration....26041
Parked Regeneration Switch Indicator....26041
Inhibit Regeneration Switch Indicator....26042
DPF Status Warning Lamp....26043
HEST Warning Lamp....26043
Audible Alarm....26044
Switch Packs (J1708 Data Links)....26046
1. switch packs (j1708 data link)....26048
1.1. Description....26048
Overview....26048
Operation....26048
1.2. troubleshooting....26048
Switch Pack Preliminary Check....26049
Switch Pack Test....26049
12 Volt Power Distribution and Grounds....26050
1. 12-Volt power distribution and grounds....26052
1.1. Description....26052
Overview....26052
Operation....26052
1.2. troubleshooting....26052
Battery Power Distribution Check....26053
Accessory Power Distribution Preliminary Check....26053
Accessory Power Test....26053
Ignition Power Distribution Preliminary Check....26054
Ignition Power Test....26055
Ground Test....26056
Fans and Engine Accessories....26058
1. Engine Cooling Fan Control....26060
1.1. Description And Operation....26060
Overview....26060
Operation....26060
1.2. Feature Codes....26060
1.3. User Programmable Parameters....26061
1.4. Diagnostics....26061
Diagnostic Trouble Codes....26061
Displaying Diagnostic Trouble Codes....26062
1.5. Troubleshooting....26062
Preliminary Check — Engine Cooling Fan....26062
1.6. Body Controller Signals....26063
1.7. Body Controller Functions....26065
Fan Control — General Information....26065
ON/OFF Fan Control....26065
Low Air Pressure Engine Fan Override (0595BBB)....26066
Variable Speed Fan Control (0595AYH)....26067
2. Snow Valve (Engine Intake) (non Big Bore Engines)....26069
2.1. Description And Operation....26069
Overview....26069
Operation....26069
2.2. Feature Codes....26069
2.3. User Programmable Parameters....26069
2.4. Diagnostics....26070
Diagnostic Trouble Codes....26070
2.5. Troubleshooting....26070
Snow Valve Preliminary Check....26070
Snow Valve Mechanical Checks....26070
Snow Valve Module Checks....26071
2.6. Body Controller Signals....26071
2.7. Body Controller Functions....26071
3. Snow Valve (Engine Intake) (Big Bore Engines)....26072
3.1. Description And Operation....26072
Overview....26072
Operation....26072
3.2. Feature Codes....26073
3.3. User Programmable Parameters....26073
3.4. Diagnostics....26073
Diamond Logic Builder (DLB)....26073
Diagnostic Trouble Codes....26074
Displaying Diagnostic Trouble Codes....26074
3.5. Troubleshooting....26074
Snow Valve Preliminary Check....26074
Snow Valve Mechanical Checks....26075
Snow Valve Switch Test....26076
Snow Valve Module Checks....26076
3.6. Body Controller Signals....26078
3.7. Body Controller Functions....26078
To activate the feature, the following conditions must be true:....26078
If the conditions to activate the feature (above) are true, then....26078
If any of the following conditions occur, then the feature will ....26079
If any of the conditions to deactivate the feature (above) are t....26079
4. Exhaust Brake....26080
4.1. Description And Operation....26080
Overview....26080
Operation....26080
4.2. Feature Codes....26080
4.3. User Programmable Parameters....26081
4.4. Diagnostics....26081
Diamond Logic Builder (DLB)....26081
Diagnostic Trouble Codes....26081
Displaying Diagnostic Trouble Codes....26081
4.5. Troubleshooting....26082
Exhaust Brake Preliminary Check....26082
Exhaust Brake Switch Test....26083
4.6. Body Controller Signals....26083
4.7. Body Controller Functions....26084
To activate the exhaust brake feature, the following conditions ....26084
If the conditions to activate the feature (above) are true, then....26084
Battery, Charging, and Cranking System....26086
1. battery....26088
1.1. Description....26088
Overview....26088
Operation....26088
1.2. diagnostic trouble codes....26089
1.3. troubleshooting....26089
NO TITLE....26089
2. charging system....26090
2.1. Description....26090
Overview....26090
Operation....26090
2.2. diagnostic trouble codes....26090
2.3. troubleshooting....26091
3. ENGINE CRANKING....26091
3.1. Description....26091
Overview....26091
Operation....26091
3.2. troubleshooting....26092
4. Power pack 3....26092
4.1. Description....26092
Overview....26092
Operation....26092
4.2. troubleshooting....26093
tables....25608
Table 1Gauge Table....25608
Table 2Warning and Indicator Lamp Table – Type A....25615
Table 3Warning and Indicator Lamp Table – Type B....25623
Table 5General Text and Warning Messages requested by means of a....25636
Table 6General Text and Warning Messages Generated by the Electr....25637
Table 18Fuel Level Sensor Voltage Checks....25666
Table 20Transmission Oil Temperature Sensor Voltage Checks....25668
Table 22Axle Temperature Sensor Voltage Checks....25670
Table 24Axle Temperature Sensor Voltage Checks....25672
Table 26Air Pressure Transducer Voltage Checks....25676
Table 27Direct Drive Warning Lamp Table....25680
Table 29Ambient Air Temperature Sensor Test....25685
Table 30Ambient Air Temperature Sensor Table....25685
Table 32Feature Codes....25693
Table 33Diagnostic Trouble Codes....25694
Table 34Snow plow lighting preliminary checks....25696
Table 35Auxiliary Lights Relay Tests....25697
Table 36Diagnostic Trouble Codes....25699
Table 37Back Up Lights Preliminary Checks....25700
Table 38Back Up Lights Test....25701
Table 39Backup Light Relay Tests....25702
Table 40Backup Light Ball Switch Tests....25702
Table 41Feature Code....25703
Table 42Diagnostic Trouble Codes....25705
Table 43Dome and Courtesy Lights Preliminary Checks....25706
Table 44Door Switch Short Circuit Tests....25707
Table 45Door Switch Open Circuit Tests....25707
Table 46Dome Light Short Circuit Test....25708
Table 47Dome Light Open Circuit Test....25708
Table 48Feature Codes....25709
Table 49Diagnostic Trouble Codes....25710
Table 50Fog Light System Preliminary Checks....25711
Table 51Fog Light Switch Test....25712
Table 52Fog Light Open Circuit Test....25712
Table 53Fog Light Short Circuit Test....25713
Table 54Feature Codes....25714
Table 55Diagnostic Trouble Codes....25715
Table 56Headlight System Preliminary Checks....25717
Table 57Headlight Switch and Headlight Dimmer Test....25718
Table 58Headlight Open Circuit Test....25719
Table 59Headlight Short Circuit Test....25720
Table 60Feature Codes....25721
Table 61Diagnostic Trouble Codes....25723
Table 62Stop, Turn, and Hazards System Preliminary Checks....25725
Table 63Turn Signal Switch Test....25726
Table 64Hazard Switch Test....25726
Table 65Brake Switch Test....25727
Table 66Output Open Circuit Test....25727
Table 67Output Short Circuit Test....25728
Table 68Feature Codes....25729
Table 69Diagnostic Trouble Codes....25731
Table 70Tail, Marker, Park, and Clearance Lighting Preliminary C....25732
Table 71Headlight Switch Tests....25732
Table 72Interrupt Switch Tests....25733
Table 73Park Light Open Circuit Tests....25734
Table 74Park Light Short Circuit Tests....25734
Table 75Feature Codes....25735
Table 76Diagnostic Trouble Codes....25736
Table 77Work Light System Preliminary Checks....25737
Table 78Work Light Switch Test....25738
Table 79Work Light Open Circuit Test....25739
Table 80Work Light Short Circuit Test....25739
Table 82Gauge Table....25744
Table 88Axle Temperature Sensor Voltage Checks....25755
Table 90Axle Temperature Sensor Voltage Checks....25758
Table 93Cigar Lighter and Power Feed Preliminary Check....25771
Table 94Cigar Lighter Tests....25771
Table 95Cigar Lighter Power Source Tests....25772
Table 96Two Post Power Source Tests....25772
Table 97C.B. Radio Power Source Preliminary Check....25774
Table 98C.B. Radio Power Connector Tests....25775
Table 99Feature Codes....25777
Table 100Diagnostic Trouble Codes....25777
Table 101Compass/Temperature Display Preliminary Check....25779
Table 102Compass/Temperature Display Voltage Checks....25779
Table 103Feature Codes....25781
Table 104Diagnostic Trouble Codes....25783
Table 105Power Locks Preliminary Check....25787
Table 106Power Windows Preliminary Check....25787
Table 107One Door Lock Inop Test....25788
Table 108All Door Locks Inop Test....25788
Table 109One Power Window Inop Test....25789
Table 110All Power Windows Inop Test....25789
Table 111Feature Codes....25790
Table 112Diagnostic Trouble Codes....25791
Table 113Cruise Control Preliminary Check....25793
Table 114Steering Wheel Mounted Cruise Control Command Switch Te....25794
Table 115Steering Wheel Mounted Cruise Control Command Switch Te....25795
Table 116Feature Codes....25797
Table 117Theft Deterrent Preliminary Check....25800
Table 118Theft Deterrent System Test....25800
Table 119Feature Codes....25802
Table 120Diagnostic Trouble Codes....25804
Table 121Electric Horn Preliminary Check....25804
Table 122Electric Horn Test....25805
Table 123Feature Codes....25807
Table 124Diagnostic Trouble Codes....25808
Table 125Air Horns Preliminary Checks....25808
Table 126Air Horn Test....25809
Table 127Power Mirror Preliminary Check....25811
Table 128Power Mirror Tests....25812
Table 129Feature Codes....25814
Table 130Diagnostic Trouble codes....25816
Table 131Heated Mirror Preliminary Check....25817
Table 132Heated Mirrors Test....25818
Table 133Left Heated Mirror Test....25818
Table 134Right Heated Mirror Test....25819
Table 135Radio Preliminary Check....25821
Table 136Radio Test....25821
Table 137Two-Way Radio Circuit Tests....25823
Table 138Feature Codes....25825
Table 139Diagnostic Trouble Codes....25827
Table 140Wiper and Washer Preliminary Check....25829
Table 141Washer Test....25831
Table 142Wiper Park Test....25831
Table 143Wiper Switch Test....25832
Table 144Wiper Motor Test....25833
Table 145Feature Codes....25835
Table 146Lighted Air Shield DTC....25836
Table 147Roof Auxiliary Load Preliminary Check....25836
Table 148Roof Auxiliary Load Test....25837
Table 149IP Mounted Roof Auxiliary Load Switch Test....25837
Table 150Lighted Air Shield Preliminary Check....25838
Table 151Lighted Air Shield Test....25839
Table 152Self Contained Air Seats Preliminary Check....25840
Table 153Self Contained Air Seat Test....25841
Table 154Heated Seats Preliminary Check....25842
Table 155Heated Seat Test....25843
Table 157Seat Belt Preliminary Check....25845
Table 1580595BAG Seat Belt Test....25846
Table 159Feature Codes....25847
Table 160Diagnostic Trouble Codes....25847
Table 161Brake Switch Preliminary Check....25849
Table 162Brake Switch Test....25850
Table 163Feature Code....25851
Table 164Diagnostic Trouble Codes....25852
Table 165Clutch Switch Preliminary Checks....25853
Table 166No Engine Crank Clutch Switch Test....25854
Table 167Cruise Control Clutch Switch Test....25854
Table 168Feature Code....25855
Table 169Diagnostic Trouble Codes....25856
Table 170Feature Code....25864
Table 171Diagnostic Trouble codes....25864
Table 172Trailer Turn Signal Relay System Preliminary Checks....25866
Table 173Left Trailer Turn Signal Inop Test....25867
Table 174Right Trailer Turn Signal Inop Test....25868
Table 175Feature Codes....25869
Table 176Diagnostic Trouble Codes....25870
Table 177Trailer Auxiliary Power Circuit Preliminary Checks....25870
Table 178Trailer Auxiliary Circuit Tests....25870
Table 188Axle Pressure Transducer Voltage Checks....25886
Table 192RPM Checks....25894
Table 193Feature Codes....25896
Table 194Auxiliary Power Source Preliminary Check....25897
Table 195Aux Power Source Tests....25897
Table 197Diagnostic Trouble Codes....25899
Table 198Two-Speed Switch Preliminary Check....25900
Table 199Two-Speed Switch Test....25900
Table 200Air Dryer and Heated Drain Valve Preliminary Check....25901
Table 201Heated Drain Valve Test....25902
Table 202Air Dryer Test....25902
Table 203Feature Codes....25904
Table 204Diagnostic Trouble Codes....25906
Table 205Fuel Transfer Pump Preliminary Check....25907
Table 206Fuel Transfer Pump Won’t Run Test....25907
Table 207Fuel Transfer Pump Continuously Runs Test....25909
Table 208Feature Code....25910
Table 210Water in Fuel Preliminary Check....25911
Table 211Water Probe Test....25912
Table 212Feature Code....25913
Table 213Diagnostic Trouble Codes....25914
Table 214Electric Trailer Brake Preliminary Check....25914
Table 215Electric Trailer Brake Test....25915
Table 216Feature Code....25917
Table 217Diagnostic Trouble Codes....25919
Table 218Air Solenoid Preliminary Check....25927
Table 219Feature Code....25929
Table 220Diagnostic Trouble Codes....25930
Table 221Suspension Dump Preliminary Check....25932
Table 222Suspension Dump Test....25932
Table 223Feature Code....25934
Table 224Diagnostic Trouble Codes....25935
Table 225Lift Gate Preliminary Check....25936
Table 226Lift Gate Test....25936
Table 227Feature Code....25937
Table 228Diagnostic Trouble Codes....25938
Table 229Fifth Wheel Slide Preliminary Check....25939
Table 230Fifth Wheel Slide Test....25939
Table 231Feature Code....25941
Table 232Diagnostic Trouble Codes....25942
Table 233Differential Lock Preliminary Check....25944
Table 234(0595ACT) Differential Lock Test....25944
Table 235(0595ACU) Differential Lock Test....25945
Table 236Feature Code....25947
Table 237Diagnostic Trouble Codes....25948
Table 238Power Divider Lock Preliminary Check....25949
Table 239Power Divider Lock Test....25949
Table 240Feature Code....25951
Table 241Diagnostic Trouble Codes....25952
Table 242Remote Start/Stop Preliminary Check....25952
Table 243Remote Start/Stop System Tests....25954
Table 247PTO Hour Meter/ PTO Indicator Checks....25979
Table 249Additional Signals Used for PTO Operation....25981
Table 254Wheelchair Lift Interlock Checks....25986
Table 256Additional Signals Used for Wheelchair Lift Interlock O....25988
Table 260Park Position Unlock Solenoid Checks — Eaton T-Handle &....26004
Table 261LCT Column Shifter Interlock Checks....26005
Table 262TCM Power, Ground and Data Link Circuit Checks....26005
Table 263Shift Selector Power and Ground Circuit Checks....26006
Table 269RESCM Checks....26023
Table 276Parked Regeneration (Particulate_Trap_Regeneration_Forc....26035
Table 277Inhibit Regeneration (Particulate_Trap_Regeneration_Inh....26036
Table 279Switch Pack Preliminary Check....26049
Table 280Switch Pack Test....26049
Table 281Battery Power Distribution Check....26053
Table 282Accessory Power Distribution Check....26053
Table 283Accessory Power Test....26053
Table 284Ignition Power Distribution Check....26054
Table 285Ignition Power Test....26055
Table 286Ground Test....26056
Table 292 Snow Valve Mechanical Checks....26070
Table 293 Snow Valve Module Checks....26071
Table 298 Snow Valve Mechanical Checks....26075
Table 299 Snow Valve Switch Test....26076
Table 300 Snow Valve Module Checks....26076
Table 305 Exhaust Brake Switch Test....26083
Table 307Diagnostic Trouble codes....26089
Table 308Diagnostic Trouble codes....26090
S08327 - 2007 - 2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual....26096
S08339 - 2007 MY ProStar _ LoneStar Chassis Built January, 2007 and After Electrical Circuit Diagrams Manual....26229
S08354 - 2007 MY ProStar _ LoneStar Models Built After January 2007 Electrical System Troubleshooting Guide Manual....26634
toc....26638
SAFETY INFORMATION....26638
MANUAL INTRODUCTION....26640
1. Manual Introduction....26642
2. VEHICLE ELECTRICAL SYSTEM OVERVIEW....26643
3. Electrical Circuit Diagram Book....26643
3.1. Circuit Diagrams....26643
Circuit Diagram Instructions....26644
3.2. Connector Body Composite....26647
4. Troubleshooting....26648
4.1. Verify the Problem....26648
4.2. Important Steps Before Performing Circuit Tests....26648
4.3. Review Feature Operation....26649
4.4. Check the Circuit Diagram....26649
4.5. Perform Circuit and System Tests....26650
4.6. Perform the Repair....26650
4.7. Verify the Repair....26650
5. ELECTRICAL TEST EQUIPMENT....26650
5.1. EZ-Tech® Electronic Service Tool (Est)....26650
5.2. Body Controller Breakout Box (ZTSE4477)....26650
5.3. FLUKE 88 DIGITAL MULTIMETER (DMM)....26651
5.4. Jumper Wires, Test Leads, and Test Lights....26652
Jumper Wires....26652
Test Leads....26653
Test Lights....26654
5.5. Ohm's Law Review....26654
5.6. VOLTMETER....26656
Measuring Voltage....26656
5.7. AMMETER....26659
Measuring Amperage....26659
5.8. OHMMETER....26661
Measuring Resistance....26661
Checking For Open Circuits....26663
Checking For Short Circuits....26664
6. Bench Testing Relays....26665
ELECTRONIC GAUGE CLUSTER....26668
1. Electronic Gauge Cluster....26670
1.1. System Description....26670
Overview....26670
Operation....26670
1.2. Feature Codes....26676
1.3. User Programmable Parameters....26678
1.4. Diagnostic Trouble Codes....26681
1.5. Troubleshooting....26688
Preliminary Checks....26688
EGC Circuit Test....26690
Secondary Instrument Cluster Circuit Test....26691
EGC Backlighting Circuit Test....26692
EGC Gauge Test....26693
Warning Lamp Test....26694
Fuel Level Gauge Circuit Test....26696
Transmission Oil Temperature Sensor Circuit Tests....26697
Engine Oil Temperature Sensor Circuit Test....26697
Front and Rear Axle Temperature Circuit Tests....26698
Air Pressure Transducer Circuit Tests....26700
Parking Brake Air Transducer....26701
Air Restriction Gauge....26702
Engine Coolant Level Monitor ....26703
1.6. Electronic Gauge Cluster Programming....26703
SWITCH PACKS (J1708 DATA LINK)....26704
1. Switch Packs (J1708 Data Link) ....26706
1.1. Description....26706
Overview....26706
Operation....26706
1.2. Diagnostic Trouble Codes....26706
1.3. Troubleshooting....26707
Switch Pack Preliminary Check....26708
Switch Pack Circuit Test....26708
J1708 Data Link Circuit Test....26709
LIGHTING SYSTEM....26712
1. Backup Lights....26716
1.1. System Description....26716
Overview....26716
Operation....26716
1.2. Feature Code....26716
1.3. User Programmable Parameters....26717
1.4. Diagnostic Trouble Codes....26717
1.5. Troubleshooting....26717
Backup Lights Preliminary Checks....26718
Backup Light Circuit Test....26718
Backup Light Switch Test....26719
2. Dome and Courtesy Lights....26719
2.1. System Description....26719
Overview....26720
Operation....26720
2.2. Feature Codes....26720
2.3. User Programmable Parameters....26720
2.4. Diagnostic Trouble Codes....26721
2.5. Troubleshooting....26721
Dome and Courtesy Lights Preliminary Checks....26722
Door Switch Circuit Tests....26723
Cab Dome Light Circuit Test....26724
Sleeper Dome Light Circuit Test....26725
3. Fog Lights and Spot Light....26726
3.1. System Description....26726
Overview....26726
Operation....26726
3.2. Feature Codes....26726
3.3. User Programmable Parameters....26726
3.4. Diagnostic Trouble Codes....26726
3.5. Troubleshooting....26727
Fog Light System Preliminary Check....26728
Fog Light Switch Test....26728
Fog Light Circuit Test....26729
Spot Light Circuit Test....26731
4. Luggage Compartment Lights....26731
4.1. System Description....26731
Overview....26731
Operation....26731
4.2. Feature Code....26731
4.3. User Programmable Parameters....26731
4.4. Diagnostic Trouble Codes....26731
4.5. Troubleshooting....26731
Luggage Compartment Light Preliminary Check....26732
Luggage Compartment Door Switch Circuit Test....26732
Luggage Light Switch Circuit Test ....26733
5. Headlights And Daytime Running Lights (DTRL)....26734
5.1. System Description....26734
Overview....26734
Operation....26734
5.2. Feature Codes....26735
5.3. User Programmable Parameters....26735
5.4. Diagnostic Trouble Codes....26736
5.5. Troubleshooting....26737
Headlight System Preliminary Check....26738
Headlight Switch Test....26739
Right Headlight Circuit Test....26740
Left Headlight Circuit Test....26740
6. Stop, Turn, and Hazards....26741
6.1. System Description....26741
Overview....26741
Operation....26741
6.2. Feature Codes....26742
6.3. User Programmable Parameters....26742
6.4. Diagnostic Trouble Codes....26742
6.5. Troubleshooting....26746
Stop, Turn, and Hazards System Preliminary Check....26746
Turn Signal Switch Test....26747
Brake Switch Test....26748
Left Front Turn Signal Circuit Test....26750
Right Front Turn Signal Circuit Test....26750
Left Rear Turn Signal Circuit Test....26751
Right Rear Turn Signal Circuit Test....26751
7. Tail, Marker, Park, and Clearance Lighting....26751
7.1. System Description....26751
Overview....26751
Operation....26752
7.2. Feature Codes....26752
7.3. User Programmable Parameters....26752
7.4. Diagnostic Trouble Codes....26752
7.5. Troubleshooting....26754
Tail, Marker, Park, and Clearance Lighting Preliminary Check....26754
Headlight Switch Test....26755
Taillight Circuit Test....26756
8. Work Lights....26756
8.1. System Description....26756
Overview....26756
Operation....26756
8.2. Feature Codes....26756
8.3. User Programmable Parameters....26757
8.4. Diagnostic Trouble Codes....26757
8.5. Troubleshooting....26758
Work Light System Preliminary Check....26758
Work Light Switch Test....26759
Work Light Circuit Tests....26760
9. Lighted Air Shield....26760
9.1. System Description....26760
Overview....26761
Operation....26761
9.2. Feature Codes....26761
9.3. User Programmable Parameters....26761
9.4. Diagnostic Trouble Code....26761
9.5. Troubleshooting....26761
Lighted Air Shield Preliminary Check....26762
Lighted Air Shield Test....26762
10. Floor Lights....26763
10.1. System Description....26763
Overview....26763
Operation....26763
10.2. Feature Codes....26763
10.3. User Programmable Parameters....26764
10.4. Diagnostic Trouble Codes....26764
10.5. Troubleshooting....26764
Floor Lights Preliminary Check....26764
Floor Light Relay Circuit Test....26765
Cab Floor Light Circuit Test....26766
Sleeper Floor Light Circuit Test....26766
11. Trailer Lighting....26766
11.1. System Description....26766
Overview....26766
Operation....26766
11.2. Feature Codes....26767
11.3. User Programmable Parameters....26767
11.4. Diagnostic Trouble Codes....26767
11.5. Troubleshooting....26769
Trailer Lights Preliminary Check....26769
Trailer Socket Circuit Test....26769
Trailer Left Turn Relay Circuit Test....26770
Trailer Right Turn Relay Circuit Test....26771
Trailer Marker Light Relay Circuit Test....26773
Trailer Taillight Relay Circuit Test....26773
Trailer Stop Light Relay Circuit Test....26775
Trailer ABS ECU Relay Circuit Test....26775
CAB FEATURES....26778
1. Cigar Lighter And Power Feed....26784
1.1. System description....26784
Overview....26784
Cigar Lighter Operation....26784
Cigar Lighter Power Source and Two-Post Power Source Operation....26784
1.2. Feature Codes....26784
1.3. User Programmable Parameters....26784
1.4. Diagnostic Trouble Codes....26784
1.5. Troubleshooting....26784
Cigar Lighter and Power Feed Preliminary Check....26784
Cigar Lighter Circuit Test....26785
Auxiliary Power Source Circuit Test....26786
2. CB Power Radio....26786
2.1. System Description....26786
Overview....26786
Operation....26786
2.2. Feature Codes....26786
2.3. User Programmable Parameters....26786
2.4. Diagnostic Trouble Codes....26786
2.5. Troubleshooting....26787
CB Radio Power Source Preliminary Check....26787
CB Radio Circuit Test....26787
3. Compass and Temperature Display....26787
3.1. System Description....26787
Overview....26788
Temperature Display Operation....26788
Compass Display Operation....26788
3.2. Feature Codes....26788
3.3. User Programmable Parameters....26788
3.4. Diagnostic Trouble Codes....26788
3.5. troubleshooting....26789
Compass and Temperature Display Preliminary Check....26789
Compass/Temperature Display Circuit Tests....26790
Ambient Temperature Sensor Circuit Test....26790
4. Power Windows and Locks....26791
4.1. System Description....26791
Overview....26791
Power Window Operation....26791
Power Door Lock Operation....26792
4.2. Feature Codes....26793
4.3. User Programmable Parameters....26793
4.4. Diagnostic Trouble Codes....26794
4.5. Troubleshooting....26795
Power Window and Lock Preliminary Check....26795
Locks and Windows Inoperative Circuit Test....26796
Power Window Circuit Test....26797
Power Door Lock Circuit Test....26797
5. Cruise Control....26797
5.1. System Description....26797
Overview....26798
Operation....26798
5.2. Feature Codes....26798
5.3. User Programmable Parameters....26799
5.4. Diagnostic Trouble Codes....26800
5.5. Troubleshooting....26800
Cruise Control Preliminary Check....26800
Cruise Control Switch Test....26802
6. Electric Horn....26803
6.1. System Description....26803
Overview....26803
Operation....26803
6.2. Feature Codes....26803
6.3. User Programmable Parameters....26804
6.4. Diagnostic Trouble Codes....26805
6.5. Troubleshooting....26805
Electric Horn Preliminary Check....26805
Electric Horn Circuit Test....26806
7. Air Horn....26807
7.1. System Description....26807
Overview....26807
Operation....26807
7.2. Feature Codes....26807
7.3. User Programmable Parameters....26807
7.4. Diagnostic Trouble Codes....26808
7.5. Troubleshooting....26808
Air Horn Preliminary Check....26808
Air Horn Circuit Test....26809
8. Power Mirrors....26809
8.1. System Description....26809
Overview....26809
Operation....26809
8.2. Feature Codes....26810
8.3. User Programmable Parameters....26810
8.4. Diagnostic Trouble Codes....26810
8.5. Troubleshooting....26810
Power Mirror Preliminary Check....26811
Driver Power Mirror Circuit Test....26811
Passenger Power Mirror Circuit Test....26812
9. Heated Mirror....26813
9.1. System Description....26813
Overview....26813
Operation....26813
9.2. Feature Codes....26813
9.3. User Programmable Parameters....26813
9.4. Diagnostic Trouble Codes....26813
9.5. Troubleshooting....26814
Heated Mirror Preliminary Check....26814
Heated Mirror Switch Test....26815
Driver Heated Mirror Circuit Test....26816
Passenger Heated Mirror Circuit Test....26817
10. Radio (Entertainment), Speakers....26817
10.1. System Description....26817
Overview....26817
Operation....26817
10.2. Feature Codes....26817
10.3. User Programmable Parameters....26818
10.4. Diagnostic Trouble Codes....26818
10.5. Troubleshooting....26818
Radio Preliminary Check....26818
Radio Circuit Test....26819
Speaker Circuit Test....26819
Steering Wheel Radio Switch Circuit Test....26820
11. Two-Way Radio....26820
11.1. System Description....26820
Overview....26821
Operation....26821
11.2. Feature Codes....26821
11.3. User Programmable Parameters....26821
11.4. Diagnostic Trouble Codes....26821
11.5. Troubleshooting....26821
Two-Way Radio Circuit Test....26821
12. Windshield Wiper And Washer Pump....26822
12.1. System Description....26822
Overview....26822
Wiper Operation....26822
Park Operation....26822
Washer Operation....26822
12.2. Feature Codes....26822
12.3. User Programmable Parameters....26823
12.4. Diagnostic Trouble Codes....26823
12.5. Troubleshooting....26825
Wiper and Washer Preliminary Check....26826
Washer Pump Circuit Test....26826
Wiper Switch Circuit Test....26828
Wiper Motor Circuit Test....26829
13. Roof Auxiliary Load And Air Shield Light....26829
13.1. system description....26829
Overview....26829
Roof Auxiliary Load Operation....26830
Air Shield Light Operation....26830
13.2. Feature Codes....26830
13.3. User Programmable Parameters....26830
13.4. Diagnostic Trouble Codes....26830
Roof Auxiliary Load ....26830
Lighted Air Shield....26830
13.5. Troubleshooting....26831
Roof Auxiliary Load Preliminary Check....26831
Lighted Air Shield Preliminary Check....26832
Roof Auxiliary Load Switch Test....26832
Roof Auxiliary Load Circuit Test....26833
Lighted Air Shield Circuit Test....26834
14. Brake Light Switch....26835
14.1. System Description....26835
Overview....26835
Operation....26835
14.2. Feature Codes....26835
14.3. User Programmable Parameters....26836
14.4. Diagnostic Trouble Codes....26836
14.5. Troubleshooting....26838
Brake Switch Preliminary Check....26838
Brake Switch Test....26838
15. Clutch Switch....26839
15.1. System Description....26839
Overview....26839
Operation....26839
15.2. Feature Codes....26839
15.3. User Programmable Parameters....26839
15.4. Diagnostic Trouble Codes....26839
15.5. Troubleshooting....26841
Clutch Switch Preliminary Check....26841
Engine Crank Clutch Switch Test....26842
Cruise Control Clutch Switch Test....26842
16. Load Shedding....26842
16.1. System Description....26842
Overview....26842
Operation....26843
16.2. Feature Codes....26843
16.3. User Programmable Parameters....26843
16.4. Diagnostic Trouble Codes....26843
16.5. Troubleshooting....26844
Latching Relay Circuit Test....26844
17. Trip Recorder....26845
17.1. System Description....26845
Overview....26845
Operation....26845
17.2. Feature Code....26846
17.3. User Programmable Parameters....26846
17.4. Diagnostic Trouble Codes....26846
17.5. Troubleshooting....26846
Trip Recorder Preliminary Check....26846
Trip Recorder Circuit Test....26847
18. Theft Deterrent....26848
18.1. System Description....26848
Overview....26848
Operation....26848
18.2. Feature Code....26848
18.3. User Programmable Parameters....26848
18.4. Diagnostic Trouble Codes....26848
18.5. Troubleshooting....26849
Theft Deterrent Preliminary Check....26849
Theft Deterrent System Test....26849
19. Seat Belt And Seat Sensor....26851
19.1. System Description....26851
Overview....26851
Operation....26851
19.2. Feature Codes....26852
19.3. User Programmable Parameters....26852
19.4. Diagnostic Trouble Codes....26852
19.5. Troubleshooting....26852
Seat Belt Preliminary Check....26853
Seat Belt Test....26853
20. Self-Contained Air Seat....26854
20.1. System Description....26854
Overview....26854
Operation....26854
20.2. Feature Code....26854
20.3. User Programmable Parameters....26854
20.4. Diagnostic Trouble Codes....26854
20.5. Troubleshooting....26854
Driver and Passenger Self-Contained Air Seats Preliminary Check....26854
Driver and Passenger Self-Contained Air Seat Test....26855
21. Heated Seats....26856
21.1. System Description....26856
Overview....26856
Operation....26856
21.2. Feature Codes....26856
21.3. User Programmable Parameters....26856
21.4. Diagnostic Trouble Code....26856
21.5. Troubleshooting....26857
Driver and Passenger Heated Seats Preliminary Check....26857
Driver and Passenger Heated Seat Test....26857
22. Auxiliary Toggle Switch....26858
22.1. System Description....26858
Overview....26858
Operation....26858
22.2. Feature Code....26858
22.3. User Programmable Parameters....26858
22.4. Diagnostic Trouble Codes....26858
22.5. Troubleshooting....26859
Auxiliary Toggle Switch Preliminary Check....26859
Auxiliary Toggle Switch Circuit Test....26860
CHASSIS FEATURES....26862
1. Air Dryer and Heated Drain Valve....26866
1.1. System Description....26866
Overview....26866
Operation....26866
1.2. Feature Codes....26866
1.3. User Programmable Parameters....26866
1.4. Diagnostic Trouble Codes....26866
1.5. Troubleshooting....26866
Air Dryer and Heated Drain Valve Preliminary Check....26866
Heated Drain Valve Circuit Test....26867
Air Dryer Circuit Test....26867
2. Air Solenoid....26868
2.1. System Description....26868
Overview....26868
Operation....26868
2.2. Feature Codes....26868
2.3. User Programmable Parameters....26868
2.4. Diagnostic Trouble Codes....26868
2.5. Troubleshooting....26874
Air Solenoid Preliminary Check....26874
Air Solenoid Circuit Test....26874
3. Suspension Dump....26875
3.1. System Description....26875
Overview....26875
Operation....26876
3.2. Feature Code....26876
3.3. User Programmable Parameters....26876
3.4. Diagnostic Trouble Codes....26877
3.5. Troubleshooting....26878
Suspension Dump Preliminary Check....26879
Suspension Dump Test....26879
4. Differential Lock....26880
4.1. System Description....26880
Overview....26880
Operation....26880
4.2. Feature Codes....26881
4.3. User Programmable Parameters....26882
4.4. Diagnostic Trouble Codes....26882
4.5. Troubleshooting....26884
Differential Lock Preliminary Check....26884
Differential Lock Test....26885
5. Power Divider Lock....26885
5.1. System Description....26885
Overview....26885
Operation....26886
5.2. Feature Code....26886
5.3. User Programmable Parameters....26886
5.4. Diagnostic Trouble Codes....26887
5.5. Troubleshooting....26888
Power Divider Lock Preliminary Check....26888
Power Divider Lock Test....26889
6. Power Take Off....26889
6.1. System Description....26889
Overview....26889
Operation....26889
6.2. Feature Codes....26889
6.3. User Programmable Parameters....26890
6.4. Diagnostic Trouble Codes....26890
6.5. Troubleshooting....26892
Power Take Off Preliminary Check....26892
Power Take Off Circuit Test....26892
7. Anti-Lock Braking System....26894
7.1. System Description....26894
Overview....26894
Operation....26894
Communication....26894
7.2. Feature Codes....26894
7.3. User Programmable Parameters....26895
7.4. Diagnostic Trouble Codes....26895
7.5. Troubleshooting....26896
Anti Lock Braking System Preliminary Check....26897
ABS Module Circuit Test....26897
8. Fifth Wheel Slide....26901
8.1. System Description....26901
Overview....26901
Operation....26901
8.2. Feature Code....26901
8.3. User Programmable Parameters....26901
8.4. Diagnostic Trouble Codes....26902
8.5. Troubleshooting....26902
Fifth Wheel Slide Preliminary Check....26903
Fifth Wheel Slide Test....26903
9. Fuel Heater....26905
9.1. System Description....26905
Overview....26905
Operation....26905
9.2. Feature Code....26905
9.3. User Programmable Parameters....26905
9.4. Diagnostic Trouble Codes....26905
9.5. Troubleshooting....26906
Fuel Heater Preliminary Check....26906
Fuel Heater Circuit Test ....26907
10. Remote Power Module....26908
10.1. System Description....26908
Overview....26908
Operation....26908
10.2. Feature Codes....26908
10.3. User Programmable Parameters....26909
10.4. Diagnostic Trouble Codes....26909
10.5. Troubleshooting....26912
RPM Preliminary Check....26912
RPM Circuit Test....26913
11. Axle Load Monitor....26913
11.1. System Description....26913
Overview....26913
Operation....26913
11.2. Feature Codes....26914
11.3. User Programmable Parameters....26914
11.4. Diagnostic Trouble Codes....26915
11.5. Troubleshooting....26916
Axle Load Monitor Preliminary Check....26917
Axle Pressure Transducer Circuit Test....26917
12. Water In Fuel Monitor....26918
12.1. System Description....26918
Overview....26918
Operation....26918
12.2. Feature Code....26918
12.3. User Programmable Parameters....26918
12.4. Diagnostic Trouble Codes....26918
12.5. Troubleshooting....26919
Water-In-Fuel Monitor Preliminary Check....26919
Water Probe Circuit Test....26919
TRANSMISSIONS....26920
1. Automatic and Manual Transmissions....26922
1.1. System Description....26922
Overview....26922
Operation....26922
1.2. Feature Codes....26923
1.3. User Programmable Parameters....26923
1.4. Diagnostic Trouble Codes....26923
1.5. Troubleshooting....26925
Transmission Preliminary Check....26925
Eaton TCM Circuit Test....26927
Freedomline TCM Circuit Test....26929
Shifter Module Circuit Test....26930
1.6. Body Controller Signals....26933
Body Controller Signals....26933
MULTIPLEXING (DATA LINKS)....26934
1. Multiplexing (Data Links)....26936
1.1. Description....26936
Overview....26936
Operation....26936
1.2. Troubleshooting....26937
J1939 Data Link Terminating Resistors....26937
Body Controller....26938
J1939 Data Link Circuit Test....26938
J1708 Data Link Circuit Test....26939
AFTERTREATMENT....26940
1. Aftertreatment System....26942
1.1. System Description....26942
Overview....26942
Operation....26942
1.2. Feature Codes....26944
1.3. User Programmable Parameters....26944
1.4. Diagnostic Trouble Codes....26944
1.5. Troubleshooting....26946
Aftertreatment Preliminary Check....26946
Inhibit Regeneration Switch Test....26946
Parked Regeneration Switch Test....26947
Warning Lamp Test....26948
12 VOLT POWER DISTRIBUTION AND GROUND....26950
1. 12 Volt Power Distribution and Ground....26952
1.1. Description....26952
Overview....26952
Operation....26952
1.2. Troubleshooting....26952
Battery Power Distribution Check....26953
Accessory Power Distribution Preliminary Check....26953
Accessory Power Test....26953
Ignition Power Distribution Preliminary Check....26955
Ignition Power Test....26956
Ground Test....26957
FANS AND ENGINE ACCESSORIES....26958
1. Fan Systems....26960
1.1. System Description....26960
Overview....26960
Operation....26960
1.2. Feature Codes....26960
1.3. User Programmable Parameters....26961
1.4. Diagnostic Trouble Codes....26961
1.5. Troubleshooting....26961
Fan System Preliminary Check....26962
Fan Override Switch Test....26962
2. Compression Brake....26963
2.1. System Description....26963
Overview....26963
Operation....26963
2.2. Feature Codes....26963
2.3. User Programmable Parameters....26963
2.4. Diagnostic Trouble Codes....26963
2.5. Troubleshooting....26964
Compression Brake Preliminary Check....26964
Compression Brake Switch Test....26964
BATTERY, CHARGING, AND CRANKING SYSTEM....26966
1. Battery....26968
1.1. Description....26968
Overview....26968
Operation....26968
1.2. Diagnostic Trouble Codes....26969
1.3. Troubleshooting....26969
2. Charging System....26970
2.1. Description....26970
Overview....26970
Operation....26970
2.2. Diagnostic Trouble Codes....26970
2.3. Troubleshooting....26971
3. Engine Cranking....26971
3.1. Description....26971
Overview....26971
Operation....26971
3.2. Troubleshooting....26972
4. Powerpack 3....26972
4.1. Description....26972
Overview....26972
Operation....26972
4.2. Troubleshooting....26973
VEHICLE AND DRIVER INFORMATION DISPLAY....26974
1. Vehicle Information Display....26976
1.1. System Description....26976
Overview....26976
Operation....26976
1.2. Feature Codes....26976
1.3. User Programmable Parameters....26977
1.4. Diagnostic Trouble Codes....26977
1.5. Troubleshooting....26977
Vehicle Information Display Preliminary Check....26977
Vehicle Information Display Circuit Test....26977
2. Driver Information Display....26978
2.1. System Description....26978
Overview....26978
Operation....26979
2.2. Feature Codes....26979
2.3. User Programmable Parameters....26979
2.4. Diagnostic Trouble Codes....26979
2.5. Troubleshooting....26979
Driver Information Display Preliminary Check....26980
Driver Information Display Circuit Test....26980
SLEEPER FEATURES....26984
1. Remote Radio....26986
1.1. System Description....26986
Overview....26986
Operation....26986
1.2. Feature Codes....26986
1.3. User Programmable Parameters....26986
1.4. Diagnostic Trouble Codes....26986
1.5. Troubleshooting....26986
Remote Radio and Auxiliary Controls Preliminary Check....26986
Steering Wheel Switch Test....26987
Auxiliary Controls Circuit Test....26988
2. Sleeper Fan....26988
2.1. System Description....26988
Overview....26988
Operation....26989
2.2. Feature Codes....26989
2.3. User Programmable Parameters....26989
2.4. Diagnostic Trouble Codes....26989
2.5. Troubleshooting....26989
Sleeper Fan Preliminary Check....26989
Sleeper Fan Circuit Test....26990
3. Power Source....26990
3.1. System Description....26990
Overview....26990
Operation....26990
3.2. Feature Codes....26991
3.3. User Programmable Parameters....26991
3.4. Diagnostic Trouble Codes....26991
3.5. Troubleshooting....26991
Power Source Preliminary Checks....26991
Power Source Circuit Test....26991
4. Television/Refrigerator Accommodation....26992
4.1. System Description....26992
Overview....26992
Operation....26992
4.2. Feature Codes....26992
4.3. User Programmable Parameters....26992
4.4. Diagnostic Trouble Codes....26992
4.5. Troubleshooting....26993
Refrigerator/Television Preliminary Check....26993
Refrigerator Circuit Test....26993
Television Power Source Circuit Test....26994
5. Flat Panel TV/DVD Player Accommodation....26994
5.1. system description....26994
Overview....26994
Operation....26994
5.2. Feature Codes....26994
5.3. Diagnostic Trouble Codes....26994
5.4. Troubleshooting....26994
6. Remote Start/Stop....26995
6.1. System Description....26995
Overview....26995
Operation....26995
6.2. Feature Code....26996
6.3. User Programmable Parameters....26996
6.4. Diagnostic Trouble Codes....26996
6.5. Troubleshooting....26997
Remote Start/Stop Preliminary Check....26997
Remote Start/Stop Test....26997
7. Cummins Icon....26999
7.1. System Description....26999
Overview....26999
Operation....27000
7.2. Feature Codes....27000
7.3. User Programmable Parameters....27001
7.4. Diagnostic Trouble Codes....27001
7.5. Troubleshooting....27001
Preliminary Check....27002
ICON Circuit Test....27002
tables....26654
Table 1Ohm's Law....26654
Table 2Relay Bench Test....26667
Table 3Warning Light and Signal Path....26674
Table 4EGC Audible Alarm....26675
Table 5Electronic Gauge Cluster Feature Codes....26676
Table 6Diagnostic Trouble Codes....26681
Table 7EGC Preliminary Checks....26689
Table 8EGC Circuit Test....26690
Table 9Secondary Instrument Cluster Circuit Test....26691
Table 10EGC Backlighting Circuit Test....26693
Table 11EGC Gauge Test....26693
Table 12Warning Lamp Test....26695
Table 13Fuel Level Gauge Circuit Test....26696
Table 14Transmission Oil Temperature Sensor Circuit Test....26697
Table 15Engine Oil Temperature Sensor Circuit Test....26697
Table 16Temperature Sensor Performance Specification....26698
Table 17Rear Axle Temperature Sensor Circuit Test....26699
Table 18Front Axle Temperature Sensor Circuit Test....26700
Table 19Air Pressure Transducer Circuit Test....26701
Table 20Parking Brake Air Transducer Circuit Test....26702
Table 21 Air Restriction Gauge Circuit Test....26702
Table 22Low Coolant Sensor Circuit Test....26703
Table 23Diagnostic Trouble Codes....26706
Table 24Switch Pack Preliminary Check....26708
Table 25Switch Pack Circuit Test....26708
Table 26J1708 Data Link Circuit Test....26709
Table 27Feature Code....26716
Table 28Diagnostic Trouble Codes....26717
Table 29Backup Light Preliminary Checks....26718
Table 30 Backup Light Circuit Test....26718
Table 31Backup Light Switch Test....26719
Table 32Feature Code....26720
Table 33Diagnostic Trouble Codes....26721
Table 34Dome and Courtesy Lights Preliminary Checks....26722
Table 35Door Switch Circuit Test....26723
Table 36Cab Dome Light Circuit Test....26724
Table 37Sleeper Dome Light Circuit Test....26725
Table 38Feature Codes....26726
Table 39Diagnostic Trouble Codes....26727
Table 40Fog Light System Preliminary Check....26728
Table 41Fog Light Switch Test....26729
Table 42Fog Light Circuit Test....26729
Table 43Spot Light Circuit Test....26731
Table 44Luggage Compartment Light Preliminary Check....26732
Table 45Luggage Compartment Door Switch Circuit Test....26732
Table 46Luggage Light Switch Circuit Test ....26733
Table 47Feature Codes....26735
Table 48Diagnostic Trouble Codes....26736
Table 49Headlight System Preliminary Check....26738
Table 50Headlight Switch Test....26739
Table 51Right Headlight Circuit Test....26740
Table 52Left Headlight Circuit Test....26740
Table 53Feature Codes....26742
Table 54Diagnostic Trouble Codes....26743
Table 55Stop, Turn, and Hazards System Preliminary Check....26746
Table 56Turn Signal Switch Test....26747
Table 57Brake Switch Test....26748
Table 58Left Front Turn Signal Circuit Test....26750
Table 59Right Front Turn Signal Circuit Test....26750
Table 60Left Rear Turn Signal Circuit Test....26751
Table 61Right Rear Turn Signal Circuit Test....26751
Table 62Feature Codes....26752
Table 63Diagnostic Trouble Codes....26752
Table 64Tail, Marker, Park, and Clearance Lighting Preliminary C....26754
Table 65Headlight Switch Test....26755
Table 66Taillight Circuit Test....26756
Table 67Feature Codes....26757
Table 68Diagnostic Trouble Codes....26758
Table 69Work Light System Preliminary Check....26758
Table 70Work Light Switch Test....26759
Table 71Sleeper Cab Work Light Circuit Test....26760
Table 72Day Cab Work Light Circuit Test....26760
Table 73Feature Codes....26761
Table 74Diagnostic Trouble Codes....26761
Table 75Lighted Air Shield Preliminary Check....26762
Table 76Lighted Air Shield Test....26762
Table 77Feature Codes....26763
Table 78Diagnostic Trouble Codes....26764
Table 79Floor Lights Preliminary Check....26764
Table 80Floor Light Relay Circuit Test....26765
Table 81Cab Floor Light Circuit Test....26766
Table 82Sleeper Floor Light Circuit Test....26766
Table 83Feature Codes....26767
Table 84Diagnostic Trouble Codes....26767
Table 85Trailer Lights Preliminary Check....26769
Table 86Trailer Socket Circuit Test....26769
Table 87Trailer Left Turn Relay Circuit Test....26771
Table 88Trailer Right Turn Relay Circuit Test....26772
Table 89Trailer Marker Light Relay Circuit Test....26773
Table 90Trailer Taillight Relay Circuit Test....26774
Table 91Trailer Stop Light Relay Circuit Test....26775
Table 92Trailer ABS ECU Relay Circuit Test....26775
Table 93Cigar Lighter and Power Feed Preliminary Check....26785
Table 94Cigar Lighter Circuit Test....26785
Table 95Auxiliary Power Source Circuit Test....26786
Table 96CB Radio Power Source Preliminary Check....26787
Table 97CB Radio Circuit Test....26787
Table 98Feature Codes....26788
Table 99Diagnostic Trouble Codes....26788
Table 100Compass and Temperature Display Preliminary Check....26789
Table 101Compass Display Circuit Test....26790
Table 102Ambient Temperature Sensor Circuit Test....26790
Table 103Feature Codes....26793
Table 104Diagnostic Trouble Codes....26794
Table 105Power Locks Preliminary Check....26796
Table 106Power Windows Preliminary Check....26796
Table 107Locks and Windows Inoperative Circuit Test....26796
Table 108Power Window Circuit Test....26797
Table 109Power Door Lock Circuit Test....26797
Table 110Feature Codes....26798
Table 111Diagnostic Trouble Codes....26800
Table 112Cruise Control Preliminary Check....26800
Table 113Cruise Control Switch Test....26802
Table 114Feature Codes....26803
Table 115Diagnostic Trouble Codes....26805
Table 116Electric Horn Preliminary Check....26805
Table 117Electric Horn Circuit Test....26806
Table 118Feature Codes....26807
Table 119Diagnostic Trouble Codes....26808
Table 120Air Horn Preliminary Check....26808
Table 121Air Horn Circuit Test....26809
Table 122Power Mirror Preliminary Check....26811
Table 123Driver Power Mirror Circuit Test....26811
Table 124Passenger Power Mirror Circuit Test....26812
Table 125Feature Codes....26813
Table 126Diagnostic Trouble Codes....26813
Table 127Heated Mirror Preliminary Check....26814
Table 128Heated Mirror Switch Test....26815
Table 129Driver Heated Mirror Circuit Test....26816
Table 130Passenger Heated Mirror Circuit Test....26817
Table 131Radio Preliminary Check....26818
Table 132Radio Circuit Test....26819
Table 133Speaker Circuit Test....26819
Table 134Steering Wheel Radio Switch Circuit Test....26820
Table 135Two-Way Radio Circuit Test....26821
Table 136Feature Codes....26822
Table 137Diagnostic Trouble Codes....26824
Table 138Wiper and Washer Preliminary Check....26826
Table 139Washer Pump Circuit Test....26826
Table 140Wiper Switch Circuit Test....26828
Table 141Wiper Motor Circuit Test....26829
Table 142Feature Codes....26830
Table 143Lighted Air Shield DTC....26831
Table 144Roof Auxiliary Load Preliminary Check....26831
Table 145Lighted Air Shield Preliminary Check....26832
Table 146Roof Auxiliary Load Switch Test....26832
Table 147Roof Auxiliary Load Circuit Test....26833
Table 148Lighted Air Shield Circuit Test....26834
Table 149Feature Codes....26836
Table 150Diagnostic Trouble Codes....26836
Table 151Brake Switch Preliminary Check....26838
Table 152Brake Switch Test....26838
Table 153Feature Code....26839
Table 154Diagnostic Trouble Codes....26840
Table 155Clutch Switch Preliminary Check....26841
Table 156Engine Crank Clutch Switch Test....26842
Table 157Cruise Control Clutch Switch Test....26842
Table 158Feature Code....26843
Table 159Diagnostic Trouble Codes....26844
Table 160Latching Relay Circuit Test....26845
Table 161Feature Code....26846
Table 162Trip Recorder Preliminary Check....26846
Table 163Trip Recorder Circuit Test....26847
Table 164Feature Code....26848
Table 165Theft Deterrent Preliminary Check....26849
Table 166Theft Deterrent System Test....26849
Table 167Feature Code....26852
Table 168Seat Belt Preliminary Check....26853
Table 169Seat Belt Test....26853
Table 170Driver and Passenger Self-Contained Air Seats Prelimina....26854
Table 171Driver and Passenger Self-Contained Air Seat Test....26855
Table 172Driver and Passenger Heated Seats Preliminary Check....26857
Table 173Driver and Passenger Heated Seat Test....26857
Table 174Auxiliary Toggle Switch Preliminary Check....26859
Table 175Auxiliary Toggle Switch Circuit Test....26860
Table 176Air Dryer and Heated Drain Valve Preliminary Check....26866
Table 177Heated Drain Valve Circuit Test....26867
Table 178Air Dryer Circuit Test....26867
Table 179Diagnostic Trouble Codes....26869
Table 180Air Solenoid Preliminary Check....26874
Table 181Air Solenoid Circuit Test....26875
Table 182Feature Code....26876
Table 183Diagnostic Trouble Codes....26877
Table 184Suspension Dump Preliminary Check....26879
Table 185Suspension Dump Test....26879
Table 186Feature Code....26881
Table 187Diagnostic Trouble Codes....26883
Table 188Differential Lock Preliminary Check....26884
Table 189Differential Lock Test....26885
Table 190Feature Code....26886
Table 191Diagnostic Trouble Codes....26887
Table 192Power Divider Lock Preliminary Check....26888
Table 193Power Divider Lock Test....26889
Table 194Feature Code....26890
Table 195Diagnostic Trouble Codes....26890
Table 196Power Take Off Preliminary Check....26892
Table 197Power Take Off Circuit Test....26892
Table 198Feature Code....26895
Table 199Diagnostic Trouble Codes....26896
Table 200Anti Lock Braking System Preliminary Check....26897
Table 201Bendix® ABS Module Circuit Test....26897
Table 202Wabco® ABS Module Circuit Test....26899
Table 203Feature Code....26901
Table 204Diagnostic Trouble Codes....26902
Table 205Fifth Wheel Slide Preliminary Check....26903
Table 206Fifth Wheel Slide Test....26903
Table 207Feature Code....26905
Table 208Diagnostic Trouble Codes....26906
Table 209Fuel Heater Preliminary Check....26906
Table 210Fuel Heater Circuit Test ....26907
Table 211Diagnostic Trouble Codes....26909
Table 212RPM Preliminary Check....26912
Table 213RPM Circuit Test....26913
Table 214Feature Code....26914
Table 215Diagnostic Trouble Codes....26915
Table 216Axle Load Monitor Preliminary Check....26917
Table 217Axle Pressure Transducer Circuit Test....26917
Table 218Diagnostic Trouble Codes....26918
Table 219Water In Fuel Monitor Preliminary Check....26919
Table 220Water Probe Circuit Test....26919
Table 221Feature Code....26923
Table 222Diagnostic Trouble Codes....26924
Table 223Transmission Preliminary Check....26925
Table 224Eaton TCM Circuit Test....26927
Table 225Freedomline TCM Circuit Test....26929
Table 226Shifter Module Circuit Test....26931
Table 227Park Position Unlock Solenoid Check....26932
Table 228Body Controller Signals....26933
Table 229J1939 Data Link Circuit Test....26939
Table 230J1708 Data Link Circuit Test....26939
Table 231Accumulation Level Indications....26943
Table 232Feature Code....26944
Table 233Diagnostic Trouble Codes....26945
Table 234Aftertreatment Preliminary Check....26946
Table 235Inhibit Regeneration Switch Test....26946
Table 236Parked Regeneration Switch Test....26947
Table 237Warning Lamp Test....26948
Table 238Battery Power Distribution Preliminary Check....26953
Table 239Accessory Power Distribution Check....26953
Table 240Accessory Power Circuit Test....26953
Table 241Ignition Power Distribution Check....26955
Table 242Ignition Power Circuit Test....26956
Table 243Ground Circuit Test....26957
Table 244Feature Code....26960
Table 245Diagnostic Trouble Codes....26961
Table 246Fan System Preliminary Check....26962
Table 247Fan Override Switch Test....26962
Table 248Feature Code....26963
Table 249Diagnostic Trouble Codes....26964
Table 250Compression Brake Preliminary Check....26964
Table 251Compression Brake Switch Test....26965
Table 252Diagnostic Trouble Codes....26969
Table 253Diagnostic Trouble Codes....26970
Table 254Feature Code....26977
Table 255Vehicle Information Display Preliminary Check....26977
Table 256Vehicle Information Display Circuit Test....26977
Table 257Feature Code....26979
Table 258Driver Information Display Preliminary Check....26980
Table 259Driver Information Display Circuit Test....26980
Table 260Radio and Auxiliary Controls Preliminary Check....26987
Table 261Steering Wheel Radio Switch Test....26987
Table 262Auxiliary Controls Circuit Test....26988
Table 263Sleeper Fan Preliminary Check....26989
Table 264Sleeper Fan Circuit Test....26990
Table 265Power Source Preliminary Checks....26991
Table 266Power Source Circuit Test....26991
Table 267Refrigerator/Television Preliminary Check....26993
Table 268Refrigerator Circuit Test....26993
Table 269Television Power Source Circuit Test....26994
Table 270Feature Code....26996
Table 271Diagnostic Trouble Codes....26996
Table 272Remote Start/Stop Preliminary Check....26997
Table 273Remote Start/Stop Test....26998
Table 274Feature Code....27001
Table 275Diagnostic Trouble Codes....27001
Table 276Preliminary Check....27002
Table 277ICON Circuit Test....27002
S08358 - 2011 Auto Start Stop Service Manual....27006
toc....27008
tables....27022
S08360 - ProStar _ LoneStar Models Built After June 2010 Electrical System Troubleshooting Guide Manual....27062
S08361 - 2010 Electrical Troubleshooting....27450
toc....27454
SAFETY INFORMATION....27454
MANUAL INTRODUCTION....27456
1. Manual Introduction....27458
2. Vehicle Electrical System Overview....27459
3. Electrical Circuit Diagram Book....27459
3.1. CIRCUIT DIAGRAMS....27459
Circuit Diagram Instructions....27460
3.2. CONNECTOR BODY COMPOSITE....27463
4. Troubleshooting....27464
4.1. Verify The Problem....27464
4.2. Important Steps Before Performing Circuit Tests....27464
4.3. Review Feature Operation....27465
4.4. Check the Circuit Diagram....27465
4.5. Performing Circuit And System Tests....27466
4.6. Perform The Repair....27466
4.7. Verify The Repair....27466
5. Electrical Test Equipment....27466
5.1. EZ-TECH® Electronic Service Tool (EST)....27466
5.2. Body Controller Breakout Box (ZTSE4477)....27466
5.3. FLUKE 88 Digital Multimeter (DMM)....27467
5.4. MIDTRONICS EXP-1000HD....27468
5.5. Jumper Wires, Test Leads, And Test Lights....27469
Jumper Wires....27469
Test Leads....27470
Test Lights....27471
5.6. Ohm's Law Review....27471
5.7. Voltmeter....27473
Measuring Voltage....27473
5.8. Ammeter....27476
Measuring Amperage....27476
5.9. Ohmmeter....27478
Measuring Resistance....27478
Checking For Open Circuits....27480
Checking For Short Circuits....27481
6. Bench Testing Relays....27482
ELECTRONIC GAUGE CLUSTER....27486
1. Electronic Gauge Cluster....27488
1.1. System Description....27488
Overview....27488
Operation....27488
1.2. Feature Codes....27493
1.3. User Programmable Parameters....27494
1.4. Diagnostic Trouble Codes....27499
1.5. Troubleshooting....27507
Preliminary Checks....27507
Electronic Gauge Cluster Circuit Test....27509
EGC Backlight Circuit Test....27511
EGC Gauge Test....27511
Warning Lamp Test....27513
Fuel Level Gauge Circuit Test....27514
Transmission Oil Temperature Circuit Tests....27515
Front Rear and Rear Rear Axle Temperature Circuit Tests....27516
Air Pressure Transducer Circuit Tests....27517
Park Brake Switch Circuit Test....27520
Air Restriction Gauge Circuit Test....27521
Engine Coolant Level Monitor Circuit Test....27521
1.6. Electronic Gauge Cluster Programming....27522
SWITCH PACKS (J1708 DATA LINK)....27524
1. Switch Packs....27526
1.1. Description....27526
Overview....27526
Operation....27526
1.2. Diagnostic Trouble Codes....27526
1.3. Troubleshooting....27527
Switch Pack Preliminary Check....27528
Switch Pack Circuit Test....27528
J1708 Data Link Circuit Test....27529
LIGHTING SYSTEM....27530
1. Backup Lights....27534
1.1. System Description....27534
Overview....27534
Operation....27534
1.2. Feature Code....27534
1.3. user programmable parameters....27535
1.4. diagnostic trouble codes....27535
1.5. Troubleshooting....27535
Backup Lights Preliminary Checks....27536
Backup Light Circuit Test (Automatic Transmission)....27536
Backup Light Switch Test (Manual Transmission)....27538
2. Dome And Courtesy Lights....27539
2.1. System Description....27539
Overview....27539
Operation....27539
2.2. Feature Code....27540
2.3. User Programmable Parameters....27540
2.4. Diagnostic Trouble Codes....27540
2.5. Troubleshooting ....27541
Dome and Courtesy Lights Preliminary Checks....27541
Door Switch Circuit Tests....27542
Cab Dome Light Circuit Test....27543
Courtesy Lights Circuit Test....27545
3. Fog Lights....27545
3.1. System Description....27545
Overview....27545
Operation....27545
3.2. Feature Codes....27546
3.3. User Programmable Parameters ....27546
3.4. Diagnostic Trouble Codes....27546
3.5. Troubleshooting....27547
Fog Light System Preliminary Check....27547
Fog Light Switch Test....27548
Fog Light Circuit Test....27549
4. Headlights And Daytime Running Lights (DTRL)....27550
4.1. system description....27550
Overview....27551
Operation....27551
4.2. Feature Codes....27551
4.3. User Programmable Parameters....27551
4.4. Diagnostic Trouble Codes....27551
4.5. Troubleshooting....27553
Headlight System Preliminary Check....27554
Headlight Switch Test....27555
Turn Signal Switch Circuit Test....27556
Right Headlight Circuit Test....27557
Left Headlight Circuit Test....27559
5. Stop, Turn, And Hazard Lights....27559
5.1. System Description....27559
Overview....27559
Operation....27560
5.2. Feature Codes....27560
5.3. User Programmable Parameters....27560
5.4. Diagnostic Trouble Codes....27560
5.5. Troubleshooting....27563
Stop, Turn, and Hazards System Preliminary Check....27563
Turn Signal Switch Circuit Test....27564
Brake Switch Circuit Test....27566
Left Front Turn Signal Circuit Test....27568
Right Front Turn Signal Circuit Test....27568
Left Rear Turn Signal Circuit Test....27569
Right Rear Turn Signal Circuit Test....27570
6. Tail, Marker, Park, And Clearance Lighting....27570
6.1. System Description....27570
Overview....27570
Operation....27571
6.2. Feature Codes....27571
6.3. User Programmable Parameters....27571
6.4. Diagnostic Trouble Codes....27571
6.5. Troubleshooting....27572
Tail, Marker, Park, and Clearance Lighting Preliminary Check....27572
Headlight Switch Test....27572
Tail Light Circuit Test....27574
Park, Marker, Clearance, and Identification Lights Circuit Test....27574
7. Work Light....27575
7.1. System Description....27575
Overview....27575
Operation....27575
7.2. Feature Codes....27575
7.3. User Programmable Parameters....27575
7.4. Diagnostic Trouble Codes....27576
7.5. Troubleshooting....27576
Work Light System Preliminary Check....27577
Work Light Switch Test....27577
Work Light Circuit Tests....27578
8. Roof Auxiliary Load And Air Shield Light....27579
8.1. System Description....27579
Overview....27579
Roof Auxiliary Load Operation....27579
Air Shield Light Operation....27579
8.2. Feature Codes....27579
8.3. User Programmable Parameters....27580
8.4. Diagnostic Trouble CodeS....27580
Roof Auxiliary Load ....27580
Lighted Air Shield....27580
8.5. Troubleshooting....27580
Roof Auxiliary Load Preliminary Check....27580
Lighted Air Shield Preliminary Check....27581
Roof Auxiliary Load Switch Test....27582
Roof Auxiliary Load Circuit Test....27583
Lighted Air Shield Circuit Test....27583
9. Trailer Lighting....27584
9.1. System Description....27584
Overview....27584
Operation....27584
9.2. Feature Codes....27584
9.3. User Programmable Parameters....27584
9.4. Diagnostic Trouble CodeS....27584
9.5. Troubleshooting....27586
Trailer Lights Preliminary Check....27586
Trailer Socket Circuit Test....27586
Trailer Left Turn Relay Circuit Test....27588
Trailer Right Turn Relay Circuit Test....27589
Trailer Marker Light Relay Circuit Test....27590
Trailer Tail Light Relay Circuit Test....27591
Trailer Stop Light Relay Circuit Test....27592
Trailer ABS ECU Relay Circuit Test....27593
10. Auxiliary Snowplow Lighting....27593
10.1. System Description....27593
Overview....27593
Operation....27593
10.2. Feature Code....27594
10.3. user programmable parameters....27594
10.4. diagnostic trouble codes....27594
10.5. Troubleshooting....27595
Auxiliary Snowplow Lights Preliminary Checks....27595
Snowplow Switch Test....27596
Snowplow Lights Circuit Test....27596
CAB FEATURES....27598
1. Cigar Lighter And Power Feed....27604
1.1. System Description....27604
Overview....27604
Cigar Lighter Operation....27604
Cigar Lighter Power Source and Two-Post Power Source Operation....27604
1.2. Feature Codes....27604
1.3. User Programmable Parameters....27604
1.4. Diagnostic Trouble Codes....27604
1.5. Troubleshooting....27604
Cigar Lighter and Power Feed Preliminary Check....27604
Cigar Lighter Circuit Test....27605
Two-Post Power Source Circuit Test....27605
2. CB Power Radio....27606
2.1. System Description....27606
Overview....27606
Operation....27606
2.2. Feature Codes....27606
2.3. User Programmable Parameters....27606
2.4. Diagnostic Trouble Codes....27606
2.5. Troubleshooting....27606
CB Radio Power Source Preliminary Check....27607
CB Radio Circuit Test....27607
3. Compass And Temperature Display....27607
3.1. System Description....27607
Overview....27607
Temperature Display Operation....27608
Compass Display Operation....27608
3.2. Feature Codes....27608
3.3. User Programmable Parameters....27608
3.4. Diagnostic Trouble Codes....27608
3.5. Troubleshooting....27610
Compass and Temperature Display Preliminary Check....27610
Compass / Temperature Display Circuit Tests....27610
Compass Calibration....27612
Ambient Temperature Sensor Circuit Test....27613
4. Power Windows And Locks....27614
4.1. System Description....27614
Overview....27614
Power Window Operation....27614
Power Door Lock Operation....27615
4.2. Feature Codes....27615
4.3. User Programmable Parameters....27615
4.4. Diagnostic Trouble Codes....27616
4.5. Troubleshooting....27618
Power Window and Lock Preliminary Check....27619
Locks and Windows Inoperative Circuit Test....27619
Power Window Circuit Test....27620
Power Door Lock Circuit Test....27621
5. Electric Horn....27621
5.1. System Description....27621
Overview....27621
Operation....27621
5.2. Feature Codes....27621
5.3. User Programmable Parameters....27621
5.4. Diagnostic Trouble Codes....27623
5.5. Troubleshooting....27623
Electric Horn Preliminary Check....27623
Electric Horn Circuit Test....27624
6. Air Horn....27625
6.1. System Description....27625
Overview....27625
Operation....27625
6.2. Feature Codes....27625
6.3. User Programmable Parameters....27625
6.4. Diagnostic Trouble Codes....27625
6.5. Troubleshooting....27626
Air Horn Preliminary Check....27626
Air Horn Circuit Test....27627
7. Power Mirrors....27627
7.1. System Description....27627
Overview....27627
Operation....27627
7.2. Feature Codes....27628
7.3. User Programmable Parameters....27628
7.4. Diagnostic Trouble Codes....27628
7.5. Troubleshooting....27628
Power Mirror Preliminary Check....27629
Driver Power Mirror Circuit Test....27629
Passenger Power Mirror Circuit Test....27630
8. Heated Mirror....27631
8.1. System Description....27631
Overview....27631
Operation....27631
8.2. Feature Codes....27631
8.3. User Programmable Parameters....27631
8.4. Diagnostic Trouble Codes....27631
8.5. Troubleshooting....27632
Heated Mirror Preliminary Check....27632
Heated Mirror Switch Test....27633
Driver Heated Mirror Circuit Test....27633
Passenger Heated Mirror Circuit Test....27634
Heated Windshield Circuit Test....27634
9. Radio (Entertainment), Speakers....27636
9.1. System Description....27636
Overview....27636
Operation....27637
9.2. Feature Codes....27637
9.3. User Programmable Parameters....27637
9.4. Diagnostic Trouble Codes....27637
9.5. Troubleshooting....27637
Radio Preliminary Check....27637
Radio Circuit Test (16 Way Connector)....27638
Radio Circuit Test (12 Way Connector)....27638
Speaker Circuit Test (16 Way Connector)....27638
Speaker Circuit Test....27639
10. Two-Way Radio....27640
10.1. System Description....27640
Overview....27640
Operation....27640
10.2. Feature Codes....27641
10.3. User Programmable Parameters....27641
10.4. diagnostic trouble codes....27641
10.5. Troubleshooting....27641
Two-Way Radio Circuit Test....27641
11. Windshield Wiper And Washer Pump....27641
11.1. System Description....27641
Overview....27641
Wiper Operation....27642
Park Operation....27642
Washer Operation....27642
11.2. Feature Codes....27642
11.3. User Programmable Parameters....27642
11.4. Diagnostic Trouble Codes....27644
11.5. Troubleshooting....27645
Wiper and Washer Preliminary Check....27645
Washer Pump Circuit Test....27646
Wiper Switch Circuit Test....27647
Wiper Motor Circuit Test....27648
12. Park Brake And Brake Switch....27648
12.1. System Description....27648
Overview....27649
Operation....27649
12.2. Feature Codes....27649
12.3. User Programmable Parameters....27649
12.4. Diagnostic Trouble CodeS....27650
12.5. Troubleshooting....27651
Brake Switch Preliminary Check....27651
Brake Switch Test....27652
Park Brake Switch Test....27653
13. Clutch Switch....27655
13.1. System Description....27655
Overview....27655
Operation....27655
13.2. Feature Codes....27655
13.3. User Programmable Parameters....27656
13.4. Diagnostic Trouble CodeS....27656
13.5. Troubleshooting....27657
Clutch Switch Preliminary Checks....27657
Engine Crank Clutch Switch Test....27658
Cruise Control Clutch Switch Test....27660
14. Load Shedding....27660
14.1. System Description....27660
Overview....27661
Operation....27661
14.2. Feature Codes....27661
14.3. User Programmable Parameters....27661
14.4. Diagnostic Trouble CodeS....27661
14.5. Troubleshooting....27662
Latching Relay Circuit Test....27662
15. Vehicle Data Recorder....27663
15.1. System Description....27663
Overview....27663
Operation....27664
15.2. Feature Code....27664
15.3. User Programmable Parameters....27664
15.4. Diagnostic Trouble Codes....27664
15.5. Troubleshooting....27664
Vehicle Data Recorder Preliminary Check....27664
Vehicle Data Recorder Circuit Test....27665
VDR Brake Pressure Switch Circuit Test....27666
VDR Headlight Input Relay Circuit Test....27667
16. Theft Deterrent System....27668
16.1. System Description....27668
Overview....27668
Operation....27668
16.2. FEATURE CODE....27668
16.3. user programmable parameters....27668
16.4. diagnostic trouble codes....27668
16.5. Troubleshooting....27669
Theft Deterrent Preliminary Check....27670
Theft Deterrent System Test....27670
17. Seat Belt And Seat Sensor....27671
17.1. System Description....27671
Overview....27671
Operation....27672
17.2. Feature Code....27672
17.3. User Programmable Parameters....27672
17.4. Diagnostic Trouble Codes....27673
17.5. Troubleshooting....27673
Seat Belt Preliminary Check....27673
Seat Belt Indicator Circuit Test....27674
18. Self-Contained Air Seat....27675
18.1. System Description....27675
Overview....27675
Operation....27675
18.2. Feature Code....27675
18.3. User Programmable Parameters....27675
18.4. Diagnostic Trouble Codes....27675
18.5. Troubleshooting....27675
Driver and Passenger Self-Contained Air Seats Preliminary Check....27675
Driver and Passenger Self-Contained Air Seat Test....27676
19. Heated Seats....27677
19.1. System Description....27677
Overview....27677
Operation....27677
19.2. Feature Codes....27677
19.3. User Programmable Parameters....27677
19.4. Diagnostic Trouble CodeS....27677
19.5. Troubleshooting....27677
Driver and Passenger Heated Seats Preliminary Check....27677
Driver and Passenger Heated Seat Test....27677
CHASSIS FEATURES....27680
1. Heated Air Dryer and drain valve....27684
1.1. System Description....27684
Overview....27684
Operation....27684
1.2. Feature Codes....27684
1.3. User Programmable Parameters....27684
1.4. diagnostic trouble codes....27684
1.5. Troubleshooting....27684
Air Dryer and Heated Drain Valve Preliminary Check....27684
Heated Drain Valve Circuit Test....27685
Air Dryer Circuit Test....27686
2. Air Solenoid....27686
2.1. System Description....27686
Overview....27686
Operation....27686
2.2. Feature Codes....27687
2.3. User Programmable Parameters....27687
2.4. Diagnostic Trouble Codes....27687
2.5. Troubleshooting....27692
Air Solenoid Preliminary Check....27693
Air Solenoid Circuit Test....27693
3. Suspension Dump....27694
3.1. System Description....27694
Overview....27694
Operation....27694
3.2. Feature Code....27695
3.3. User Programmable Parameters....27695
3.4. Diagnostic Trouble Codes....27696
3.5. Troubleshooting....27697
Suspension Dump Preliminary Check....27697
Suspension Dump Test....27698
4. Differential Lock....27699
4.1. System description....27699
Overview....27699
Operation....27699
4.2. Feature Code....27700
4.3. User Programmable Parameters....27700
4.4. Diagnostic Trouble Codes....27701
4.5. Troubleshooting....27702
Differential Lock Preliminary Check....27703
Differential Lock Test....27703
5. Power Divider Lock....27704
5.1. System Description....27704
Overview....27704
Operation....27704
5.2. FEATURE CODE....27705
5.3. User Programmable Parameters....27705
5.4. Diagnostic Trouble Codes....27705
5.5. Troubleshooting....27706
Power Divider Lock Preliminary Check....27707
Power Divider Lock Test....27707
6. Power Take Off....27708
6.1. System Description....27708
Overview....27708
Operation....27708
6.2. Feature Code....27708
6.3. User Programmable Parameters....27708
6.4. Diagnostic Trouble Codes....27709
6.5. Troubleshooting....27710
Power Take Off Preliminary Check....27711
Power Take Off Circuit Test....27711
7. Anti-Lock Braking System ....27712
7.1. System Description....27712
Overview....27712
Operation....27712
Communication....27713
7.2. Feature Code....27713
7.3. User Programmable Parameters....27714
7.4. Diagnostic Trouble Codes....27714
7.5. Troubleshooting....27715
Anti-Lock Braking System Preliminary Check....27715
Bendix® ABS Circuit Tests....27716
Wabco® ABS Module Circuit Test....27719
8. Fifth Wheel Slide and jaw lock release....27720
8.1. System Description....27720
Overview....27720
Operation....27721
8.2. Feature Code....27721
8.3. User Programmable Parameters....27721
8.4. Diagnostic Trouble Codes....27722
8.5. Troubleshooting....27723
Fifth Wheel Slide Preliminary Check....27723
Fifth Wheel Slide Circuit Test....27723
Fifth Wheel Jaw Lock Release Circuit Test....27724
9. Fuel Heater....27724
9.1. System Description....27724
Overview....27725
Operation....27725
9.2. Feature Code....27725
9.3. User Programmable Parameters....27725
9.4. Diagnostic Trouble Codes....27725
9.5. Troubleshooting....27725
Fuel Heater Preliminary Check....27725
Fuel Heater Circuit Test ....27726
10. Remote Power Module....27726
10.1. System Description....27726
Overview....27727
Operation....27727
10.2. Feature Code....27727
10.3. User Programmable Parameters....27728
10.4. Diagnostic Trouble Codes....27728
10.5. Troubleshooting....27731
RPM Preliminary Check....27732
RPM Circuit Test....27732
11. remote start / stop....27734
11.1. System description....27734
Overview....27734
Operation....27735
11.2. FEATURE CODE....27735
11.3. user programmable parameters....27736
11.4. diagnostic trouble codes....27736
11.5. Troubleshooting....27736
Remote Start / Stop Preliminary Check....27737
Remote Start / Stop Test....27737
12. Two-speed axle ....27739
12.1. System description....27739
Overview....27739
Operation....27739
12.2. feature codes....27739
12.3. user programmable parameters....27739
12.4. diagnostic trouble codes....27739
12.5. troubleshooting....27740
Two-Speed Switch Preliminary Check....27740
Two-Speed Switch Test....27740
13. Customer installed lift gate power source....27741
13.1. System description....27741
Overview....27741
Operation....27741
13.2. FEATURE CODE....27741
13.3. user programmable parameters....27742
13.4. diagnostic trouble codes....27742
13.5. Troubleshooting....27743
Lift Gate Preliminary Check....27743
Lift Gate Circuit Test ....27744
14. Auto neutral ....27744
14.1. System description....27744
Overview....27744
Operation....27744
14.2. FEATURE CODE....27745
14.3. user programmable parameters....27745
14.4. diagnostic trouble codes....27745
14.5. Troubleshooting....27745
Auto Neutral Preliminary Check....27746
Auto Neutral Switch Test ....27746
Auto Neutral Circuit Test....27746
15. Axle Load Monitor....27748
15.1. System Description....27748
Overview....27748
Operation....27748
15.2. Feature Code....27748
15.3. User Programmable Parameters....27749
15.4. Diagnostic Trouble Codes....27750
15.5. Troubleshooting....27751
Axle Load Monitor Preliminary Check....27751
Axle Pressure Transducer Circuit Test....27751
16. water-in-fuel monitor ....27752
16.1. System Description....27752
Overview....27752
Operation....27752
16.2. Feature Code....27752
16.3. User Programmable Parameters....27752
16.4. Diagnostic Trouble Codes....27752
16.5. Troubleshooting....27753
Water-In-Fuel Monitor Preliminary Check....27753
Water Probe Circuit Test....27754
TRANSMISSIONS....27756
1. Transmission....27758
1.1. System Description....27758
Overview....27758
Operation....27758
1.2. Feature Code....27759
1.3. user programmable parameters....27759
1.4. Diagnostic Trouble Codes....27759
1.5. Troubleshooting....27761
Transmission Preliminary Check....27761
Eaton UltraShift®® TCM Circuit Test....27762
Eaton UltraShift® Selector Circuit Test....27765
Eaton T-Handle Shifter Circuit Test....27768
Eaton Hybrid TCM Circuit Test....27768
Allison TCU Circuit Test with IBB Engine....27770
Allison Shift Selector with IBB Engine ....27772
Allison TCU Circuit Test with I6/V8 Engine....27774
Allison Shifter with I6/V8 Engine....27775
Shifter Ignition Relay Circuit Test....27776
Park Position Unlock Solenoid Test....27778
1.6. Body Controller Signals....27778
Body Controller Signals....27779
MULTIPLEXING (DATA LINKS)....27780
1. Multiplexing (Data Links)....27782
1.1. Description....27782
Overview....27782
Operation....27782
1.2. Troubleshooting....27783
J1939 Data Link Terminating Resistors....27783
Body Controller....27784
J1939 Data Link Circuit Test....27784
J1708 Data Link Circuit Test....27785
12-VOLT POWER DISTRIBUTION AND GROUND....27786
1. 12-Volt Power Distribution and Grounds....27788
1.1. Description....27788
Overview....27788
Operation....27788
1.2. Troubleshooting....27788
Battery Power Distribution Check....27789
Accessory Power Distribution Preliminary Check....27789
Accessory Power Circuit Test....27790
Body Controller Accessory Feed Input Circuit Test....27791
Ignition Power Distribution Preliminary Check....27792
Ignition Power Circuit Test....27792
Ground Circuit Test....27794
FANS AND ENGINE ACCESSORIES....27796
1. Fan System....27798
1.1. System Description....27798
Overview....27798
Operation....27798
1.2. Feature Code....27798
1.3. User Programmable Parameters....27799
1.4. Diagnostic Trouble Codes....27799
1.5. Troubleshooting....27799
Fan System Preliminary Check....27800
Fan Override Switch Test....27800
2. Compression / Exhaust Brake....27801
2.1. System Description....27801
Overview....27801
Operation....27801
2.2. Feature Code....27801
2.3. User Programmable Parameters....27802
2.4. Diagnostic Trouble Codes....27802
2.5. Troubleshooting....27802
Compression / Exhaust Brake Preliminary Check....27803
Compression / Exhaust Brake Switch Test....27803
3. Aftertreatment ....27803
3.1. System Description....27803
Overview....27803
Operation....27804
3.2. Feature Code....27806
3.3. User Programmable Parameters....27806
3.4. Diagnostic Trouble Codes....27806
3.5. Troubleshooting....27807
Aftertreatment Preliminary Check....27808
Inhibit Regeneration Switch Test....27808
Parked Regeneration Switch Test....27809
Warning Lamp Test....27809
4. Cruise Control....27810
4.1. system description....27810
Overview....27810
Operation....27810
4.2. feature codes....27811
4.3. User Programmable Parameters....27811
4.4. diagnostic trouble codes....27811
4.5. Troubleshooting....27812
Cruise Control Preliminary Check....27813
Cruise Control Switch Test....27814
5. Snow Valve....27815
5.1. System Description....27815
Overview....27815
Operation....27815
5.2. Feature Code....27816
5.3. User Programmable Parameters....27816
5.4. Diagnostic Trouble Codes....27816
5.5. Troubleshooting....27816
Snow Valve Preliminary Check....27816
Snow Valve Module Circuit Test....27817
BATTERY, CHARGING, AND CRANKING SYSTEM....27818
1. Battery System....27820
1.1. Description....27820
Overview....27820
Operation....27820
1.2. Diagnostic Trouble Codes....27821
1.3. Troubleshooting....27821
Battery Test....27821
Battery Test Results....27822
Cable Drop Test....27822
Battery Pack Test....27822
Battery Pack Test Results....27822
2. Charging System....27823
2.1. Description....27823
Overview....27823
Operation....27823
2.2. Diagnostic Trouble Codes....27823
2.3. Troubleshooting....27824
Charging System Test....27824
Charging System Test Results....27824
3. Cranking System....27825
3.1. Description....27825
Overview....27825
Operation....27825
3.2. Troubleshooting....27826
Starting System Test....27826
Starting System Test Results....27826
4. Powerpack 3....27826
4.1. Description....27826
Overview....27827
Operation....27827
4.2. Troubleshooting....27827
VEHICLE AND DRIVER INFORMATION DISPLAY....27828
1. vehicle information display....27830
1.1. System description....27830
Overview....27830
Operation....27830
1.2. FEATURE CODE....27830
1.3. user programmable parameters....27831
1.4. diagnostic trouble codes....27831
1.5. Troubleshooting....27831
Vehicle Information Display Preliminary Check....27831
Vehicle Information Display Circuit Test....27831
2. Driver information display....27832
2.1. System description....27832
Overview....27832
Operation....27833
2.2. FEATURE CODE....27833
2.3. user programmable parameters....27833
2.4. diagnostic trouble codes....27833
2.5. Troubleshooting....27833
Driver Information Display Preliminary Check....27834
Driver Information Display Circuit Test....27834
tables....27471
Table 1Ohm's Law....27471
Table 2Relay Bench Test....27484
Table 3Gauges and Signal Paths....27489
Table 4Warning Lamp and Signal Path....27490
Table 5Audible Alarms....27492
Table 6Electronic Gauge Cluster Feature Codes....27493
Table 7Diagnostic Trouble Codes....27499
Table 8EGC Preliminary Checks....27507
Table 9Electronic Gauge Cluster Circuit Test....27509
Table 10EGC Backlighting Circuit Test....27511
Table 11EGC Gauge Test....27512
Table 12Warning Lamp Test....27513
Table 13Fuel Level Gauge Circuit Test....27514
Table 14Transmission Oil Temperature Circuit Test....27515
Table 15Rear Rear Axle Temperature Circuit Test....27516
Table 16Front Rear Axle Temperature Circuit Test....27517
Table 17Air Pressure Transducer Circuit Test....27518
Table 18Park Brake Switch Circuit Test....27520
Table 19 Air Restriction Gauge Circuit Test....27521
Table 20Low Coolant Sensor Circuit Test....27521
Table 21Diagnostic Trouble Codes....27526
Table 22Switch Pack Preliminary Check....27528
Table 23Switch Pack Circuit Test....27528
Table 24J1708 Data Link Circuit Test....27529
Table 25Feature Code....27534
Table 26Diagnostic Trouble Codes....27535
Table 27Backup Lights Preliminary Checks....27536
Table 28 Backup Light Circuit Test....27536
Table 29Backup Light Switch Test....27538
Table 30Feature Code....27540
Table 31Diagnostic Trouble Codes....27540
Table 32Dome and Courtesy Lights Preliminary Checks....27541
Table 33Door Switch Circuit Test....27542
Table 34Cab Dome Light Circuit Test....27543
Table 35Courtesy Lights Circuit Test....27545
Table 36Feature Codes....27546
Table 37Diagnostic Trouble Codes....27546
Table 38Fog Light System Preliminary Check....27547
Table 39Fog Light Switch Test....27548
Table 40Fog Light Circuit Test....27549
Table 41Feature Codes....27551
Table 42Diagnostic Trouble Codes....27552
Table 43Headlight System Preliminary Check....27554
Table 44Headlight Switch Test....27555
Table 45Turn Signal Switch Circuit Test....27556
Table 46Right Headlight Circuit Test....27557
Table 47Left Headlight Circuit Test....27559
Table 48Feature Codes....27560
Table 49Diagnostic Trouble Codes....27560
Table 50Stop, Turn, and Hazards System Preliminary Check....27563
Table 51Turn Signal Switch Circuit Test....27564
Table 52Brake Switch Circuit Test....27566
Table 53Left Front Turn Signal Circuit Test....27568
Table 54Right Front Turn Signal Circuit Test....27569
Table 55Left Rear Turn Signal Circuit Test....27569
Table 56Right Rear Turn Signal Circuit Test....27570
Table 57Feature Codes....27571
Table 58Diagnostic Trouble Codes....27571
Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....27572
Table 60Headlight Switch Test....27573
Table 61Tail Light Circuit Test....27574
Table 62Park, Marker, Clearance, and Identification Lights Circu....27574
Table 63Feature Codes....27575
Table 64Diagnostic Trouble Codes....27576
Table 65Work Light System Preliminary Check....27577
Table 66Work Light Switch Test....27577
Table 67Work Light Circuit Test....27578
Table 68Feature Codes....27579
Table 69Lighted Air Shield DTC....27580
Table 70Roof Auxiliary Load Preliminary Check....27580
Table 71Lighted Air Shield Preliminary Check....27581
Table 72Roof Auxiliary Load Switch Test....27582
Table 73Roof Auxiliary Load Circuit Test....27583
Table 74Lighted Air Shield Circuit Test....27583
Table 75Feature Codes....27584
Table 76Diagnostic Trouble Codes....27585
Table 77Trailer Lights Preliminary Check....27586
Table 78Trailer Socket Circuit Test....27586
Table 79Trailer Left Turn Relay Circuit Test....27588
Table 80Trailer Right Turn Relay Circuit Test....27589
Table 81Trailer Marker Light Relay Circuit Test....27590
Table 82Trailer Tail Light Relay Circuit Test....27591
Table 83Trailer Stop Light Relay Circuit Test....27592
Table 84Trailer ABS ECU Relay Circuit Test....27593
Table 85Feature Code....27594
Table 86Diagnostic Trouble Codes....27594
Table 87Auxiliary Snowplow Lights Preliminary Checks....27595
Table 88 Snowplow Switch Test....27596
Table 89Snowplow Lights Circuit Test....27596
Table 90Cigar Lighter and Power Feed Preliminary Check....27605
Table 91Cigar Lighter Circuit Test....27605
Table 92Two-Post Power Source Circuit Test....27605
Table 93CB Radio Power Source Preliminary Check....27607
Table 94CB Radio Circuit Test....27607
Table 95Feature Codes....27608
Table 96Diagnostic Trouble Codes....27608
Table 97Compass and Temperature Display Preliminary Check....27610
Table 98Compass Display Circuit Test....27611
Table 99Ambient Temperature Sensor Circuit Test....27614
Table 100Feature Codes....27615
Table 101Diagnostic Trouble Codes....27616
Table 102Power Locks Preliminary Check....27619
Table 103Power Windows Preliminary Check....27619
Table 104Locks and Windows Inoperative Circuit Test....27619
Table 105Power Window Circuit Test....27620
Table 106Power Door Lock Circuit Test....27621
Table 107Feature Codes....27621
Table 108Diagnostic Trouble Codes....27623
Table 109Electric Horn Preliminary Check....27623
Table 110Electric Horn Circuit Test....27624
Table 111Feature Codes....27625
Table 112Diagnostic Trouble Codes....27626
Table 113Air Horn Preliminary Checks....27626
Table 114Air Horn Circuit Test....27627
Table 115Power Mirror Preliminary Check....27629
Table 116Driver Power Mirror Circuit Test....27629
Table 117Passenger Power Mirror Circuit Test....27630
Table 118Feature Codes....27631
Table 119Diagnostic Trouble codes....27632
Table 120Heated Mirror Preliminary Check....27632
Table 121Heated Mirror Switch Test....27633
Table 122Driver Heated Mirror Circuit Test....27633
Table 123Passenger Heated Mirror Circuit Test....27634
Table 124Heated Windshield Circuit Test....27635
Table 125Radio Preliminary Check....27637
Table 126Radio Circuit Test (16 Way Connector)....27638
Table 127Radio Circuit Test (12 Way Connector)....27638
Table 128Speaker Circuit Test (16 Way Connector)....27639
Table 129Speaker Circuit Test (12 Way Connector)....27640
Table 130Two-Way Radio Circuit Test....27641
Table 131Feature Codes....27642
Table 132Diagnostic Trouble Codes....27644
Table 133Wiper and Washer Preliminary Check....27645
Table 134Washer Pump Circuit Test....27646
Table 135Wiper Switch Circuit Test....27647
Table 136Wiper Motor Circuit Test....27648
Table 137Feature Codes....27649
Table 138Diagnostic Trouble Codes....27650
Table 139Brake Switch Preliminary Check....27651
Table 140Brake Switch Circuit Test....27652
Table 141Park Brake Switch Circuit Test....27653
Table 142Feature Code....27656
Table 143Diagnostic Trouble Codes....27656
Table 144Clutch Switch Preliminary Checks....27657
Table 145Engine Crank Clutch Switch Test....27658
Table 146Cruise Control Clutch Switch Test....27660
Table 147Feature Code....27661
Table 148Diagnostic Trouble Codes....27662
Table 149Latching Relay Circuit Test....27663
Table 150Vehicle Data Recorder Preliminary Check....27664
Table 151 Vehicle Data Recorder Circuit Test....27665
Table 152VDR Brake Pressure Switch Circuit Test....27666
Table 153VDR Headlight Input Relay Circuit Test....27667
Table 154Feature Code....27668
Table 155Diagnostic Trouble Codes....27669
Table 156Theft Deterrent Preliminary Check....27670
Table 157Theft Deterrent System Test....27670
Table 158Feature Code....27672
Table 159Seat Belt Preliminary Check....27673
Table 160Seat Belt Indicator Circuit Test....27674
Table 161Driver and Passenger Self-Contained Air Seats Prelimina....27675
Table 162Driver and Passenger Self-Contained Air Seat Test....27676
Table 163Driver and Passenger Heated Seats Preliminary Check....27677
Table 164Driver and Passenger Heated Seat Test....27678
Table 165Air Dryer and Heated Drain Valve Preliminary Check....27684
Table 166Heated Drain Valve Circuit Test....27685
Table 167Air Dryer Circuit Test....27686
Table 168Feature Codes....27687
Table 169Diagnostic Trouble Codes....27687
Table 170Air Solenoid Preliminary Check....27693
Table 171Air Solenoid Circuit Test....27694
Table 172Feature Code....27695
Table 173Diagnostic Trouble Codes....27696
Table 174Suspension Dump Preliminary Check....27698
Table 175Suspension Dump Test....27698
Table 176Feature Codes....27700
Table 177Diagnostic Trouble Codes....27701
Table 178Differential Lock Preliminary Check....27703
Table 179Differential Lock Test....27703
Table 180Feature Code....27705
Table 181Diagnostic Trouble Codes....27706
Table 182Power Divider Lock Preliminary Check....27707
Table 183Power Divider Lock Test....27707
Table 184Feature Code....27708
Table 185Diagnostic Trouble Codes....27709
Table 186Power Take Off Preliminary Check....27711
Table 187Power Take Off Circuit Test....27711
Table 188Feature Code....27713
Table 189Diagnostic Trouble Codes....27715
Table 190Anti-Lock Braking System Preliminary Check....27715
Table 191Bendix® ABS Module Circuit Test....27716
Table 192Bendix® Steering Wheel Sensor Circuit Test....27718
Table 193Bendix® Yaw Sensor Circuit Test....27718
Table 194Wabco® ABS Module Circuit Test....27719
Table 195Feature Code....27721
Table 196Diagnostic Trouble Codes....27722
Table 197Fifth Wheel Slide Preliminary Check....27723
Table 198Fifth Wheel Slide Circuit Test....27723
Table 199Fifth Wheel Jaw Lock Release Circuit Test....27724
Table 200Fuel Heater Preliminary Check....27725
Table 201Fuel Heater Circuit Test ....27726
Table 202Diagnostic Trouble Codes....27728
Table 203RPM Preliminary Check....27732
Table 204RPM Circuit Test....27732
Table 205Feature Code....27735
Table 206Diagnostic Trouble Codes....27736
Table 207Remote Start / Stop Preliminary Check....27737
Table 208Remote Start / Stop Test....27737
Table 209Feature Codes....27739
Table 210Diagnostic Trouble Codes....27739
Table 211Two-Speed Switch Preliminary Check....27740
Table 212Two-Speed Switch Test....27740
Table 213Feature Code....27741
Table 214Diagnostic Trouble Codes....27742
Table 215Lift Gate Preliminary Check....27743
Table 216Lift Gate Test ....27744
Table 217Feature Code....27745
Table 218Diagnostic Trouble Codes....27745
Table 219Auto Neutral Preliminary Check....27746
Table 220Auto Neutral Switch Test ....27746
Table 221Auto Neutral Circuit Test ....27746
Table 222Feature Code....27748
Table 223Diagnostic Trouble Codes....27750
Table 224Axle Load Monitor Preliminary Check....27751
Table 225Axle Pressure Transducer Circuit Test....27751
Table 226Diagnostic Trouble Codes....27753
Table 227Water-In-Fuel Monitor Preliminary Check....27753
Table 228Water Probe Circuit Test....27754
Table 229Feature Code....27759
Table 230Diagnostic Trouble Codes....27760
Table 231Transmission Preliminary Check....27761
Table 232Eaton UltraShift® TCM Circuit Test....27763
Table 233Eaton UltraShift® Selector Circuit Test....27765
Table 234Eaton UltraShift® Selector Lighting Circuit Test ....27767
Table 235Eaton T-Handle Shifter Circuit Test....27768
Table 236Eaton T-Handle Shifter Lighting Circuit Test....27768
Table 237Eaton Hybrid TCM Circuit Test....27769
Table 238Allison TCU Circuit Test with IBB Engine....27771
Table 239Allison Shift Selector Circuit Test....27772
Table 240Allison Shift Selector Lighting Circuit Test....27774
Table 241Allison TCU Circuit Test with I6/V8 Engine....27774
Table 242Allison Column Mounted Shifter ....27775
Table 243Allison T-Handle Shifter ....27776
Table 244Shifter Ignition Relay Circuit Test....27777
Table 245Park Position Unlock Solenoid Test....27778
Table 246Body Controller Signals....27779
Table 247J1939 Data Link Circuit Test....27785
Table 248J1708 Data Link Circuit Test....27785
Table 249Battery Power Distribution Preliminary Check....27789
Table 250Accessory Power Distribution Check....27789
Table 251Accessory Power Circuit Test....27790
Table 252Body Controller Accessory Feed Input Circuit Test....27791
Table 253Ignition Power Distribution Check....27792
Table 254Ignition Power Circuit Test....27792
Table 255Ground Circuit Test....27794
Table 256Feature Code....27799
Table 257Diagnostic Trouble Codes....27799
Table 258Fan System Preliminary Check....27800
Table 259Fan Override Switch Test....27800
Table 260Feature Code....27801
Table 261Diagnostic Trouble Codes....27802
Table 262Compression / Exhaust Brake Preliminary Check....27803
Table 263Compression Brake Switch Test....27803
Table 264Soot Accumulation Level Indications....27805
Table 265Feature Code....27806
Table 266Diagnostic Trouble Codes....27806
Table 267Aftertreatment Preliminary Check....27808
Table 268Inhibit Regeneration Switch Test....27808
Table 269Parked Regeneration Switch Test....27809
Table 270Warning Lamp Test....27809
Table 271Feature Code....27811
Table 272Diagnostic Trouble Codes....27812
Table 273Cruise Control Preliminary Check....27813
Table 274Cruise Control Switch Test....27814
Table 275Feature Code....27816
Table 276Snow Valve Preliminary Check....27816
Table 277Snow Valve Module Circuit Test....27817
Table 278Diagnostic Trouble Codes....27821
Table 279Diagnostic Trouble Codes....27823
Table 280Feature Code....27831
Table 281Vehicle Information Display Preliminary Check....27831
Table 282Vehicle Information Display Circuit Test....27831
Table 283Feature Code....27833
Table 284Driver Information Display Preliminary Check....27834
Table 285Driver Information Display Circuit Test....27834
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Service Manual....27838
toc....27842
SAFETY INFORMATION....27842
MANUAL INTRODUCTION....27844
1. Manual Introduction....27846
2. Vehicle Electrical System Overview....27847
3. Electrical Circuit Diagram Book....27847
3.1. CIRCUIT DIAGRAMS....27847
Circuit Diagram Instructions....27848
3.2. CONNECTOR BODY COMPOSITE....27851
4. Troubleshooting....27852
4.1. Verify The Problem....27852
4.2. Important Steps Before Performing Circuit Tests....27852
4.3. Review Feature Operation....27853
4.4. Check the Circuit Diagram....27853
4.5. Performing Circuit And System Tests....27854
4.6. Perform The Repair....27854
4.7. Verify The Repair....27854
5. Electrical Test Equipment....27854
5.1. EZ-TECH® Electronic Service Tool (EST)....27854
5.2. Body Controller Breakout Box (ZTSE4477)....27854
5.3. FLUKE 88 Digital Multimeter (DMM)....27855
5.4. MIDTRONICS EXP-1000HD....27856
5.5. Jumper Wires, Test Leads, And Test Lights....27857
Jumper Wires....27857
Test Leads....27858
Test Lights....27859
5.6. Ohm's Law Review....27859
5.7. Voltmeter....27861
Measuring Voltage....27861
5.8. Ammeter....27864
Measuring Amperage....27864
5.9. Ohmmeter....27866
Measuring Resistance....27866
Checking For Open Circuits....27868
Checking For Short Circuits....27869
6. Bench Testing Relays....27870
ELECTRONIC GAUGE CLUSTER....27874
1. Electronic Gauge Cluster....27876
1.1. System Description....27876
Overview....27876
Operation....27876
1.2. Feature Codes....27881
1.3. User Programmable Parameters....27882
1.4. Diagnostic Trouble Codes....27887
1.5. Troubleshooting....27895
Preliminary Checks....27895
Electronic Gauge Cluster Circuit Test....27897
EGC Backlight Circuit Test....27899
EGC Gauge Test....27899
Warning Lamp Test....27901
Fuel Level Gauge Circuit Test....27902
Transmission Oil Temperature Circuit Tests....27903
Front Rear and Rear Rear Axle Temperature Circuit Tests....27904
Air Pressure Transducer Circuit Tests....27905
Park Brake Switch Circuit Test....27908
Air Restriction Gauge Circuit Test....27909
Engine Coolant Level Monitor Circuit Test....27909
1.6. Electronic Gauge Cluster Programming....27910
SWITCH PACKS (J1708 DATA LINK)....27912
1. Switch Packs....27914
1.1. Description....27914
Overview....27914
Operation....27914
1.2. Diagnostic Trouble Codes....27914
1.3. Troubleshooting....27915
Switch Pack Preliminary Check....27916
Switch Pack Circuit Test....27916
J1708 Data Link Circuit Test....27917
LIGHTING SYSTEM....27918
1. Backup Lights....27922
1.1. System Description....27922
Overview....27922
Operation....27922
1.2. Feature Code....27922
1.3. user programmable parameters....27923
1.4. diagnostic trouble codes....27923
1.5. Troubleshooting....27923
Backup Lights Preliminary Checks....27924
Backup Light Circuit Test (Automatic Transmission)....27924
Backup Light Switch Test (Manual Transmission)....27926
2. Dome And Courtesy Lights....27927
2.1. System Description....27927
Overview....27927
Operation....27927
2.2. Feature Code....27928
2.3. User Programmable Parameters....27928
2.4. Diagnostic Trouble Codes....27928
2.5. Troubleshooting ....27929
Dome and Courtesy Lights Preliminary Checks....27929
Door Switch Circuit Tests....27930
Cab Dome Light Circuit Test....27931
Courtesy Lights Circuit Test....27933
3. Fog Lights....27933
3.1. System Description....27933
Overview....27933
Operation....27933
3.2. Feature Codes....27934
3.3. User Programmable Parameters ....27934
3.4. Diagnostic Trouble Codes....27934
3.5. Troubleshooting....27935
Fog Light System Preliminary Check....27935
Fog Light Switch Test....27936
Fog Light Circuit Test....27937
4. Headlights And Daytime Running Lights (DTRL)....27938
4.1. system description....27938
Overview....27939
Operation....27939
4.2. Feature Codes....27939
4.3. User Programmable Parameters....27939
4.4. Diagnostic Trouble Codes....27939
4.5. Troubleshooting....27941
Headlight System Preliminary Check....27942
Headlight Switch Test....27943
Turn Signal Switch Circuit Test....27944
Right Headlight Circuit Test....27945
Left Headlight Circuit Test....27947
5. Stop, Turn, And Hazard Lights....27947
5.1. System Description....27947
Overview....27947
Operation....27948
5.2. Feature Codes....27948
5.3. User Programmable Parameters....27948
5.4. Diagnostic Trouble Codes....27948
5.5. Troubleshooting....27951
Stop, Turn, and Hazards System Preliminary Check....27951
Turn Signal Switch Circuit Test....27952
Brake Switch Circuit Test....27954
Left Front Turn Signal Circuit Test....27956
Right Front Turn Signal Circuit Test....27956
Left Rear Turn Signal Circuit Test....27957
Right Rear Turn Signal Circuit Test....27958
6. Tail, Marker, Park, And Clearance Lighting....27958
6.1. System Description....27958
Overview....27958
Operation....27959
6.2. Feature Codes....27959
6.3. User Programmable Parameters....27959
6.4. Diagnostic Trouble Codes....27959
6.5. Troubleshooting....27960
Tail, Marker, Park, and Clearance Lighting Preliminary Check....27960
Headlight Switch Test....27960
Tail Light Circuit Test....27962
Park, Marker, Clearance, and Identification Lights Circuit Test....27962
7. Work Light....27963
7.1. System Description....27963
Overview....27963
Operation....27963
7.2. Feature Codes....27963
7.3. User Programmable Parameters....27963
7.4. Diagnostic Trouble Codes....27964
7.5. Troubleshooting....27964
Work Light System Preliminary Check....27965
Work Light Switch Test....27965
Work Light Circuit Tests....27966
8. Roof Auxiliary Load And Air Shield Light....27967
8.1. System Description....27967
Overview....27967
Roof Auxiliary Load Operation....27967
Air Shield Light Operation....27967
8.2. Feature Codes....27967
8.3. User Programmable Parameters....27968
8.4. Diagnostic Trouble CodeS....27968
Roof Auxiliary Load ....27968
Lighted Air Shield....27968
8.5. Troubleshooting....27968
Roof Auxiliary Load Preliminary Check....27968
Lighted Air Shield Preliminary Check....27969
Roof Auxiliary Load Switch Test....27970
Roof Auxiliary Load Circuit Test....27971
Lighted Air Shield Circuit Test....27971
9. Trailer Lighting....27972
9.1. System Description....27972
Overview....27972
Operation....27972
9.2. Feature Codes....27972
9.3. User Programmable Parameters....27972
9.4. Diagnostic Trouble CodeS....27972
9.5. Troubleshooting....27974
Trailer Lights Preliminary Check....27974
Trailer Socket Circuit Test....27974
Trailer Left Turn Relay Circuit Test....27976
Trailer Right Turn Relay Circuit Test....27977
Trailer Marker Light Relay Circuit Test....27978
Trailer Tail Light Relay Circuit Test....27979
Trailer Stop Light Relay Circuit Test....27980
Trailer ABS ECU Relay Circuit Test....27981
10. Auxiliary Snowplow Lighting....27981
10.1. System Description....27981
Overview....27981
Operation....27981
10.2. Feature Code....27982
10.3. user programmable parameters....27982
10.4. diagnostic trouble codes....27982
10.5. Troubleshooting....27983
Auxiliary Snowplow Lights Preliminary Checks....27983
Snowplow Switch Test....27984
Snowplow Lights Circuit Test....27984
CAB FEATURES....27986
1. Cigar Lighter And Power Feed....27992
1.1. System Description....27992
Overview....27992
Cigar Lighter Operation....27992
Cigar Lighter Power Source and Two-Post Power Source Operation....27992
1.2. Feature Codes....27992
1.3. User Programmable Parameters....27992
1.4. Diagnostic Trouble Codes....27992
1.5. Troubleshooting....27992
Cigar Lighter and Power Feed Preliminary Check....27992
Cigar Lighter Circuit Test....27993
Two-Post Power Source Circuit Test....27993
2. CB Power Radio....27994
2.1. System Description....27994
Overview....27994
Operation....27994
2.2. Feature Codes....27994
2.3. User Programmable Parameters....27994
2.4. Diagnostic Trouble Codes....27994
2.5. Troubleshooting....27994
CB Radio Power Source Preliminary Check....27995
CB Radio Circuit Test....27995
3. Compass And Temperature Display....27995
3.1. System Description....27995
Overview....27995
Temperature Display Operation....27996
Compass Display Operation....27996
3.2. Feature Codes....27996
3.3. User Programmable Parameters....27996
3.4. Diagnostic Trouble Codes....27996
3.5. Troubleshooting....27998
Compass and Temperature Display Preliminary Check....27998
Compass / Temperature Display Circuit Tests....27998
Compass Calibration....28000
Ambient Temperature Sensor Circuit Test....28001
4. Power Windows And Locks....28002
4.1. System Description....28002
Overview....28002
Power Window Operation....28002
Power Door Lock Operation....28003
4.2. Feature Codes....28003
4.3. User Programmable Parameters....28003
4.4. Diagnostic Trouble Codes....28004
4.5. Troubleshooting....28006
Power Window and Lock Preliminary Check....28007
Locks and Windows Inoperative Circuit Test....28007
Power Window Circuit Test....28008
Power Door Lock Circuit Test....28009
5. Electric Horn....28009
5.1. System Description....28009
Overview....28009
Operation....28009
5.2. Feature Codes....28009
5.3. User Programmable Parameters....28009
5.4. Diagnostic Trouble Codes....28011
5.5. Troubleshooting....28011
Electric Horn Preliminary Check....28011
Electric Horn Circuit Test....28012
6. Air Horn....28013
6.1. System Description....28013
Overview....28013
Operation....28013
6.2. Feature Codes....28013
6.3. User Programmable Parameters....28013
6.4. Diagnostic Trouble Codes....28013
6.5. Troubleshooting....28014
Air Horn Preliminary Check....28014
Air Horn Circuit Test....28015
7. Power Mirrors....28015
7.1. System Description....28015
Overview....28015
Operation....28015
7.2. Feature Codes....28016
7.3. User Programmable Parameters....28016
7.4. Diagnostic Trouble Codes....28016
7.5. Troubleshooting....28016
Power Mirror Preliminary Check....28017
Driver Power Mirror Circuit Test....28017
Passenger Power Mirror Circuit Test....28018
8. Heated Mirror....28019
8.1. System Description....28019
Overview....28019
Operation....28019
8.2. Feature Codes....28019
8.3. User Programmable Parameters....28019
8.4. Diagnostic Trouble Codes....28019
8.5. Troubleshooting....28020
Heated Mirror Preliminary Check....28020
Heated Mirror Switch Test....28021
Driver Heated Mirror Circuit Test....28021
Passenger Heated Mirror Circuit Test....28022
Heated Windshield Circuit Test....28022
9. Radio (Entertainment), Speakers....28024
9.1. System Description....28024
Overview....28024
Operation....28025
9.2. Feature Codes....28025
9.3. User Programmable Parameters....28025
9.4. Diagnostic Trouble Codes....28025
9.5. Troubleshooting....28025
Radio Preliminary Check....28025
Radio Circuit Test (16 Way Connector)....28026
Radio Circuit Test (12 Way Connector)....28026
Speaker Circuit Test (16 Way Connector)....28026
Speaker Circuit Test....28027
10. Two-Way Radio....28028
10.1. System Description....28028
Overview....28028
Operation....28028
10.2. Feature Codes....28029
10.3. User Programmable Parameters....28029
10.4. diagnostic trouble codes....28029
10.5. Troubleshooting....28029
Two-Way Radio Circuit Test....28029
11. Windshield Wiper And Washer Pump....28029
11.1. System Description....28029
Overview....28029
Wiper Operation....28030
Park Operation....28030
Washer Operation....28030
11.2. Feature Codes....28030
11.3. User Programmable Parameters....28030
11.4. Diagnostic Trouble Codes....28032
11.5. Troubleshooting....28033
Wiper and Washer Preliminary Check....28033
Washer Pump Circuit Test....28034
Wiper Switch Circuit Test....28035
Wiper Motor Circuit Test....28036
12. Park Brake And Brake Switch....28036
12.1. System Description....28036
Overview....28037
Operation....28037
12.2. Feature Codes....28037
12.3. User Programmable Parameters....28037
12.4. Diagnostic Trouble CodeS....28038
12.5. Troubleshooting....28039
Brake Switch Preliminary Check....28039
Brake Switch Test....28040
Park Brake Switch Test....28041
13. Clutch Switch....28043
13.1. System Description....28043
Overview....28043
Operation....28043
13.2. Feature Codes....28043
13.3. User Programmable Parameters....28044
13.4. Diagnostic Trouble CodeS....28044
13.5. Troubleshooting....28045
Clutch Switch Preliminary Checks....28045
Engine Crank Clutch Switch Test....28046
Cruise Control Clutch Switch Test....28048
14. Load Shedding....28048
14.1. System Description....28048
Overview....28049
Operation....28049
14.2. Feature Codes....28049
14.3. User Programmable Parameters....28049
14.4. Diagnostic Trouble CodeS....28049
14.5. Troubleshooting....28050
Latching Relay Circuit Test....28050
15. Vehicle Data Recorder....28051
15.1. System Description....28051
Overview....28051
Operation....28052
15.2. Feature Code....28052
15.3. User Programmable Parameters....28052
15.4. Diagnostic Trouble Codes....28052
15.5. Troubleshooting....28052
Vehicle Data Recorder Preliminary Check....28052
Vehicle Data Recorder Circuit Test....28053
VDR Brake Pressure Switch Circuit Test....28054
VDR Headlight Input Relay Circuit Test....28055
16. Theft Deterrent System....28056
16.1. System Description....28056
Overview....28056
Operation....28056
16.2. FEATURE CODE....28056
16.3. user programmable parameters....28056
16.4. diagnostic trouble codes....28056
16.5. Troubleshooting....28057
Theft Deterrent Preliminary Check....28058
Theft Deterrent System Test....28058
17. Seat Belt And Seat Sensor....28059
17.1. System Description....28059
Overview....28059
Operation....28060
17.2. Feature Code....28060
17.3. User Programmable Parameters....28060
17.4. Diagnostic Trouble Codes....28061
17.5. Troubleshooting....28061
Seat Belt Preliminary Check....28061
Seat Belt Indicator Circuit Test....28062
18. Self-Contained Air Seat....28063
18.1. System Description....28063
Overview....28063
Operation....28063
18.2. Feature Code....28063
18.3. User Programmable Parameters....28063
18.4. Diagnostic Trouble Codes....28063
18.5. Troubleshooting....28063
Driver and Passenger Self-Contained Air Seats Preliminary Check....28063
Driver and Passenger Self-Contained Air Seat Test....28064
19. Heated Seats....28065
19.1. System Description....28065
Overview....28065
Operation....28065
19.2. Feature Codes....28065
19.3. User Programmable Parameters....28065
19.4. Diagnostic Trouble CodeS....28065
19.5. Troubleshooting....28065
Driver and Passenger Heated Seats Preliminary Check....28065
Driver and Passenger Heated Seat Test....28065
CHASSIS FEATURES....28068
1. Heated Air Dryer and drain valve....28072
1.1. System Description....28072
Overview....28072
Operation....28072
1.2. Feature Codes....28072
1.3. User Programmable Parameters....28072
1.4. diagnostic trouble codes....28072
1.5. Troubleshooting....28072
Air Dryer and Heated Drain Valve Preliminary Check....28072
Heated Drain Valve Circuit Test....28073
Air Dryer Circuit Test....28074
2. Air Solenoid....28074
2.1. System Description....28074
Overview....28074
Operation....28074
2.2. Feature Codes....28075
2.3. User Programmable Parameters....28075
2.4. Diagnostic Trouble Codes....28075
2.5. Troubleshooting....28080
Air Solenoid Preliminary Check....28081
Air Solenoid Circuit Test....28081
3. Suspension Dump....28082
3.1. System Description....28082
Overview....28082
Operation....28082
3.2. Feature Code....28083
3.3. User Programmable Parameters....28083
3.4. Diagnostic Trouble Codes....28084
3.5. Troubleshooting....28085
Suspension Dump Preliminary Check....28085
Suspension Dump Test....28086
4. Differential Lock....28087
4.1. System description....28087
Overview....28087
Operation....28087
4.2. Feature Code....28088
4.3. User Programmable Parameters....28088
4.4. Diagnostic Trouble Codes....28089
4.5. Troubleshooting....28090
Differential Lock Preliminary Check....28091
Differential Lock Test....28091
5. Power Divider Lock....28092
5.1. System Description....28092
Overview....28092
Operation....28092
5.2. FEATURE CODE....28093
5.3. User Programmable Parameters....28093
5.4. Diagnostic Trouble Codes....28093
5.5. Troubleshooting....28094
Power Divider Lock Preliminary Check....28095
Power Divider Lock Test....28095
6. Power Take Off....28096
6.1. System Description....28096
Overview....28096
Operation....28096
6.2. Feature Code....28096
6.3. User Programmable Parameters....28096
6.4. Diagnostic Trouble Codes....28097
6.5. Troubleshooting....28098
Power Take Off Preliminary Check....28099
Power Take Off Circuit Test....28099
7. Anti-Lock Braking System ....28100
7.1. System Description....28100
Overview....28100
Operation....28100
Communication....28101
7.2. Feature Code....28101
7.3. User Programmable Parameters....28102
7.4. Diagnostic Trouble Codes....28102
7.5. Troubleshooting....28103
Anti-Lock Braking System Preliminary Check....28103
Bendix® ABS Circuit Tests....28104
Wabco® ABS Module Circuit Test....28107
8. Fifth Wheel Slide and jaw lock release....28108
8.1. System Description....28108
Overview....28108
Operation....28109
8.2. Feature Code....28109
8.3. User Programmable Parameters....28109
8.4. Diagnostic Trouble Codes....28110
8.5. Troubleshooting....28111
Fifth Wheel Slide Preliminary Check....28111
Fifth Wheel Slide Circuit Test....28111
Fifth Wheel Jaw Lock Release Circuit Test....28112
9. Fuel Heater....28112
9.1. System Description....28112
Overview....28113
Operation....28113
9.2. Feature Code....28113
9.3. User Programmable Parameters....28113
9.4. Diagnostic Trouble Codes....28113
9.5. Troubleshooting....28113
Fuel Heater Preliminary Check....28113
Fuel Heater Circuit Test ....28114
10. Remote Power Module....28114
10.1. System Description....28114
Overview....28115
Operation....28115
10.2. Feature Code....28115
10.3. User Programmable Parameters....28116
10.4. Diagnostic Trouble Codes....28116
10.5. Troubleshooting....28119
RPM Preliminary Check....28120
RPM Circuit Test....28120
11. remote start / stop....28122
11.1. System description....28122
Overview....28122
Operation....28123
11.2. FEATURE CODE....28123
11.3. user programmable parameters....28124
11.4. diagnostic trouble codes....28124
11.5. Troubleshooting....28124
Remote Start / Stop Preliminary Check....28125
Remote Start / Stop Test....28125
12. Two-speed axle ....28127
12.1. System description....28127
Overview....28127
Operation....28127
12.2. feature codes....28127
12.3. user programmable parameters....28127
12.4. diagnostic trouble codes....28127
12.5. troubleshooting....28128
Two-Speed Switch Preliminary Check....28128
Two-Speed Switch Test....28128
13. Customer installed lift gate power source....28129
13.1. System description....28129
Overview....28129
Operation....28129
13.2. FEATURE CODE....28129
13.3. user programmable parameters....28130
13.4. diagnostic trouble codes....28130
13.5. Troubleshooting....28131
Lift Gate Preliminary Check....28131
Lift Gate Circuit Test ....28132
14. Auto neutral ....28132
14.1. System description....28132
Overview....28132
Operation....28132
14.2. FEATURE CODE....28133
14.3. user programmable parameters....28133
14.4. diagnostic trouble codes....28133
14.5. Troubleshooting....28133
Auto Neutral Preliminary Check....28134
Auto Neutral Switch Test ....28134
Auto Neutral Circuit Test....28134
15. Axle Load Monitor....28136
15.1. System Description....28136
Overview....28136
Operation....28136
15.2. Feature Code....28136
15.3. User Programmable Parameters....28137
15.4. Diagnostic Trouble Codes....28138
15.5. Troubleshooting....28139
Axle Load Monitor Preliminary Check....28139
Axle Pressure Transducer Circuit Test....28139
16. water-in-fuel monitor ....28140
16.1. System Description....28140
Overview....28140
Operation....28140
16.2. Feature Code....28140
16.3. User Programmable Parameters....28140
16.4. Diagnostic Trouble Codes....28140
16.5. Troubleshooting....28141
Water-In-Fuel Monitor Preliminary Check....28141
Water Probe Circuit Test....28142
TRANSMISSIONS....28144
1. Transmission....28146
1.1. System Description....28146
Overview....28146
Operation....28146
1.2. Feature Code....28147
1.3. user programmable parameters....28147
1.4. Diagnostic Trouble Codes....28147
1.5. Troubleshooting....28149
Transmission Preliminary Check....28149
Eaton UltraShift®® TCM Circuit Test....28150
Eaton UltraShift® Selector Circuit Test....28153
Eaton T-Handle Shifter Circuit Test....28156
Eaton Hybrid TCM Circuit Test....28156
Allison TCU Circuit Test with IBB Engine....28158
Allison Shift Selector with IBB Engine ....28160
Allison TCU Circuit Test with I6/V8 Engine....28162
Allison Shifter with I6/V8 Engine....28163
Shifter Ignition Relay Circuit Test....28164
Park Position Unlock Solenoid Test....28166
1.6. Body Controller Signals....28166
Body Controller Signals....28167
MULTIPLEXING (DATA LINKS)....28168
1. Multiplexing (Data Links)....28170
1.1. Description....28170
Overview....28170
Operation....28170
1.2. Troubleshooting....28171
J1939 Data Link Terminating Resistors....28171
Body Controller....28172
J1939 Data Link Circuit Test....28172
J1708 Data Link Circuit Test....28173
12-VOLT POWER DISTRIBUTION AND GROUND....28174
1. 12-Volt Power Distribution and Grounds....28176
1.1. Description....28176
Overview....28176
Operation....28176
1.2. Troubleshooting....28176
Battery Power Distribution Check....28177
Accessory Power Distribution Preliminary Check....28177
Accessory Power Circuit Test....28178
Body Controller Accessory Feed Input Circuit Test....28179
Ignition Power Distribution Preliminary Check....28180
Ignition Power Circuit Test....28180
Ground Circuit Test....28182
FANS AND ENGINE ACCESSORIES....28184
1. Fan System....28186
1.1. System Description....28186
Overview....28186
Operation....28186
1.2. Feature Code....28186
1.3. User Programmable Parameters....28187
1.4. Diagnostic Trouble Codes....28187
1.5. Troubleshooting....28187
Fan System Preliminary Check....28188
Fan Override Switch Test....28188
2. Compression / Exhaust Brake....28189
2.1. System Description....28189
Overview....28189
Operation....28189
2.2. Feature Code....28189
2.3. User Programmable Parameters....28190
2.4. Diagnostic Trouble Codes....28190
2.5. Troubleshooting....28190
Compression / Exhaust Brake Preliminary Check....28191
Compression / Exhaust Brake Switch Test....28191
3. Aftertreatment ....28191
3.1. System Description....28191
Overview....28191
Operation....28192
3.2. Feature Code....28194
3.3. User Programmable Parameters....28194
3.4. Diagnostic Trouble Codes....28194
3.5. Troubleshooting....28195
Aftertreatment Preliminary Check....28196
Inhibit Regeneration Switch Test....28196
Parked Regeneration Switch Test....28197
Warning Lamp Test....28197
4. Cruise Control....28198
4.1. system description....28198
Overview....28198
Operation....28198
4.2. feature codes....28199
4.3. User Programmable Parameters....28199
4.4. diagnostic trouble codes....28199
4.5. Troubleshooting....28200
Cruise Control Preliminary Check....28201
Cruise Control Switch Test....28202
5. Snow Valve....28203
5.1. System Description....28203
Overview....28203
Operation....28203
5.2. Feature Code....28204
5.3. User Programmable Parameters....28204
5.4. Diagnostic Trouble Codes....28204
5.5. Troubleshooting....28204
Snow Valve Preliminary Check....28204
Snow Valve Module Circuit Test....28205
BATTERY, CHARGING, AND CRANKING SYSTEM....28206
1. Battery System....28208
1.1. Description....28208
Overview....28208
Operation....28208
1.2. Diagnostic Trouble Codes....28209
1.3. Troubleshooting....28209
Battery Test....28209
Battery Test Results....28210
Cable Drop Test....28210
Battery Pack Test....28210
Battery Pack Test Results....28210
2. Charging System....28211
2.1. Description....28211
Overview....28211
Operation....28211
2.2. Diagnostic Trouble Codes....28211
2.3. Troubleshooting....28212
Charging System Test....28212
Charging System Test Results....28212
3. Cranking System....28213
3.1. Description....28213
Overview....28213
Operation....28213
3.2. Troubleshooting....28214
Starting System Test....28214
Starting System Test Results....28214
4. Powerpack 3....28214
4.1. Description....28214
Overview....28215
Operation....28215
4.2. Troubleshooting....28215
VEHICLE AND DRIVER INFORMATION DISPLAY....28216
1. vehicle information display....28218
1.1. System description....28218
Overview....28218
Operation....28218
1.2. FEATURE CODE....28218
1.3. user programmable parameters....28219
1.4. diagnostic trouble codes....28219
1.5. Troubleshooting....28219
Vehicle Information Display Preliminary Check....28219
Vehicle Information Display Circuit Test....28219
2. Driver information display....28220
2.1. System description....28220
Overview....28220
Operation....28221
2.2. FEATURE CODE....28221
2.3. user programmable parameters....28221
2.4. diagnostic trouble codes....28221
2.5. Troubleshooting....28221
Driver Information Display Preliminary Check....28222
Driver Information Display Circuit Test....28222
tables....27859
Table 1Ohm's Law....27859
Table 2Relay Bench Test....27872
Table 3Gauges and Signal Paths....27877
Table 4Warning Lamp and Signal Path....27878
Table 5Audible Alarms....27880
Table 6Electronic Gauge Cluster Feature Codes....27881
Table 7Diagnostic Trouble Codes....27887
Table 8EGC Preliminary Checks....27895
Table 9Electronic Gauge Cluster Circuit Test....27897
Table 10EGC Backlighting Circuit Test....27899
Table 11EGC Gauge Test....27900
Table 12Warning Lamp Test....27901
Table 13Fuel Level Gauge Circuit Test....27902
Table 14Transmission Oil Temperature Circuit Test....27903
Table 15Rear Rear Axle Temperature Circuit Test....27904
Table 16Front Rear Axle Temperature Circuit Test....27905
Table 17Air Pressure Transducer Circuit Test....27906
Table 18Park Brake Switch Circuit Test....27908
Table 19 Air Restriction Gauge Circuit Test....27909
Table 20Low Coolant Sensor Circuit Test....27909
Table 21Diagnostic Trouble Codes....27914
Table 22Switch Pack Preliminary Check....27916
Table 23Switch Pack Circuit Test....27916
Table 24J1708 Data Link Circuit Test....27917
Table 25Feature Code....27922
Table 26Diagnostic Trouble Codes....27923
Table 27Backup Lights Preliminary Checks....27924
Table 28 Backup Light Circuit Test....27924
Table 29Backup Light Switch Test....27926
Table 30Feature Code....27928
Table 31Diagnostic Trouble Codes....27928
Table 32Dome and Courtesy Lights Preliminary Checks....27929
Table 33Door Switch Circuit Test....27930
Table 34Cab Dome Light Circuit Test....27931
Table 35Courtesy Lights Circuit Test....27933
Table 36Feature Codes....27934
Table 37Diagnostic Trouble Codes....27934
Table 38Fog Light System Preliminary Check....27935
Table 39Fog Light Switch Test....27936
Table 40Fog Light Circuit Test....27937
Table 41Feature Codes....27939
Table 42Diagnostic Trouble Codes....27940
Table 43Headlight System Preliminary Check....27942
Table 44Headlight Switch Test....27943
Table 45Turn Signal Switch Circuit Test....27944
Table 46Right Headlight Circuit Test....27945
Table 47Left Headlight Circuit Test....27947
Table 48Feature Codes....27948
Table 49Diagnostic Trouble Codes....27948
Table 50Stop, Turn, and Hazards System Preliminary Check....27951
Table 51Turn Signal Switch Circuit Test....27952
Table 52Brake Switch Circuit Test....27954
Table 53Left Front Turn Signal Circuit Test....27956
Table 54Right Front Turn Signal Circuit Test....27957
Table 55Left Rear Turn Signal Circuit Test....27957
Table 56Right Rear Turn Signal Circuit Test....27958
Table 57Feature Codes....27959
Table 58Diagnostic Trouble Codes....27959
Table 59Tail, Marker, Park, and Clearance Lighting Preliminary C....27960
Table 60Headlight Switch Test....27961
Table 61Tail Light Circuit Test....27962
Table 62Park, Marker, Clearance, and Identification Lights Circu....27962
Table 63Feature Codes....27963
Table 64Diagnostic Trouble Codes....27964
Table 65Work Light System Preliminary Check....27965
Table 66Work Light Switch Test....27965
Table 67Work Light Circuit Test....27966
Table 68Feature Codes....27967
Table 69Lighted Air Shield DTC....27968
Table 70Roof Auxiliary Load Preliminary Check....27968
Table 71Lighted Air Shield Preliminary Check....27969
Table 72Roof Auxiliary Load Switch Test....27970
Table 73Roof Auxiliary Load Circuit Test....27971
Table 74Lighted Air Shield Circuit Test....27971
Table 75Feature Codes....27972
Table 76Diagnostic Trouble Codes....27973
Table 77Trailer Lights Preliminary Check....27974
Table 78Trailer Socket Circuit Test....27974
Table 79Trailer Left Turn Relay Circuit Test....27976
Table 80Trailer Right Turn Relay Circuit Test....27977
Table 81Trailer Marker Light Relay Circuit Test....27978
Table 82Trailer Tail Light Relay Circuit Test....27979
Table 83Trailer Stop Light Relay Circuit Test....27980
Table 84Trailer ABS ECU Relay Circuit Test....27981
Table 85Feature Code....27982
Table 86Diagnostic Trouble Codes....27982
Table 87Auxiliary Snowplow Lights Preliminary Checks....27983
Table 88 Snowplow Switch Test....27984
Table 89Snowplow Lights Circuit Test....27984
Table 90Cigar Lighter and Power Feed Preliminary Check....27993
Table 91Cigar Lighter Circuit Test....27993
Table 92Two-Post Power Source Circuit Test....27993
Table 93CB Radio Power Source Preliminary Check....27995
Table 94CB Radio Circuit Test....27995
Table 95Feature Codes....27996
Table 96Diagnostic Trouble Codes....27996
Table 97Compass and Temperature Display Preliminary Check....27998
Table 98Compass Display Circuit Test....27999
Table 99Ambient Temperature Sensor Circuit Test....28002
Table 100Feature Codes....28003
Table 101Diagnostic Trouble Codes....28004
Table 102Power Locks Preliminary Check....28007
Table 103Power Windows Preliminary Check....28007
Table 104Locks and Windows Inoperative Circuit Test....28007
Table 105Power Window Circuit Test....28008
Table 106Power Door Lock Circuit Test....28009
Table 107Feature Codes....28009
Table 108Diagnostic Trouble Codes....28011
Table 109Electric Horn Preliminary Check....28011
Table 110Electric Horn Circuit Test....28012
Table 111Feature Codes....28013
Table 112Diagnostic Trouble Codes....28014
Table 113Air Horn Preliminary Checks....28014
Table 114Air Horn Circuit Test....28015
Table 115Power Mirror Preliminary Check....28017
Table 116Driver Power Mirror Circuit Test....28017
Table 117Passenger Power Mirror Circuit Test....28018
Table 118Feature Codes....28019
Table 119Diagnostic Trouble codes....28020
Table 120Heated Mirror Preliminary Check....28020
Table 121Heated Mirror Switch Test....28021
Table 122Driver Heated Mirror Circuit Test....28021
Table 123Passenger Heated Mirror Circuit Test....28022
Table 124Heated Windshield Circuit Test....28023
Table 125Radio Preliminary Check....28025
Table 126Radio Circuit Test (16 Way Connector)....28026
Table 127Radio Circuit Test (12 Way Connector)....28026
Table 128Speaker Circuit Test (16 Way Connector)....28027
Table 129Speaker Circuit Test (12 Way Connector)....28028
Table 130Two-Way Radio Circuit Test....28029
Table 131Feature Codes....28030
Table 132Diagnostic Trouble Codes....28032
Table 133Wiper and Washer Preliminary Check....28033
Table 134Washer Pump Circuit Test....28034
Table 135Wiper Switch Circuit Test....28035
Table 136Wiper Motor Circuit Test....28036
Table 137Feature Codes....28037
Table 138Diagnostic Trouble Codes....28038
Table 139Brake Switch Preliminary Check....28039
Table 140Brake Switch Circuit Test....28040
Table 141Park Brake Switch Circuit Test....28041
Table 142Feature Code....28044
Table 143Diagnostic Trouble Codes....28044
Table 144Clutch Switch Preliminary Checks....28045
Table 145Engine Crank Clutch Switch Test....28046
Table 146Cruise Control Clutch Switch Test....28048
Table 147Feature Code....28049
Table 148Diagnostic Trouble Codes....28050
Table 149Latching Relay Circuit Test....28051
Table 150Vehicle Data Recorder Preliminary Check....28052
Table 151 Vehicle Data Recorder Circuit Test....28053
Table 152VDR Brake Pressure Switch Circuit Test....28054
Table 153VDR Headlight Input Relay Circuit Test....28055
Table 154Feature Code....28056
Table 155Diagnostic Trouble Codes....28057
Table 156Theft Deterrent Preliminary Check....28058
Table 157Theft Deterrent System Test....28058
Table 158Feature Code....28060
Table 159Seat Belt Preliminary Check....28061
Table 160Seat Belt Indicator Circuit Test....28062
Table 161Driver and Passenger Self-Contained Air Seats Prelimina....28063
Table 162Driver and Passenger Self-Contained Air Seat Test....28064
Table 163Driver and Passenger Heated Seats Preliminary Check....28065
Table 164Driver and Passenger Heated Seat Test....28066
Table 165Air Dryer and Heated Drain Valve Preliminary Check....28072
Table 166Heated Drain Valve Circuit Test....28073
Table 167Air Dryer Circuit Test....28074
Table 168Feature Codes....28075
Table 169Diagnostic Trouble Codes....28075
Table 170Air Solenoid Preliminary Check....28081
Table 171Air Solenoid Circuit Test....28082
Table 172Feature Code....28083
Table 173Diagnostic Trouble Codes....28084
Table 174Suspension Dump Preliminary Check....28086
Table 175Suspension Dump Test....28086
Table 176Feature Codes....28088
Table 177Diagnostic Trouble Codes....28089
Table 178Differential Lock Preliminary Check....28091
Table 179Differential Lock Test....28091
Table 180Feature Code....28093
Table 181Diagnostic Trouble Codes....28094
Table 182Power Divider Lock Preliminary Check....28095
Table 183Power Divider Lock Test....28095
Table 184Feature Code....28096
Table 185Diagnostic Trouble Codes....28097
Table 186Power Take Off Preliminary Check....28099
Table 187Power Take Off Circuit Test....28099
Table 188Feature Code....28101
Table 189Diagnostic Trouble Codes....28103
Table 190Anti-Lock Braking System Preliminary Check....28103
Table 191Bendix® ABS Module Circuit Test....28104
Table 192Bendix® Steering Wheel Sensor Circuit Test....28106
Table 193Bendix® Yaw Sensor Circuit Test....28106
Table 194Wabco® ABS Module Circuit Test....28107
Table 195Feature Code....28109
Table 196Diagnostic Trouble Codes....28110
Table 197Fifth Wheel Slide Preliminary Check....28111
Table 198Fifth Wheel Slide Circuit Test....28111
Table 199Fifth Wheel Jaw Lock Release Circuit Test....28112
Table 200Fuel Heater Preliminary Check....28113
Table 201Fuel Heater Circuit Test ....28114
Table 202Diagnostic Trouble Codes....28116
Table 203RPM Preliminary Check....28120
Table 204RPM Circuit Test....28120
Table 205Feature Code....28123
Table 206Diagnostic Trouble Codes....28124
Table 207Remote Start / Stop Preliminary Check....28125
Table 208Remote Start / Stop Test....28125
Table 209Feature Codes....28127
Table 210Diagnostic Trouble Codes....28127
Table 211Two-Speed Switch Preliminary Check....28128
Table 212Two-Speed Switch Test....28128
Table 213Feature Code....28129
Table 214Diagnostic Trouble Codes....28130
Table 215Lift Gate Preliminary Check....28131
Table 216Lift Gate Test ....28132
Table 217Feature Code....28133
Table 218Diagnostic Trouble Codes....28133
Table 219Auto Neutral Preliminary Check....28134
Table 220Auto Neutral Switch Test ....28134
Table 221Auto Neutral Circuit Test ....28134
Table 222Feature Code....28136
Table 223Diagnostic Trouble Codes....28138
Table 224Axle Load Monitor Preliminary Check....28139
Table 225Axle Pressure Transducer Circuit Test....28139
Table 226Diagnostic Trouble Codes....28141
Table 227Water-In-Fuel Monitor Preliminary Check....28141
Table 228Water Probe Circuit Test....28142
Table 229Feature Code....28147
Table 230Diagnostic Trouble Codes....28148
Table 231Transmission Preliminary Check....28149
Table 232Eaton UltraShift® TCM Circuit Test....28151
Table 233Eaton UltraShift® Selector Circuit Test....28153
Table 234Eaton UltraShift® Selector Lighting Circuit Test ....28155
Table 235Eaton T-Handle Shifter Circuit Test....28156
Table 236Eaton T-Handle Shifter Lighting Circuit Test....28156
Table 237Eaton Hybrid TCM Circuit Test....28157
Table 238Allison TCU Circuit Test with IBB Engine....28159
Table 239Allison Shift Selector Circuit Test....28160
Table 240Allison Shift Selector Lighting Circuit Test....28162
Table 241Allison TCU Circuit Test with I6/V8 Engine....28162
Table 242Allison Column Mounted Shifter ....28163
Table 243Allison T-Handle Shifter ....28164
Table 244Shifter Ignition Relay Circuit Test....28165
Table 245Park Position Unlock Solenoid Test....28166
Table 246Body Controller Signals....28167
Table 247J1939 Data Link Circuit Test....28173
Table 248J1708 Data Link Circuit Test....28173
Table 249Battery Power Distribution Preliminary Check....28177
Table 250Accessory Power Distribution Check....28177
Table 251Accessory Power Circuit Test....28178
Table 252Body Controller Accessory Feed Input Circuit Test....28179
Table 253Ignition Power Distribution Check....28180
Table 254Ignition Power Circuit Test....28180
Table 255Ground Circuit Test....28182
Table 256Feature Code....28187
Table 257Diagnostic Trouble Codes....28187
Table 258Fan System Preliminary Check....28188
Table 259Fan Override Switch Test....28188
Table 260Feature Code....28189
Table 261Diagnostic Trouble Codes....28190
Table 262Compression / Exhaust Brake Preliminary Check....28191
Table 263Compression Brake Switch Test....28191
Table 264Soot Accumulation Level Indications....28193
Table 265Feature Code....28194
Table 266Diagnostic Trouble Codes....28194
Table 267Aftertreatment Preliminary Check....28196
Table 268Inhibit Regeneration Switch Test....28196
Table 269Parked Regeneration Switch Test....28197
Table 270Warning Lamp Test....28197
Table 271Feature Code....28199
Table 272Diagnostic Trouble Codes....28200
Table 273Cruise Control Preliminary Check....28201
Table 274Cruise Control Switch Test....28202
Table 275Feature Code....28204
Table 276Snow Valve Preliminary Check....28204
Table 277Snow Valve Module Circuit Test....28205
Table 278Diagnostic Trouble Codes....28209
Table 279Diagnostic Trouble Codes....28211
Table 280Feature Code....28219
Table 281Vehicle Information Display Preliminary Check....28219
Table 282Vehicle Information Display Circuit Test....28219
Table 283Feature Code....28221
Table 284Driver Information Display Preliminary Check....28222
Table 285Driver Information Display Circuit Test....28222
S09006 - Hood, Grille, Fenders and Bumper - 8500 (June 2002) Service Manual....28226
toc....28226
Table of Contents....28228
1. Description....28230
1.1. BUMPER....28230
1.2. HOOD....28231
1.3. SPLASH PANELS....28231
1.4. MUD GUARDS....28232
1.5. GRILLE....28233
1.6. AIR INTAKES....28234
1.7. FENDERS....28234
1.8. FENDER EXTENSIONS....28235
1.9. HOOD SEAL....28236
2. REMOVE AND INSTALL....28237
2.1. BUMPER....28237
Bumper Removal....28237
Bumper Install....28238
2.2. HOOD....28238
Hood Removal....28238
Hood Install....28244
2.3. SPLASH PANELS....28245
Splash Panel Removal: Passenger Side....28245
Splash Panel Removal: Drivers Side....28246
Splash Panel Install....28246
2.4. MUD GUARDS....28247
Mud Guard Removal....28247
Mud Guard Install....28248
2.5. GRILLE....28248
Grille Removal....28248
Grille Install....28249
2.6. AIR INTAKES....28250
Air Intake Removal....28250
Air Intake Install....28251
2.7. FENDERS....28251
Fender Lower Section Removal....28252
Valance Removal....28253
Fender Valance Install....28253
Headlight Removal....28253
Headlight Install....28254
Clearance Light Removal....28255
Clearance Light Install....28256
Hood Latch Upper Remove....28257
Upper Hood Latch Install....28258
2.8. FENDER EXTENSIONS....28259
Fender Extension Removal....28259
Fender Extension Install....28260
Hood Latch Lower Assembly Removal....28261
Lower Hood Latch Install....28262
2.9. HOOD SEAL....28262
Hood Seal Removal....28262
Hood Seal Install....28263
3. ADJUSTMENTS....28264
3.1. HOOD ADJUSTMENT AND ALIGNMENT....28264
3.2. HOOD STOP ADJUSTMENT....28264
3.3. HEADLIGHT ADJUSTMENT....28265
3.4. HEADLAMP REPLACEMENT....28266
tables....28226
Torque Chart....28268
S09008 - Hood, Grille, Fenders and Bumper - 8600 (Nov 2002) Service Manual....28270
S09016 - Hood, Grille, Fenders and Bumper (Dec 2009) Service Manual....28321
toc....28323
Table of Contents....28323
1. Description....28325
1.1. Bumper....28325
1.2. Grille....28325
1.3. Hood Assembly....28326
1.4. Hood Tilt Assist....28326
1.5. Hood Seal....28326
1.6. Splash Shields....28326
1.7. Air Intake Grilles....28326
1.8. Fender....28326
1.9. Fender Extensions....28327
1.10. Headlight Assembly....28327
2. Removal and Installation Procedures....28328
2.1. Bumper....28329
Bumper – Removal....28329
Bumper – Installation....28329
2.2. Grille and Bug Screen....28330
WorkStar® Grille and Bud Screen – Removal....28330
WorkStar® Grille and Bug Screen – Installation....28331
WorkStar® Grille Shroud – Removal....28331
WorkStar® Grille Shroud – Installation....28332
TranStar® Grille and Bug Screen – Removal....28333
TranStar® Grille and Bug Screen – Installation....28334
2.3. Splash Panels....28335
WorkStar® Splash Panel – Removal....28335
WorkStar® Splash Panel – Installation....28335
WorkStar® Upper Splash Panel – Removal....28336
WorkStar® Upper Splash Panel – Installation....28336
TranStar® Splash Panels – Removal....28337
TranStar® Splash Panel – Installation....28338
2.4. Hood....28339
WorkStar® – Removal....28339
WorkStar® Hood – Installation....28345
TranStar® Hood – Removal....28347
TranStar® Hood – Installation....28352
Hood – Adjustment....28353
Hood Stop – Adjustment....28356
Hood Hatch – Removal (if equipped)....28357
Hood Hatch – Installation (if equipped)....28357
2.5. Hood Tilt Assist....28358
Hood Tilt Assist – Removal....28358
Hood Tilt Assist – Installation....28359
2.6. Torsion Bars....28360
WorkStar® Torsion Bar – Removal....28360
WorkStar® Torsion Bar – Installation....28362
TranStar® Torsion Bar – Removal....28363
TranStar® Torsion Bar – Installation....28365
2.7. Hood Latch....28366
WorkStar® Hood Latch – Removal....28366
WorkStar® Hood Latch – Installation....28367
TranStar® Hood Latch – Removal....28368
TranStar® Hood Latch – Installation....28368
2.8. Hood Seal....28369
WorkStar® Hood Seal – Removal....28369
WorkStar® Hood Seal – Installation....28369
TranStar® Hood Seal – Removal....28370
TranStar® Hood Seal – Installation....28370
2.9. Air Intake Grille....28371
Air Intake Grille – Removal....28371
Air Intake Grille – Installation....28371
2.10. Fender Extensions....28372
WorkStar® Fender Extensions – Removal....28372
WorkStar® Fender Extensions – Installation....28372
TranStar® Fender Extensions – Removal....28373
TranStar® Fender Extensions – Installation....28373
2.11. Fenderettes....28374
Fenderette – Removal (if equipped)....28374
Fenderette – Installation (if equipped)....28374
2.12. High Beam Headlight Assembly....28375
WorkStar® High Beam Headlight Assembly – Removal....28375
WorkStar® High Beam Headlight Assembly – Installation....28376
WorkStar® High Beam Headlight Bulb – Removal....28377
WorkStar® High Beam Headlight Bulb – Installation....28377
WorkStar® High Beam Headlight Adjustment....28377
WorkStar® Turn Signal Bulb – Removal....28379
WorkStar® Turn Signal Bulb – Installation....28379
TranStar® High Beam Headlight Assembly – Removal....28380
TranStar® High Beam Headlight Assembly – Installation....28381
TranStar® High Beam Bulb Replacement....28381
TranStar® High Beam Headlight Adjustment ....28382
2.13. Low Beam Headlight Assembly....28383
WorkStar® Low Beam Headlight Assembly – Removal....28383
WorkStar® Low Beam Headlight Assembly – Installation....28383
TranStar® Low Beam Headlight Assembly – Removal....28384
TranStar® Low Beam Headlight Assembly – Installation....28385
Low Beam Bulb Replacement ....28385
tables....28386
Table 1Torque Chart....28386
S11001S - Spicer 14-Inch (356 mm) and 15 1_2-Inch (394 mm) Two-Plate, Pull-Type Clutch Supersedes CTS-5043S (March 1996) Service Manual....28387
S11003 - Spicer 14-Inch (355.6 mm) Stamped Angle-Spring Clutch Supersedes CTS-5140 (March 1996) Service Manual....28422
S11004 - Spicer 14 Inch (350 mm) Solo Clutch Supersedes CTS-5256 (March 1996) Service Manual....28468
S11006R - Clutch Control Linkage Supersedes CTS-5053R (Oct 2002) Service Manual....28502
S11014 - Hydraulic Clutch Service Manual 2010 Service Manual....28518
S11018 - 2011 Hydraulic Clutch Service Manual....28547
S12001J - Fan Drive Clutch_ Kysor 1090 Supersedes CTS-5015J (March 1996) Service Manual....28576
S12004R - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual....28598
S12005 - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual....28626
S12008 - Radiator, Removal and Replacement (2012) Service Manual....28645
cover....28645
S12008....28647
RADIATOR, REMOVE AND REPLACE....28647
DESCRIPTION....28647
RADIATOR AND COMPONENT REMOVAL....28647
CROSS-MEMBER....28647
SURGE TANK....28650
CHARGE AIR COOLER PIPES....28653
COOLING SYSTEM RADIATOR HOSE....28655
RADIATOR....28658
RADIATOR SHROUD AND FRAME....28659
CHARGE AIR COOLER....28662
RADIATOR CORE....28662
RADIATOR AND COMPONENT INSTALLATION....28662
RADIATOR CORE....28662
RADIATOR HOSE....28662
CHARGE AIR COOLER PIPES....28665
SURGE TANK....28665
FRONT CROSS-MEMBER....28666
S12011 - Radiator _ Cooling System (Aug 2012) Service Manual....28667
toc....28669
Table of Contents....28669
1. Description....28671
1.1. Deaeration Tank....28673
1.2. Fan Shroud....28673
1.3. A/C Condenser....28673
1.4. Transmission Oil Cooler....28673
1.5. Radiator....28673
1.6. Charge Air Cooler....28673
1.7. Low Temperature Radiator....28673
1.8. Fan Drive....28673
2. COOLING PACKAGE COMPONENTS....28674
2.1. Coolant Drain, Pressure Test, and Fill Procedures....28675
Coolant Drain Procedure (Recommended)....28678
Pressure Test Procedure (Recommended)....28680
Coolant Fill Procedure (Recommended)....28681
Coolant Drain Procedure (Optional)....28683
Coolant Fill Procedure (MaxxForce® DT, 9, and 10 Engines) (Optional)....28684
Coolant Fill Procedure (MaxxForce® 11 and 13 Engines) (Optional)....28685
2.2. Grille....28687
Grille - Removal....28687
Grille - Installation....28688
2.3. Deaeration Tank....28689
Deaeration Tank - Removal....28689
Deaeration Tank - Installation....28690
2.4. Expansion Tank....28691
Expansion Tank - Removal....28691
Expansion Tank - Installation....28691
2.5. A/C Condenser....28692
A/C Condenser with Charge Air Cooler - Removal....28692
A/C Condenser with Charge Air Cooler - Installation....28693
A/C Condenser with Dual Radiators - Removal....28694
A/C Condenser with Dual Radiators - Installation....28696
2.6. Fan Shroud....28697
Fan Shroud with Charge Air Cooler - Removal....28697
Fan Shroud with Charge Air Cooler- Installation....28702
Fan Shroud with Dual Radiators - Removal....28703
Fan Shroud with Dual Radiators - Installation....28706
2.7. Radiator Fan....28707
Radiator Fan with Charge Air Cooler - Removal....28707
Radiator Fan with Charge Air Cooler - Installation....28707
Radiator Fan with Dual Radiators - Removal....28707
Radiator Fan with Dual Radiators - Installation....28708
2.8. Fan Belt....28709
Fan Belt - Removal....28709
Fan Belt - Installation....28710
2.9. Fan Drive Assembly....28711
Fan Drive Assembly - Removal....28711
Fan Drive Assembly - Installation....28713
Viscous Fan Drive - Removal....28714
Viscous Fan Drive - Installation....28716
2.10. Transmission Oil Cooler....28717
Transmission Oil Cooler - Removal....28717
Transmission Oil Cooler - Installation....28719
Transmission Oil Cooler (13WAW) - Removal....28720
Transmission Oil Cooler (13WAW) - Installation....28721
2.11. Radiator Hose....28722
Heat Shrink Clamp - Removal....28722
Heat Shrink Clamp - Installation....28723
Radiator Hose with Charge Air Cooler - Removal....28726
Radiator Hose with Charge Air Cooler - Installation....28729
Radiator Hose with Dual Radiators - Removal....28730
Radiator Hose with Dual Radiators - Installation....28732
2.12. Charge Air Cooler....28733
Charge Air Cooler - Removal....28733
Charge Air Cooler - Installation....28736
2.13. Low Temperature Radiator....28738
Low Temperature Radiator - Removal....28738
Low Temperature Radiator - Installation....28742
2.14. Radiator Assembly....28744
Radiator Assembly with Charge Air Cooler - Removal....28744
Radiator Assembly with Charge Air Cooler - Installation....28750
Radiator Assembly with Dual Radiators - Removal....28752
Radiator Assembly with Dual Radiators - Installation....28758
2.15. Radiator Core....28761
Radiator Core with Charge Air Cooler - Removal....28761
Radiator Core with Charge Air Cooler - Installation....28766
Radiator Core with Dual Radiators - Removal....28767
Radiator Core with Dual Radiators - Installation....28771
tables....28772
Table 1Torque Chart....28772
S12021 - 2007 MY ProStar _ LoneStar Radiator _ Cooling System (Aug 2012) Service Manual....28775
toc....28777
Table of Contents....28777
1. DESCRIPTION....28779
1.1. Deaeration Tank....28780
1.2. Fan Shroud....28780
1.3. A/C Condenser....28780
1.4. Transmission Oil Cooler....28781
1.5. Radiator....28781
1.6. Charge Air Cooler....28781
1.7. Low Temperature Radiator....28781
1.8. Fan Drive....28781
1.9. Power Steering Oil Cooler....28781
2. COOLING PACKAGE COMPONENTS....28782
2.1. Coolant Drain, Pressure Test, and Fill Procedures....28783
Coolant Drain Procedure (Recommended)....28786
Pressure Test Procedure (Recommended)....28788
Coolant Fill Procedure (Recommended)....28789
Coolant Drain Procedure (MaxxForce® 11 and 13 Engines) (Optional)....28791
Coolant Fill Procedure (MaxxForce® 11 and 13 Engines) (Optional)....28791
2.2. Deaeration Tank....28794
Deaeration Tank - Removal....28794
Deaeration Tank - Installation....28795
2.3. Expansion Tank....28796
Expansion Tank - Removal....28796
Expansion Tank - Installation....28796
2.4. A/C Condenser....28797
A/C Condenser with Charge Air Cooler - Removal....28797
A/C Condenser with Charge Air Cooler - Installation....28798
A/C Condenser with Dual Radiators - Removal....28799
A/C Condenser with Dual Radiators - Installation....28801
2.5. Fan Shroud....28802
Fan Shroud with Charge Air Cooler - Removal....28802
Fan Shroud with Charge Air Cooler - Installation....28807
Fan Shroud with Dual Radiators - Removal....28808
Fan Shroud with Dual Radiators - Installation....28811
2.6. Radiator Fan....28812
Radiator Fan with Charge Air Cooler - Removal....28812
Radiator Fan with Charge Air Cooler - Installation....28812
Radiator Fan with Dual Radiators - Removal....28812
Radiator Fan with Dual Radiators - Installation....28813
2.7. Fan Belt....28814
Fan Belt - Removal....28814
Fan Belt - Installation....28815
2.8. Fan Drive Assembly....28816
Fan Drive Assembly - Removal....28816
Fan Drive Assembly - Installation....28818
Viscous Fan Drive - Removal....28819
Viscous Fan Drive - Installation....28821
2.9. Transmission Oil Cooler....28822
Transmission Oil Cooler - Removal....28822
Transmission Oil Cooler - Installation....28825
2.10. Radiator Hose....28826
Heat Shrink Clamp - Removal....28826
Heat Shrink Clamp - Installation....28827
Radiator Hoses with Charge Air Cooler - Removal....28830
Radiator Hoses with Charge Air Cooler - Installation....28833
Radiator Hoses with Dual Radiators - Removal....28834
Radiator Hoses with Dual Radiators - Installation....28836
2.11. Charge Air Cooler....28837
Charge Air Cooler - Removal....28837
Charge Air Cooler - Installation....28841
2.12. Low Temperature Radiator....28844
Low Temperature Radiator - Removal....28844
Low Temperature Radiator - Installation....28848
2.13. Radiator Assembly....28850
Radiator Assembly with Charge Air Cooler - Removal....28850
Radiator Assembly with Charge Air Cooler - Installation....28857
Radiator Assembly with Dual Radiators - Removal....28859
Radiator Assembly with Dual Radiators - Installation....28865
2.14. Radiator Core....28868
Radiator Core with Charge Air Cooler - Removal....28868
Radiator Core with Charge Air Cooler - Installation....28873
Radiator Core with Dual Radiators - Removal....28874
Radiator Core with Dual Radiators - Installation....28878
2.15. Power Steering Oil Cooler....28879
Power Steering Oil Cooler with Charge Air Cooler - Removal....28879
Power Steering Oil Cooler with Charge Air Cooler - Installation....28880
tables....28881
Table 1Torque Chart....28881
S12036 - Radiator_Cooling System (2010) Service Manual....28884
S13006H - 6 Speed Transmissions International Model ES52-7A and ESO65-7A 6-Plus Service Manual....28961
S13007 - 13 Speed & 18 Speed Transmissions Eaton RTLO-713 _ 18 Series Supersedes CTS-5176 (June 1996) Service Manual....29045
S13008 - 6 Speed Transmissions Eaton Series FS-5106 and FS-6206 Supersedes CTS-5179 (June 1996) Service Manual....29211
S13016 - 7 Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual....29291
S13017 - 10 Speed Transmissions Eaton RTLO Series Supersedes CTS-5196 (March 1996) Service Manual....29354
S13018 - 8 Speed, 9 Speed, And 13 Speed Transmissions Eaton Series Supersedes CTS-5205 (June 1996) Service Manual....29505
S14002 - 2 SPEED AXLE SHIFT UNIT_ EATON (Supersedes CTS-5166) Service Manual....29731
S14004 - SINGLE REDUCTION, TANDEM AXLES_ SPICER J400-S, W460-S (Supersedes CTS-5259) Service Manual....29763
S14006T - SINGLE REDUCTION CARRIERS_ ROCKWELL (Supersedes CTS-5080T) Service Manual....29856
S14008T - SINGLE SPEED REAR AXLE_ INTERNATIONAL (Supersedes CTS-5108T) Service Manual - Truck8_21_2012 12_00_00 AM....29975
S14013 - SINGLE REDUCTION, TANDEM DRIVE AXLES_ EATON (Supersedes CTS-5213) Service Manual....30026
S14016 - 2 SPEED AND DOUBLE REDUCTION SINGLE DRIVE AXLES_ EATON (Supersedes CTS-5195) Service Manual....30055
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual....30097
S16003 - Repair Instructions for Fiberglass and Plastic (ABS) Material (Formerly CTS-5173) Service Manual....30107
S16007S - Cab_ 2000, 4000, AND 8000 (Formerly CTS-5130S) Service Manual....30153
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual....30230
S16016 - Air Conditioning - Heater System_ 2000, 4000, and 8000 - 12_06_1994 and After Formerly (CTS-5227) Service Manual....30276
S16017X - Air Conditioning Compressor and Clutch, Two Cylinder Reciprocating Type - After 01_01_1993 (R-134A) (Formerly CTS-5241) Service Manual....30315
S16022Y - Air Conditioning Protection and Diagnostic System (APAds) Description, Operation, Troubleshooting, Remove, Install, and Electrical Circuit Diagrams Maintenance Manual....30342
S16025 - HEAT VENTILATION AIR CONDITIONING (HVAC), Orifice Tube System, Pre-March 2007 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600Manual - Truck2_16_2011 12_00_00 AM....30408
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 Service Manual....30654
S16038 - CAB_ 7300, 7400, 7500, 7600, 7700, 8500, 8600, TranStar, and WorkStar Models Service Manual....30801
S16039 - Heat Ventilation Air Conditioning (HVAC) System and TXV System For 2007 Service Manual....31002
S16043 - 2009 12V DC No Idle HVAC Service Manual....31193
S16046 - 3200 Bus, DuraStar, TerraStar, TranStar, WorkStar Models Heat Ventilation Air Conditioning (HVAC) for 2010 Service Manual....31293
S16053 - Heat Ventilation Air Conditioning (HVAC) for 2010 - South Africa _ 7000 RHD AND 8000 RHD Service Manual....31443
s04010 - Air Compressor_ Bendix TU-FLO 501, Supersedes CTS-5145 (March 1996) Service Manual....31594
s09002 - Hood, Grille, and Fenders - 2000, 4000, 8000 (Supersedes CTS-5269) (Feb 1999) Service Manual....31624
toc....31626
Table of Contents....31626
1. DESCRIPTION....31630
1.1. HOOD....31630
1.2. SPLASH PANELS....31633
1.3. MUD GUARDS....31635
1.4. HOOD SEALS....31638
1.5. GRILLE....31639
1.6. AIR INTAKES....31642
1.7. FENDERS....31643
1.8. SPLASH SHIELDS....31644
2. REMOVE AND INSTALL....31644
2.1. 2000 SERIES HOOD....31644
2500 and 2600 Model Original Hood — Remove....31644
2500 and 2600 Model Original Hood — Install....31646
2600 Model Aerodynamic Hood (After March, 1996) — Remove....31647
2600 Model Aerodynamic Hood (After March, 1996) — Install....31649
2.2. 4000 SERIES HOOD....31650
4700 Thru 4900 Model Hood — Remove....31650
4700 Thru 4900 Model Hood — Install....31652
2.3. 8000 SERIES HOOD....31653
8100 Model Hood (Before June 1994) — Remove....31653
8100 Model Hood (Before June 1994) — Install....31655
8100 Model Hood (After June 1994) — Remove....31656
8100 Model Hood (After June 1994) — Install....31657
8200 Model Hood — Remove....31658
8200 Model Hood — Install....31660
2.4. 2000 SERIES SPLASH PANELS....31661
2500 and 2600 Model Splash Panels (Original Hood) — Remove....31661
2500 and 2600 Model Splash Panels (Original Hood) — Install....31664
2600 Model Splash Panels (Aerodynamic Hood After March 1996) — R....31665
2600 Model Splash Panels (Aerodynamic Hood After March 1996) — I....31667
2.5. 4000 SERIES SPLASH PANELS....31668
4700 Thru 4900 Model Splash Panels — Remove....31668
4700 Thru 4900 Model Splash Panels — Install....31668
2.6. 8000 SERIES SPLASH PANELS....31669
8100 Model Splash Panels — Remove....31669
8100 Model Splash Panels — Install....31669
8200 Model Splash Panels — Remove....31669
8200 Model Splash Panels — Install....31672
2.7. 2000 SERIES MUD GUARDS....31672
2500 and 2600 Model Rear Mud Guard (Original Hood) — Remove....31672
2500 and 2600 Model Rear Mud Guard (Original Hood) — Install....31673
2600 Model Only-Outer Edge Fender and Fender Extension Mud Guard....31673
2600 Model Only-Outer Edge Fender and Fender Extension Mud Guard....31675
2600 Model Rear Mud Guard (Aerodynamic Hood After March 1996) — ....31675
2600 Model Rear Mud Guard (Aerodynamic Hood After March 1996) — ....31676
2.8. 4000 SERIES MUD GUARDS....31676
4700 Thru 4900 Model Mud Guard — Remove....31676
4700 Thru 4900 Model Mud Guard — Install....31677
2.9. 8000 SERIES MUD GUARDS....31677
8100 Model Mud Guard — Remove....31677
8100 Model Mud Guard — Install....31678
8200 Model Mud Guard — Remove....31678
8200 Model Mud Guard — Install....31679
2.10. 2000 SERIES HOOD SEALS....31679
2500 and 2600 Model with Original Hood, Cab Cowl Hood Seal — Rem....31679
2500 and 2600 Model with Original Hood, Cab Cowl Hood Seal — Ins....31679
2600 Model with Aerodynamic Hood After March 1996, Cab Cowl Hood....31679
2600 Model with Aerodynamic Hood After March 1996, Cab Cowl Hood....31680
2600 Model with Original Hood, Fender Extension Hood Seal — Remo....31680
2600 Model with Original Hood, Fender Extension Hood Seal — Inst....31681
2600 Model with Aerodynamic Hood After March 1996, Fender Extens....31681
2600 Model with Aerodynamic Hood After March 1996, Fender Extens....31681
2.11. 4000 SERIES HOOD SEALS....31682
4700 Thru 4900 Model Hood Seal — Remove....31682
4700 Thru 4900 Model Hood Seal — Install....31683
2.12. 8000 SERIES HOOD SEALS....31683
8100 Model Hood Seal — Remove....31683
8100 Model Hood Seal — Install....31684
8200 Model Hood Seal — Remove....31684
8200 Model Hood Seal — Install....31684
2.13. 2000 SERIES GRILLE....31684
2500 and 2600 Model Grille (Original Hood) — Remove....31684
2500 and 2600 Model Grille (Original Hood) — Install....31685
2500 and 2600 Model Stationary Grille (Original Hood), Grille Tr....31686
2500 and 2600 Model Stationary Grille (Original Hood), Grille Tr....31687
2500 and 2600 Model Stationary Grille (Original Hood), Vertical ....31687
2500 and 2600 Model Stationary Grille (Original Hood), Vertical ....31687
2600 Model Grille (Aerodynamic Hood After March 1996), Upper Gri....31688
2600 Model Grille (Aerodynamic Hood After March 1996), Upper Gri....31689
2600 Model Grille (Aerodynamic Hood After March 1996), Lower Gri....31689
2600 Model Grille (Aerodynamic Hood After March 1996), Lower Gri....31690
2.14. 4000 SERIES GRILLE....31690
4700 thru 4900 Model Standard Grille....31690
4700 thru 4900 Model Stationary Grille — Remove....31690
4700 thru 4900 Model Stationary Grille — Install....31691
2.15. 8000 SERIES GRILLE....31691
8100 Model Grille....31691
8200 Model Grille, Upper Grille — Remove....31692
8200 Model Grille, Upper Grille — Install....31693
8200 Model Grille, Lower Grille — Remove....31693
8200 Model Grille, Lower Grille — Install....31693
3. ADJUSTMENTS....31694
3.1. RADIATOR....31694
2000 Series....31694
4000 Series — Forward Radiator Adjustment....31694
4000 Series — Rearward Radiator Adjustment....31696
8000 Series, 8100 Model (Before June 1994) — Forward Radiator Ad....31696
8000 Series, 8100 Model (Before June 1994) — Rearward Radiator A....31698
8000 Series, 8100 Model (After June 1994)....31698
8000 Series, 8200 Model....31698
3.2. HOOD....31698
2000 Series — 2500 and 2600 Hood Adjustment Forward or Back at t....31699
2000 Series — 2500 and 2600 Hood Adjustment Up or Down at the Lo....31701
2000 Series — 2500 and 2600 Hood Adjustment Side-to-Side at the ....31702
2000 Series — 2600 Hood Adjustment Forward or Back at the Lower ....31703
2000 Series — 2600 Hood Adjustment Side-to-Side at the Lower Hin....31705
4000 Series — 4700, 4800 and 4900 Hood Adjustment Forward or Bac....31706
4000 Series — 4700, 4800 and 4900 Hood Adjustment Up or Down at ....31707
4000 Series — 4700, 4800 and 4900 Hood Adjustment Side-to-Side a....31708
8000 Series — 8100 Hood Adjustment Forward or Back at the Lower ....31710
8000 Series — 8100 Hood Adjustment Up or Down at the Lower Hinge....31711
8000 Series — 8100 Hood Adjustment Side-to-Side at the Upper Hin....31712
8000 Series — 8100 Hood Adjustment Forward or Back and Up or Dow....31713
8000 Series — 8100 Hood Adjustment Side-to-Side at the Upper Hin....31714
8000 Series — 8200 Hood Adjustment Forward or Back at the Lower ....31715
8000 Series — 8200 Hood Adjustment Side-to-Side at the Lower Hin....31716
8000 Series — 8200 Hood Adjustment Up or Down at the Upper Hinge....31717
tables....31718
Table 1Torque Chart....31718
International/Navistar TranStar, ProStar Series Trucks Repair Service Manual
