International Navistar 5000-Series PayStar 9000-Series 9200i 9300 9400i 9900i Truck Repair Service Manual PDF - MINT5000PAYSTAR.zip
A full factory-level repair guide, complete with electrical wiring schematics, covering International/Navistar trucks from the 5000-Series (PayStar) and 9000-Series lines. Inside you'll find every technical detail needed to service, troubleshoot, fix, and rebuild these trucks the way professional technicians do.
What the International/Navistar 5000-Series (PayStar) and 9000-Series workshop service and repair manual contains:
* 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: 13,721 pages
File Format: PDF
Language: English
000000241 - SERVICE MANUAL Electrical Circuit Diagrams PayStar - 5900 (MaxxForce 11,13, 15L, N13 or ISX15 Engines with SCR).pdf
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10 Service Manual.pdf
0000001843 - Radiator, Cooling System- PayStar and 9900 Service Manual.pdf
0000002321 - PayStar 5000i and 9000i Conventional Cab Service (Supersedes S16021) Service Manual.pdf
0000002441 - PayStar Series Electrical Circuit Diagrams with MaxxForce 11_13, 15L, N13 or ISX15 Engines (Supersedes S08352) Circuit Diagrams.pdf
0000002568 - 5000i, 9100 , 9200i, 9400i, 9900i Models Heater System _ Air Conditioning (Supersedes S16023) Service Manual.pdf
0000003261 - 9900 Series Electrical Circuit Diagram Manual.pdf
0000003261 - SERVICE MANUAL Electrical Circuit Diagrams 9900 Series.pdf
0000011981 - PayStar _ 9200i and 9900i Series Electrical Circuit Diagrams (Supersedes S08326).pdf
0000628059 - 9900, PayStar, ProStar, TranStar, WorkStar Heavy Duty (HD) Radiator _ Cooling System (EPA 10 SCR) Service Manual (Supersedes 0000001601, 0000001843 & 0000002222).pdf
1087459R2 - 9300 Series Electrical Circuit Diagrams 1988 (Supersedes CTS-4382E) Circuit Diagrams.pdf
4328434 - New Truck Processing Manual.pdf
CTS-5119TA - 5000, 9200, 9300 and 9400 Electrical Circuit Diagrams Built After July 12, 1996.pdf
s04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual.pdf
s12005 - Radiator Shutters, Supersedes CTS-5084 (March 1996) Service Manual.pdf
S02005R - Rockwell Front Non-Drive Steering Axle, Supersedes CTS-5046R (April 1996) Service Manual.pdf
S02006 - Front Steer Axle_ Eaton EFA-12, Supersedes CTS-5171 (April 1996) Service Manual.pdf
S02007 - Front Steer Axle_ Eaton E1200I I-Beam, Supersedes CTS-5212 (March 1996) Service Manual.pdf
S02008 - Rockwell Front Drive Axle Wheel Ends, Supersedes CTS-5081 (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
S03007 - Hendrickson Air Suspension with Trailing Leaf Springs, Supersedes CTS-5125 (March 1996) Service Manual.pdf
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual.pdf
S03010 - Neway AD-123_246 Drive Axle Air Suspensions, Supersedes CTS-5191 (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
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
S04011 - Air Compressor_ Midland Models EL-1300 and EL-1600, Supersedes CTS-5146 (March 1996) Service Manual.pdf
S04013 - Stopmaster Wedge Type Brake, Supersedes CTS-5172 (March 1996) Service Manual.pdf
S04014 - Air Compressor_ Holset SS 296 and QE 296_338, Supersedes CTS-5197 (March 1996) Service Manual.pdf
S04020X - DCM and DDM Drum Type Parking Brake, Supersedes CTS-5135TA (July 1997) Service Manual.pdf
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual.pdf
S04022 - Antilock Air Brake System_ Bendix, Supersedes CTS-5059 (April 1998) Service Manual.pdf
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual.pdf
S04038 - EC-17 Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Service Manual.pdf
S04042 - Antilock Brakes _ Traction Control Troubleshooting_ Bendix Built March 1, 1998 and After, Supersedes CTS-5291 (Aug 2000) Service Manual.pdf
S04053 - ECE-13 Brake System (2010) Service Manual.pdf
S04055 - MCAC 465 Air Compressor Model PayStar, ProStar, TranStar, and WorkStar Vehicles SERVICE MANUAL.pdf
S04057 - ECE-13 Brake System Service Manual (9800 LHD) (2010) Service Manual.pdf
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual.pdf
S05004 - Power Steering Gear_ Sheppard Model 292, 392, 492, Supersedes CTS-5218 (April 1996) Service Manual.pdf
S05009T - Steering Column Assembly, Tilt_Telescoping, Supersedes CTS-5072T (Feb 1997) Service Manual.pdf
S05010T - 9600, 9700, 9800 Models Steering Column Assembly, Tilt, Supersedes CTS-5073T (Feb 1997) Service Manual.pdf
S05011 - 5000, 9200, 9300, 9400 Steering Column Assembly, Standard, Supersedes CTS-5078 (May 1996) Service Manual.pdf
S05015Y - Power Steering Gear_ Sheppard M-Series, Supersedes CTS-5262 (Sept 2000) Service Manual.pdf
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual.pdf
S08007 - 9200, 9300, 9400 Model Pro Sleeper Electrical System, Supersedes CTS-5201 (July 1992) 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
S08033 - General Instrument Electronic Programmable Speedometer _ Tachometer, Supersedes CTS-5048 (1991) Service Manual.pdf
S08035X - 9200, 9300 and 9400 Gauges and Warning Lights, Supersedes CTS-5180 (Oct 1999) Service Manual.pdf
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual.pdf
S08127 - 9300 and 9400 Electronic Engine Controls - General Information, Supersedes CTS-5051-I (1991) Service Manual.pdf
S08154X - Speedometer _ Tachometer Diagnostics and Service, Supersedes CTS-5257 (Oct 1999) Service Manual.pdf
S08156 - 9800 Series Heating, Ventilation, and Air Conditioning (HVAC) Troubleshooting Guide, Supersedes CTS-5275 (Feb 1998) Service Manual.pdf
S08157 - 9200, 9300 and 9400 Models with Pro Sleeper and Skyrise Sleeper Heating, Ventilation, and Air Conditioning (HVAC) Troubleshooting Guide, Supersedes CTS-5284 (Feb 1998) Service Manual.pdf
S08184 - 9200, 9400 and 9900 Chassis (Only with Pro Sleeper Cab) Built October 1, 1998 to July 18, 1999 Electrical Circuit Diagrams, Supersedes CTS-5273W (Oct 1998).pdf
S08185 - 5000, 9100, 9200, 9400 and 9900 Chassis (Only with Daycab and With or Without Box Sleeper) Built October 1, 1998 To July 18, 1999 Electrical Circuit Diagrams, Supersedes CTS-5119W (Oct 1998).pdf
S08191 - 5000, 9100, 9200, 9400,and 9900 Models Electrical System Troubleshooting Guide, Supersedes CTS-5301 (Feb 1999) Service Manual.pdf
S08207X - 5000i, 5000, 9000, 9000i Model Gauges and Warning Lights, Supersedes CTS-5293 (Oct 1999) Circuit Diagrams.pdf
S08210 - 5000i, 9000i, 9100i, 9200i, 9400i and 9900i Model Electrical System Troubleshooting Guide (June 2002) Service Manual.pdf
S08225 - 5000i, 9100 i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built June 3, 2002 and After.pdf
S08225Y - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built July 19, 1999 To August 31, 2000 Circuit Diagrams.pdf
S08225YA - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built September 1, 2000 To June 2, 2002 Circuit Diagrams.pdf
S08242W - 9800 Model Electrical Circuit Diagram Built November 1, 1998 to March 31, 2004 Circuit Diagrams.pdf
S08270 - Electrical System Troubleshooting Guide 9800 Models Built Date 11_01_1998 Supersedes CTS-5304 (Oct 2002) Service Manual.pdf
S08316 - 5500, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 to February 28, 2007 Electrical Circuit Diagrams Manual.pdf
S08318 - 9800 Model Built April 1, 2004 and After Electrical Circuit Diagrams Manual.pdf
S08319 - Inverter_Charger Power System (Sept 2003) Service Manual.pdf
S08326 - 5500i, 5600i, 5900i, 9200i, and 9900i Chassis Built March 1, 2007 and After — ELECTRICAL CIRCUIT DIAGRAMS.pdf
S08346 - SERVICE MANUAL 9800 LHD Model Built November 01, 2010 - ELECTRICAL CIRCUIT DIAGRAMS.pdf
S09001V - Hood, Grille, and Fenders - 5000, 9100, 9200, 9300, and 9400 (Supersedes CTS-5154V) (1999) Service Manual.pdf
S09004 - Hood, Grille, and Fenders - 5000i, 9000i (Oct 2000) 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
S11008 - Clutch Control Linkage Supersedes CTS-5063R (March 1996) Service Manual.pdf
S11009R - Clutch Control Linkage Supersedes CTS-5064R (March 1996) Service Manual.pdf
S11010K - Clutch Control Linkage Supersedes CTS-5117K (March 1996) Service Manual.pdf
S11011 - Clutch Control Linkage Supersedes CTS-5231 (March 1996) Service Manual.pdf
S11016- 9800 HYDRAULIC, MECHANICAL 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
S12034 - Radiator _ Cooling System Service Manual (2010).pdf
S13001 - 9600 _ 9700 Shift Control Linkage Adjustment Procedure with Manual Transmission Supersedes CTS-5094 (March 1996) Service Manual.pdf
S13003 - Power Take Off_ Rockwell Rear Engine Mounted Supersedes CTS-5210 (June 1996) Service Manual.pdf
S13007 - 13 Speed And 18 Speed Transmissions Eaton RTLO-713 _ 18 Series Supersedes CTS-5176 (June 1996) Service Manual.pdf
S13015 - 10 Speed And 15 Speed Transmissions Eaton RT, RTO, and RTX Series Supersedes CTS-5187 (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
S13019 - 18 Speed Transmissions Eaton RTLO-14618 and RTLO-16618 Series Supersedes CTS-5206 (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
S14009 - SINGLE REDUCTION, TANDEM AXLE_ INTERNATIONAL (Supersedes CTS-5124) Service Manual.pdf
S14013 - SINGLE REDUCTION, TANDEM DRIVE AXLES_ EATON (Supersedes CTS-5213) Service Manual.pdf
S14014 - SINGLE REDUCTION, SINGLE SPEED AXLES_ SPICER D135-S, F155-S, F170-S SERIES (Supersedes CTS-5233) 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
S16001 - MAJOR STRUCTURAL REPAIR_ 9600 (Formerly CTS-4338) Service Manual.pdf
S16003 - Repair Instructions for Fiberglass and Plastic (ABS) Material (Formerly CTS-5173) Service Manual.pdf
S16005V - CAB_ 5000, 9100, 9200, 9300, 9400 (Formerly CTS-5024V) Service Manual.pdf
S16006 - Cab - Tilt_ 9600 and 9700 Sleeper and Non-Sleeper Cabs (Formerly CTS-5129) Service Manual.pdf
S16008 - Add-On Sleeper Box (Formerly CTS-5152) Service Manual.pdf
S16009 - Aerodynamic Panels (Formerly CTS-5153) Service Manual.pdf
S16010 - Aerodynamic Panels 9200, 9300, 9400 (Formerly CTS-5155) Service Manual .pdf
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual.pdf
S16015 - AIR CONDITIONING - HEATER SYSTEM_ 5000, 9000 Series Without Lowered heater Box 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
S16018 - CAB - TILT_ 9800 Service Manual.pdf
S16019 - AIR CONDITIONING BASIC THEORY, SYSTEM DIAGNOSIS AND SERVICE (with R-134a Refrigerant System) Service Manual.pdf
S16020 - AIR CONDITIONING - HEATER SYSTEM_ 9000 Pro Sleeper After 05_01_1997, and 9800 Model After 07_01_1997 Service Manual.pdf
S16022Y - Air Conditioning Protection and Diagnostic System (APAds) Description, Operation, Troubleshooting, Remove, Install, and Electrical Circuit Diagrams Maintenance Manual.pdf
S16024 - SKIRT PANELS, AERO SIDE SKIRT PANELS, BODY AIR DEFLECTORS, BUMPERS AND ROOFS Service Manual.pdf
S16028 - West Coast Magnum Mirrors and Aero Mirrors Service Manual.pdf
S16037 - No Idle APU_HVAC System Model_ 9200i 9400i 9900i 9900ix Feature Code_ 12WTK 16UZV Service Manual.pdf
S16049 - AIR CONDITIONING - HEATER SYSTEM 9800 HVAC Service Manual.pdf
S16050 - CAB - TILT_ Model 9800 (RHD) Service Manual.pdf
S16051 - AIR CONDITIONING - HEATER SYSTEM_ 9800 (RHD) Service Manual.pdf
S082252 - 5000i, 9100i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built from June 3, 2002 To November 3, 2002.pdf
S082252A - 5000i, 9200i, 9400i and 9900i Chassis Electrical Circuit Diagrams Built November 4, 2002 to November 30, 2005.pdf
TABLE OF CONTENTS
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10 Service Manual....1
toc....3
Summary of Changes....3
1. Description....9
1.1. Theory of Operation....15
Aftertreatment regeneration burns soot to ash when excess soot buildup occurs. For regeneration to occur, the Engine Control Module (ECM) must detect a DPF restriction by monitoring temperature and pressure sensors....15
1.2. Switchback / Horizontal....16
1.3. Vertical / Vertical....17
1.4. In-Line....18
2. General Service Information....19
2.1. Exhaust Aftertreatment System Modifications....20
2.2. Gaskets and Fasteners....21
2.3. Diesel Particulate Filter (DPF) Indexing....21
2.4. DPF and DOC Cleaning....21
2.5. DPF General Inspection....22
DPF Inspection Points....23
2.6. DOC General Inspection....26
DOC Inspection Points....26
2.7. DPF / DOC Thread Repair....30
12 MM Thread Replacement....30
14 MM Thread Replacement....34
2.8. DOC and DPF Reuse Guidelines....38
General Information....38
Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted....39
Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged....40
Diesel Particulate Filter (DPF) Inlet / Outlet – New....41
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1)....42
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2)....43
Diesel Particulate Filter (DPF) Inlet – Clean....44
Diesel Particulate Filter (DPF) Inlet – Gouged....45
Diesel Particulate Filter (DPF) Inlet – Ash....46
Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings....47
Diesel Particulate Filter (DPF) Outlet – Soot Stains....48
Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process....49
Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains ....50
Diesel Particulate Filter (DPF) Outlet – Face Cracked....51
Diesel Particulate Filter (DPF) Outlet – Coolant Staining....52
Diesel Particulate Filter (DPF) Outlet – Melted....53
2.9. Decomposition Reactor Tube Cleaning....54
2.10. Diesel Exhaust Fluid (DEF) Dosing Valve cleaning....55
2.11. DEF Supply Module Filter Inspection....57
2.12. Diesel Exhaust Fluid (DEF) System Contamination....59
2.13. DEF System Decontamination Procedure....62
2.14. Diesel Exhaust Fluid (DEF) Refractometer Tool....63
Using the DEF Refractometer....63
DEF Refractometer Maintenance....65
2.15. Diesel Exhaust Fluid (DEF) Dosing System Reuse Guidelines....66
2.16. Diesel Exhaust Fluid (DEF) Tank Draining....69
3. Switchback / Horizontal....70
3.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....70
Switchback / Horizontal – Removal....70
Switchback / Horizontal – Installation....72
Diesel Exhaust Fluid (DEF) Dosing Valve – Removal....73
Diesel Exhaust Fluid (DEF) Dosing Valve – Installation....74
Decomposition Reactor Tube – Removal....75
Decomposition Reactor Tube – Installation....76
Aftertreatment Assembly Mounting Bracket – Removal....77
Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly Mounting Bracket – Installation....78
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal....79
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation....79
Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal....81
Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation....81
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped)....83
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped)....83
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal....84
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation....84
(DPF) Temperature Sensors and Module – Removal....86
Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation....86
Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal....88
Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation....89
Diesel Particulate Filter (DPF) High Pressure Tube – Removal....90
Diesel Particulate Filter (DPF) High Pressure Tube – Installation....90
Diesel Particulate Filter (DPF) Low Pressure Tube – Removal....91
Diesel Particulate Filter (DPF) Low Pressure Tube – Installation....91
4. Vertical / Vertical ....92
4.1. Navistar® N13 Engine....92
Vertical / Vertical....92
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal....93
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Installation....93
Power Distribution Module (PDM) – Removal....94
Power Distribution Module (PDM) – Installation....94
Aftertreatment Control Module (ACM) – Removal....95
Aftertreatment Control Module (ACM) – Installation....95
5. In–Line....96
5.1. Cummins ISB6.7 or Navistar® N9 and N10 Engines....96
In-Line....96
6. Diesel Exhaust Fluid (DEF) System....97
6.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....97
Diesel Exhaust Fluid (DEF) Tank – Removal....97
Diesel Exhaust Fluid (DEF) Tank – Installation....100
Power Distribution Module (PDM) – Removal....101
Power Distribution Module (PDM) – Installation....101
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal....102
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation....105
Diesel Exhaust Fluid (DEF) Tank Lines – Removal....106
Diesel Exhaust Fluid (DEF) Tank Lines – Installation....108
Diesel Exhaust Fluid (DEF) Supply Module – Removal....109
Diesel Exhaust Fluid (DEF) Supply Module – Installation....110
Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal....111
Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation....111
Aftertreatment Control Module (ACM) – Removal....112
Aftertreatment Control Module (ACM) – Installation....113
Diesel Exhaust Fluid (DEF) Tank Bracket – Removal....114
Diesel Exhaust Fluid (DEF) Tank Bracket – Installation....115
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal....116
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation....117
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal....118
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation....119
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal....120
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation....122
Diesel Exhaust Fluid (DEF) System....123
7. Acronym List....124
tables....20
Table 2Minimum Clearance Between Exhaust System Components and Other Chassis Components....20
Table 32Acronym List....124
Table 33Torque Chart....125
0000001843 - Radiator, Cooling System- PayStar and 9900 Service Manual....126
toc....128
Summary of Changes....128
1. Description....134
1.1. Deaeration Tank....135
1.2. Fan Shroud....135
1.3. A/C Condenser....135
1.4. Transmission Oil Cooler....135
1.5. Radiator....136
1.6. Charge Air Cooler....136
1.7. Low-Temperature Radiator....136
1.8. Fan Drive....137
2. Removal and Installation....138
2.1. Cooling Package Cleaning Procedures....139
2.2. Coolant Drain, Pressure Test, and Fill Procedures....142
Coolant Drain Procedure (MaxxForce's 11 Liter, 13 Liter, 15 Liter and Cummins®ISX 15) (Recommended)....144
Pressure Test Procedure (MaxxForces 11 Liter, 13 Liter, 15 Liter& Cummins®ISX 15) (Recommended)....146
Coolant Fill Procedure (MaxxForce's 11 Liter, 13 Liter, 15 Liter & Cummins®ISX 15) (Recommended)....147
Coolant Drain Procedure (MaxxForce 11 Liter, 13 Liter, 15 Liter& Cummins®ISX 15) (Optional)....149
Coolant Fill Procedure MaxxForce 11 Liter, 13 Liter, 15 Liter (Optional)....150
Coolant Fill Procedure – Cummins® ISX 15 Engines (Optional)....152
2.3. Grille....153
Grille – Removal (All Engines)....153
Grille – Installation (All Engines)....153
2.4. Deaeration Tank....154
Deaeration Tank – Removal....154
Deaeration Tank – Installation....155
2.5. A/C Condenser....156
MaxxForce 11 Liter, 13 Liter, and 15 Liter A/C Condenser – Removal....156
MaxxForce 11 Liter, 13 Liter, and 15 Liter A/C Condenser – Installation....157
PayStar / 9900 with Cummins® ISX 15 A/C Condenser – Removal....158
PayStar / 9900 with Cummins® ISX 15 A/C Condenser – Installation....159
2.6. Fan Shroud....160
Upper Fan Shroud (MaxxForce11 Liter &13 Liter) – Removal....160
Upper Fan Shroud (MaxxForce 11 Liter or 13 Liter – Installation....161
Lower Fan Shroud (MaxxForce 11 Liter or 13 Liter ) – Removal....162
Lower Fan Shroud (MaxxForce 11 Liter or 13 Liter ) – Installation....164
Upper Fan Shroud (MaxxForce 15 Liter) – Removal....164
Upper Fan Shroud (MaxxForce 15 Liter ) – Installation....166
Lower Fan Shroud (MaxxForce 15 Liter ) – Removal....167
Lower Fan Shroud (MaxxForce 15 Liter ) – Installation....168
Fan Shroud (Two and Three Piece) Cummins® ISX 15 Engines – Removal....168
Fan Shroud (Two Piece) Cummins® ISX 15 Engines – Installation ....170
2.7. Radiator Fan....172
Radiator Fan (MaxxForce 11 Liter or 13 Liter) – Removal....172