International Navistar CF500 CF600 CityStar 3 5 Truck Workshop Repair Service Manual PDF - MINTCFCITYS.zip
All-inclusive service and repair manual featuring Electrical Wiring Diagrams for International/Navistar CF500, CF600, CityStar 3, and CityStar 5 vehicles — packed with the technical data needed to service, troubleshoot, fix, and rebuild these trucks the way expert technicians do.
Covered inside the International/Navistar CF500, CF600, CityStar 3, and CityStar 5 workshop service repair manual:
* 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: 7,974 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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TABLE OF CONTENTS
0000002484 - BE, CE, CE Propane Autogas, HC and RE Buses Exhaust Aftertreatment System with DPF (Supersedes S07006) Revision 2 Service Manual....1
toc....3
Summary of Changes....3
1. Description....7
1.1. Theory of Operation....14
MaxxForce® DT....14
MaxxForce® 7....14
Cummins® ISB6.7....14
PSI 8.8 LPG Engine....14
1.2. Single Horizontal / Horizontal....15
2. General Service Information....16
2.1. Exhaust Aftertreatment System Modifications....17
2.2. Diesel Particulate Filter (DPF) Cleaning....18
Diesel Particulate Filter (DPF) and Diesel Oxidation Catalyst (DOC) Inspection....18
2.3. Gaskets And Fasteners....18
2.4. Diesel Particulate Filter (DPF) Indexing....19
2.5. Decomposition Reactor Tube Cleaning....19
2.6. Diesel Exhaust Fluid (DEF) Dosing Valve Cleaning....20
2.7. Diesel Exhaust Fluid (DEF) Tank Draining....21
3. Component Replacement....23
3.1. MaxxForce® 7 OR DT Systems....23
Pressure Tubes and Pressure Sensor – Removal....23
Pressure Tubes and Pressure Sensor – Installation....24
Temperature Sensor – Removal....25
Temperature Sensor – Installation....25
Doser Control Unit (DCU) (CE and BE) – Removal....26
Doser Control Unit (DCU) (CE and BE) – Installation....26
Doser Control Unit (DCU) (HC) – Removal....27
Doser Control Unit (DCU) (HC) – Installation....27
Doser Control Unit (DCU) (RE) – Removal....28
Doser Control Unit (DCU) (RE) – Installation....28
4. Single Horizontal / Horizontal....30
4.1. MaxxForce® 7 OR DT ENGINE....30
Diesel Particulate Filter (DPF) (RE Bus) – Removal....30
Diesel Particulate Filter (DPF) (RE Bus) – Installation....31
Diesel Particulate Filter (DPF) (BE, CE, and HC Bus) – Removal....32
Diesel Particulate Filter (DPF) (BE, CE, and HC Bus) – Installation....33
5. In–Line....34
5.1. Cummins® ISB6.7 Engine....34
Diesel Particulate Filter (DPF) – Removal....34
Diesel Particulate Filter (DPF) – Installation....34
Decomposition Reactor Tube – Removal....36
Decomposition Reactor Tube – Installation....37
Selective Catalyst Reduction (SCR) Canister – Removal....38
Selective Catalyst Reduction (SCR) Canister – Installation....39
Selective Catalyst Reduction (SCR) NOx Out Sensor and Module – Removal....40
Selective Catalyst Reduction (SCR) NOx Out Sensor and Module – Installation....41
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal....42
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation....42
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal....43
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation....43
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal....44
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation....44
Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF) Temperature Sensors and Module – Removal....45
Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF) Temperature Sensors and Module – Installation....46
Diesel Particulate Filter (DPF) Differential Pressure / Outlet Pressure Sensor Module – Removal....47
Diesel Particulate Filter (DPF) Differential Pressure / Outlet Pressure Sensor Module – Installation....48
Diesel Particulate Filter (DPF) Differential Pressure Tube – Removal....49
Diesel Particulate Filter (DPF) Differential Pressure Tube – Installation....49
Diesel Particulate Filter (DPF) Differential Outlet Pressure Tube – Removal....50
Diesel Particulate Filter (DPF) Differential Outlet Pressure Tube – Installation....50
6. Switchback / Horizontal....51
6.1. Cummins® ISB6.7 Engine....51
Switchback / Horizontal....51
7. Horizontal Dual Catalytic Converters....52
7.1. PSI 8.8L LPG Engine....52
Horizontal Dual Catalytic Converters....52
8. Diesel Exhaust Fluid (DEF) System....53
8.1. Cummins® ISB6.7....53
Diesel Exhaust Fluid (DEF) Tank – Removal....53
Diesel Exhaust Fluid (DEF) Tank – Installation....55
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal....56
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation....57
Diesel Exhaust Fluid (DEF) Tank Lines – Removal....58
Diesel Exhaust Fluid (DEF) Tank Lines – Installation....59
Diesel Exhaust Fluid (DEF) Supply Module – Removal....60
Diesel Exhaust Fluid (DEF) Supply Module – Installation....61
Diesel Exhaust Fluid (DEF) Dosing Unit Filter – Removal....62
Diesel Exhaust Fluid (DEF) Dosing Unit Filter – Installation....62
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal....63
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation....64
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal....66
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation....67
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal....68
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation....70
9. Acronym List....71
tables....17
Table 2Minimum Clearance Between Exhaust System Components and Other Chassis Components....17
Table 3Acronym List....71
Table 4Torque Chart....71
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toc....74
Table of Contents....74
2. INSTRUCTIONS AND CHARTS (CHAPTER 2)....90
2.1. Abbreviations, P. 1....90
2.2. Acronyms, P. 2....91
2.3. Circuit Diagram Instructions, P. 3....92
2.4. Circuit Number Identification And Color, P. 4....93
2.5. Circuit Number Identification And Color (Cont.), P. 5....94
2.6. Circuit Number Identification And Color (Cont.), P. 6....95
2.7. Circuit Number Identification And Color (Cont.), P. 7....96
2.8. Lamp Bulb Chart, P. 8....97
2.9. Relay Function And Wiring Guide, P. 9....98
2.10. Schematic Symbol Chart, P. 10....99
2.11. Schematic Symbol Chart (Cont.), P. 11....100
2.12. Schematic Symbol Chart (Cont.), P. 12....101
2.13. Schematic Symbol Chart (Cont.), P. 13....102
2.14. Schematic Symbol Chart (Cont.), P. 14....103
2.15. Schematic Symbol Chart (Cont.), P. 15....104
2.16. Schematic Symbol Chart (Cont.), P. 16....105
2.17. Schematic Symbol Chart (Cont.), P. 17....106
2.18. Schematic Symbol Chart (Cont.), P. 18....107
2.19. RE Bus Wiring Layout, P. 19....108
2.20. Bus Body Fuse Block, P. 20....109
3. 12 VOLT POWER DISTRIBUTION AND DATA LINK (CHAPTER 3)....110
3.1. Battery Feeds, P. 1....110
3.2. Ignition Feeds, P. 2....111
3.3. Chassis Ground, P. 3....112
3.4. Chassis Ground (Cont.), P. 4....113
3.5. Chassis Ground (Cont.), P. 5....114
3.6. Chassis Ground (Cont.), P. 6....115
3.7. Body Ground – Electric Panel, P. 7....116
3.8. Body Ground – Electric Panel (Cont.), P. 8....117
3.9. Body Ground – Electric Panel (Cont.), P. 9....118
3.10. Body Ground – Electric Panel (Cont.), P. 10....119
3.11. Body Ground – Electric Panel (Cont.), P. 11....120
3.12. Body Ground – Electric Panel (Cont.), P. 12....121
3.13. Body Ground – Front Cap, P. 13....122
3.14. Body Ground – Front Cap (Cont.), P. 14....123
3.15. Body Ground – Front End, P. 15....124
3.16. Body Ground – Rear Cap, P. 16....125
3.17. Body Ground – Rear Cap (Cont.), P. 17....126
3.18. Body Ground – Left Hand Body, P. 18....127
3.19. Body Ground – Left Hand Body (Cont.), P. 19....128
3.20. Body Ground – Right Hand Body, P. 20....129
3.21. Body Ground – Right Hand Body (Cont.), P. 21....130
3.22. Body Ground – Front End, P. 22....131
3.23. Power Distribution Control Module, P. 23....132
3.24. Power Distribution Control Module (Cont.), P. 24....133
3.25. Power Distribution Control Module (Cont.), P. 25....134
3.26. Body Circuit – ACC and IGN Feed, P. 26....135
3.27. Body Circuit – Master Disconnect, P. 27....136
3.28. Body Circuit – Noise Suppression, P. 28....137
3.29. Body Circuit Fuse Block, P. 29....138
3.30. Body Circuit Fuse Block (Cont.), P. 30....139
3.31. Body Circuit Fuse Block (Cont.), P. 31....140
3.32. Body Circuit Fuse Block (Cont.), P. 32....141
3.33. Body Circuit Fuse Block (Cont.), P. 33....142
3.34. Body Circuit Fuse Block (Cont.), P. 34....143
3.35. DC Outlet, P. 35....144
3.36. J1708 Datalink, P. 36....145
3.37. J1939 Datalink Connection with WTEC Trans, P. 37....146
3.38. J1939 Datalink Connection with LCT Trans, P. 38....147
3.39. Battery Isolator, P. 39....148
3.40. J1939 Datalink Connection with WTEC Trans with Tachograph,....149
3.41. Reference Splice, P. 41....150
4. CHARGING AND CRANKING SYSTEM (CHAPTER 4)....151
4.1. Charging System, P. 1....151
4.2. Cranking System, P. 2....152
4.3. Starter Interrupt / Vandal Lock – Emergency Exit, P. 3....153
4.4. Starter Connections with 222WB, P. 4....154
5. GAUGES AND WARNING LIGHTS (CHAPTER 5)....155
5.1. Turn Signals, Douglas T / S Switch (Tilt Column), P. 1....155
5.2. Turn Signals, Douglas T / S Switch (Tilt Column) with AUX H....156
5.3. Headlight System with Tilt Column (Standard DRL), P. 3....157
5.4. Headlight System with Tilt Column (Headlight Always On), P.....158
5.5. Fuel Level Gauge, P. 5....159
5.6. Transmission Oil Temperature Gauge, P. 6....160
5.7. 300 Amp Ammeter, P. 7....161
5.8. Engine Oil Pressure, Speedometer, Tachometer, Water Tempera....162
5.9. Engine Compartment Temp Sensor / Indicator, P. 9....163
5.10. Engine Compartment and Electrical Panel Temp Sensor / Indi....164
5.11. Parking Brake and Warning Light with Air Brakes, P. 11....165
5.12. Low Oil Pressure, Hi Water Temp, Bk Warning, Low Coolant L....166
5.13. MSM Ignition / Ground, MSM Datalink, Wait to Start, Change....167
5.14. Fuel Filter Light, Water in Fuel Light, P. 14....168
5.15. Front and Rear Diagnostic / Programming Connector, P. 15....169
5.16. Headlight Warning Buzzer, P. 16....170
5.17. Stop Light Switch, P. 17....171
5.18. Tachograph, P. 18....172
5.19. Ammeter Sensor Connections, P. 19....173
5.20. Fire Suppression, P. 20....174
5.21. Rear Cap Fire Suppression and with Eng Compartment Temp Se....175
6. PUPIL WARNING LIGHT ACTIVATION (CHAPTER 6)....176
6.1. ELS – Sequential Flasher System, P. 1....176
6.2. ELS – Sequential Flasher System (Cont.), P. 2....177
6.3. Weldon Sequential Flasher System, P. 3....178
6.4. Weldon Sequential Flasher System (Cont.), P. 4....179
6.5. Weldon Non Sequential Flasher System, P. 5....180
6.6. Weldon Non Sequential Flasher System (Cont.), P. 6....181
6.7. Separate Override – Hot All Time, P. 7....182
6.8. Florida Warning Light System, P. 8....183
6.9. Florida Warning Light System (Cont.), P. 9....184
6.10. Maryland Warning Lights System, P. 10....185
6.11. Maryland Warning Lights System (Cont.), P. 11....186
6.12. Ohio Warning Light System, P. 12....187
6.13. Ohio Warning Light System (Cont.), P. 13....188
6.14. Virginia Warning Light System, P. 14....189
6.15. Virginia Warning Light System (Cont.), P. 15....190
6.16. Warning Light and Driver Alert Sign without Light Monitor,....191
6.17. Warning Light and Driver Alert Sign without Light Monitor ....192
6.18. Warning Light and Driver Alert Sign without Light Monitor ....193
6.19. Warning Lights with Lamp Monitor, P. 19....194
6.20. Driver Alert Warning Lights with Lamp Monitor, P. 20....195
6.21. Driver Alert Warning Lights with Lamp Monitor (Cont.), P. ....196
6.22. Driver Alert Warning Lights with Lamp Monitor (Cont.), P. ....197
6.23. Driver Alert Warning Lights with Lamp Monitor (Cont.), P. ....198
6.24. Driver Alert Warning Lights with Lamp Monitor (Cont.), P. ....199
6.25. Driver Alert Warning Lights with Lamp Monitor (Cont.), P. ....200
6.26. Driver Alert Warning Lights with Lamp Monitor (Cont.), P. ....201
6.27. Indicator Lights, P. 24....202
6.28. ELS – Sequential Flasher System with Sound Off Light Monit....203
6.29. Weldon – Sequential Flasher System with Sound Off Light Mo....204
7. EXTERNAL LIGHTS (CHAPTER 7)....205
7.1. Back-up Light and Alarm without Options, P. 1....205
7.2. Back-up Light and Alarm with Options, P. 2....206
7.3. Back-up Light Activated by Rear Oval Kick Out Window, P. 3....207
7.4. Destination Sign Front and Rear, P. 4....208
7.5. Fog Lights, P. 5....209
7.6. Head Lights, P. 6....210
7.7. Left Switch Panel Mounted Strobe Light Switch, P. 7....211
7.8. Strobe Light Activated by Warning Lights with Overhead Swit....212
7.9. Strobe Light Activated by Stop Arm with Overhead Switch, P.....213
7.10. Left Side Turn Lights, P. 10....214
7.11. Left Side Turn Lights (Cont.), P. 11....215
7.12. Left Side Turn Lights (Cont.), P. 11A....216
7.13. Right Side Turn Lights, P. 12....217
7.14. Right Side Turn Lights (Cont.), P. 13....218
7.15. Right Side Turn Lights (Cont.), P. 13A....219
7.16. Front Turn / Markers Lamps without Cowl Mounted Turn Lamps....220
7.17. Front Turn / Markers with Additional Turn Lamps Only on Co....221
7.18. Front Turn / Markers with Additional Park and Turn Lamps o....222
7.19. Clearance Lights, P. 15....223