S40e Master [modo De Compatibilidad].pdf

INTRODUCTION Series s 40E Overhaul / Electroniics and Diagnostics Cou urse

Series 40E Left Side View

Series 40E25ST0041/2 2/15 99

3

Series 40E Right Side View

Series 40E25ST0041/2 2/15 99

4

Series 40E Front View

Series 40E25ST0041/2 2/15 99

5

Series 40E Rear View

Series 40E25ST0041/2 2/15 99

6

Series 40E Engine Cutaway

Series 40E25ST0041/2 2/15 99

7

Series 40E Emission Identification

Series 40E25ST0041/2 2/15 99

8

Series 40E Se erial Number Description • Engine Identifying Code:

WN1234

N XXXXXXX

– WL == 7.6TA – WN == 8.7TA

• Country of Origin: – U.S.A. USA

• Starting Engine Serial Nu umber: – (Sequence Number)

• Stamped on pad located on crankcase left side Series 40E25ST0041/2 2/15 99

9

THE FOUR R STROKE CYC CLE

FO OUR STROKE CYCLE

Series 40E25ST0041/2 2/15 99

1

INDUCT TION,COMPRESSION, POWER,EXHAUST.

Series 40E25ST0041/2 2/15 99

1

GENE ERAL CONSTR RUCTION

Series 40E C Cylinder Head Overview

Series 40E25ST0041/2 2/15 99

1

Series 40E Intake Port Protection

Series 40E25ST0041/2 2/15 99

1

Series 40E C Cylinder Head Assembly

Fuel Supply

High Pressure Oil

Series 40E25ST0041/2 2/15 99

1

Series 40E I Injector Sleeve Location

Series 40E25ST0041/2 2/15 99

1

Series 40E Injector Sleeve Tools

Series 40E25ST0041/2 2/15 99

1

Series 40E Injec ctor Sleeve Replacement

Series 40E25ST0041/2 2/15 99

1

Series 40E Supply Manifold

Series 40E25ST0041/2 2/15 99

2

Series 40E Supply Manifold Gasket

Series 40E25ST0041/2 2/15 99

2

Series 40E Cylinder Head Dye Penetrant P Crack Check

Series 40E25ST0041/2 2/15 99

2

Series 40E Flatness Check

Series 40E25ST0041/2 2/15 99

2

Series 40E Cylinderr Head Thickness Check

Series 40E25ST0041/2 2/15 99

2

Series 40E Valve Guide Removal

Series 40E25ST0041/2 2/15 99

2

Series 40E Valve Guide Installation

Series 40E25ST0041/2 2/15 99

2

Series 40E Valve e Seat Removal (Stage 1)

Series 40E25ST0041/2 2/15 99

2

Series 40E Valve e Seat Removal (Stage 2)

Series 40E25ST0041/2 2/15 99

2

Series 40E Valve Seat Installation

Series 40E25ST0041/2 2/15 99

2

Series 40E Valve Assembly

Series 40E25ST0041/2 2/15 99

3

Test valve rotator

Series 40E25ST0041/2 2/15 99

3

Series 40E Valve Stem Seals

Series 40E25ST0041/2 2/15 99

3

Series 40E Valve Components

Series 40E25ST0041/2 2/15 99

3

Series 40E Valve Depth Check

Series 40E25ST0041/2 2/15 99

3

Series 40E C Cylinder Head Overview

Series 40E25ST0041/2 2/15 99

3

Series 40E Rocker Arm Clearance

Series 40E25ST0041/2 2/15 99

3

Rocker Lever B Bushing Measurement

Series 40E25ST0041/2 2/15 99

3

Series 40E Valve Rotator

Series 40E25ST0041/2 2/15 99

3

Valv ve Assembly Installed

Series 40E25ST0041/2 2/15 99

3

Piston 7.6 7 6 Liter Engine

Series 40E25ST0041/2 2/15 99

4

Piston/Connecting Rod d Assembly 7.6L 7 6L Engine

Series 40E25ST0041/2 2/15 99

4

Piston Cro own with Skirt and Pin

Series 40E25ST0041/2 2/15 99

4

PISTON ASSEMBL LY- 8.7 LY 8 7 LITER ENGINE

Series 40E25ST0041/2 2/15 99

4

Piston Ring Formation

Series 40E25ST0041/2 2/15 99

4

Piston Gage Pins

Series 40E25ST0041/2 2/15 99

4

Piston Piin Bushing Clearance

Series 40E25ST0041/2 2/15 99

4

Cylinder Block

Series 40E25ST0041/2 2/15 99

4

Cylinder Liners

Series 40E25ST0041/2 2/15 99

4

Series 40E Cylinder Liner L Bore Measurement

Series 40E25ST0041/2 2/15 99

4

Crankcas se Counterbore Depth

Series 40E25ST0041/2 2/15 99

5

Series 40E L Liner Flange Bore Depth

Series 40E25ST0041/2 2/15 99

5

Counterboring Tool

Series 40E25ST0041/2 2/15 99

5

Lubricate O Rings

Series 40E25ST0041/2 2/15 99

5

Liner Protrusion Check

Series 40E25ST0041/2 2/15 99

5

Crankshaft

Series 40E25ST0041/2 2/15 99

5

Crankshaft Journal

Series 40E25ST0041/2 2/15 99

5

Main Bearing Shells

Series 40E25ST0041/2 2/15 99

5

Measure e Crankshaft Journals

Series 40E25ST0041/2 2/15 99

5

Series 40E Crrankshaft Gear Removal

Series 40E25ST0041/2 2/15 99

5

Rear Seal Wearr Sleeve Replacement

Series 40E25ST0041/2 2/15 99

6

Install Rear Oil Seal

Series 40E25ST0041/2 2/15 99

6

Rear O Oil Seal Installer Tool

Series 40E25ST0041/2 2/15 99

6

Re ear Oil Seal Alignment

Series 40E25ST0041/2 2/15 99

6

Flywheel Installation

Series 40E25ST0041/2 2/15 99

6

Camshaft

Series 40E25ST0041/2 2/15 99

6

Mea asure Camshaft Lobe

Series 40E25ST0041/2 2/15 99

6

Ca amshaft Bushing Tool

Series 40E25ST0041/2 2/15 99

6

Camsha aft Bushing Positions

Series 40E25ST0041/2 2/15 99

6

Camsh haft Rear O Ring Seal

Series 40E25ST0041/2 2/15 99

6

Roller Tappets

Series 40E25ST0041/2 2/15 99

7

Oil Gallery End Plug

Series 40E25ST0041/2 2/15 99

7

Series 40E Timing Gear Assembly

Series 40E25ST0041/2 2/15 99

7

Series 40E Crankcase Front Cover (Front Half)

Series 40E25ST0041/2 2/15 99

7

Front Damper Pulley

Series 40E25ST0041/2 2/15 99

7

Electric Heat Pad T To Install Front Pulley

Series 40E25ST0041/2 2/15 99

7

THE AIR SYSTEM

F Features And Benefits

Series 40E25ST0041/2 2/15 99

7

Series 40E Combustion Air Flow

Series 40E25ST0041/2 2/15 99

7

Charge Air Cooler

Series 40E25ST0041/2 2/15 99

7

Series 40E Intake Manifold / Rocker Cover

Series 40E25ST0041/2 2/15 99

8

Exhaust Manifold

Series 40E25ST0041/2 2/15 99

8

Wasttegated Turbocharger

Series 40E25ST0041/2 2/15 99

8

Wastegate

Series 40E25ST0041/2 2/15 99

8

Wastegate Control

Series 40E25ST0041/2 2/15 99

8

Wastegate Adjusting Rod

Series 40E25ST0041/2 2/15 99

8

W Wastegate Adjustment

Series 40E25ST0041/2 2/15 99

8

Turbocha arger Shaft Movement

Series 40E25ST0041/2 2/15 99

8

LUBRIC CATION SYSTEM

Series 40E25ST0041/2 2/15 99

8

Lu ubricating Oil System

Series 40E25ST0041/2 2/15 99

9

Oil Pump

Series 40E25ST0041/2 2/15 99

9

Oil Pump Inspection

Series 40E25ST0041/2 2/15 99

9

Oil Pump Inspection

Series 40E25ST0041/2 2/15 99

9

Oil Pressure Relief Valve Location

Series 40E25ST0041/2 2/15 99

9

Relief And Regulating Valves

Series 40E25ST0041/2 2/15 99

9

Relief Valve Aperture

Series 40E25ST0041/2 2/15 99

9

Oil Pressure Regu ulating Valve Location

Series 40E25ST0041/2 2/15 99

9

Oil Coolerr And Filter Assembly

Series 40E25ST0041/2 2/15 99

9

Oil Cooler Assembly

Series 40E25ST0041/2 2/15 99

9

Oil Cooler C Exploded View

Series 40E25ST0041/2 2/15 99

10

Oil Cooler Pressure Test

Series 40E25ST0041/2 2/15 99

10

O Filter Bypass Valve Oil

Normal Flow

Restricted Flow

Series 40E25ST0041/2 2/15 99

10

Oil Temperature Control Valve

Series 40E25ST0041/2 2/15 99

10

Oil Temperature Control

Series 40E25ST0041/2 2/15 99

10

Oil Filter / Cooler / Filter F Header Oil Flow

Series 40E25ST0041/2 2/15 99

10

Oil Spray Tubes

Series 40E25ST0041/2 2/15 99

10

Oil Spray S Tubes Installed

Series 40E25ST0041/2 2/15 99

10

Series 40E Oil Degradation Oil Chang ge Interval Oxidation Additive Depletion Combustion Products

Increased Viscosity, Hard Starting Increased Wear and D Deposits it All of the Above

• Oil Degradation is Affectted by Engine Operating Ti Time, Fuel F l Rate R t and d Oil API A Classification Cl ifi ti

Series 40E25ST0041/2 2/15 99

10

Series 40E SAE Viscosity Grades 30 20W-40 15W W-40 PREFERRED PREFERRED

10W W-30

5W-30 0W-30 °F

-20

°C -30

Series 40E25ST0041/2 2/15 99

-10 -25

0 -20

10 -15

-10

20

30 -5

40 0 0

5

50

60

70

10

15

20

80 25

90 30

100 35

40

10

Series 40E Oil Change Intervals • 19,300 , km (12,000 ( , m miles) ) • 450 Hours • 6 Months Oil Capacity • 22.7 22 7 L (24 q quarts) arts) without witho t filter change • 26.4 L (28 quarts) with w filter change

Series 40E25ST0041/2 2/15 99

Sulfur Content of Fuel

Oil Change Interval

Below 0.5% 0.5% to 1.0% Above 1.0%

Normal 3/4 Normal 1/2 Normal

11

COOLING G SYSTEM

FEATU URES AND BENEFITS • WATER PUMP » BELT DRIVEN (SERPENTINE E) » THREE RATIOS INDEPENDE ENT OF FAN SPEED • 1:3:1 131 • 1:5:1 • 1:8:1

– DEPENDENT ON ENGINE HP RATING AND APPLICATIO ON

Series 40E25ST0041/2 2/15 99

11

COOLANT SYSTEM FLOW

Series 40E25ST0041/2 2/15 99

11

WAT TER PUMP POSITION

Series 40E25ST0041/2 2/15 99

11

WATE ER PUMP ASSEMBLY

Series 40E25ST0041/2 2/15 99

11

WATE ER PUMP - DAMAGED

Series 40E25ST0041/2 2/15 99

11

Series 40E Watter Pump Sub Assembly Water Pump Seal Assembly

Water Pump p Impeller Assembly

Fan n And Pulley Hub

Bearing Shaft

Series 40E25ST0041/2 2/15 99

Water Pump Housing

11

THE ERMOSTAT POSITION

Series 40E25ST0041/2 2/15 99

11

Series 40E Thermostat Operation Out To R di t Radiator O--Ring

In From Engine g In From Engine

Series 40E25ST0041/2 2/15 99

• Thermosta at In Open Position o • Coolant To Radiator • By-Pass Closed

By-Pass B Pass To Water Pump

• Thermostat In Closed Position • By-Pass Open, Recirculation To Water Pump

11

COOLANT FILTER

Series 40E25ST0041/2 2/15 99

12

Series 40E Coolantt Filter With Check Valve Valve Spring Valve Cage

Check Valve Assembly

Valve Body Filter Element

Series 40E25ST0041/2 2/15 99

Valve D Disk

Outlet

Inlet

12

FREE EZE PROTECTION

REFRACTOMETER PG & EG

HYDROMETER EG ONLY

Series 40E25ST0041/2 2/15 99

12

FUEL S SYSTEM YSTEM

Series 40E In njection Control System

Series 40E25ST0041/2 2/15 99

12

Series 40E Fuel System Flow

Series 40E25ST0041/2 2/15 99

12

Series 40E Injection Con ntrol Pressure Reservoir

Series 40E25ST0041/2 2/15 99

12

Series 40E High Pressure Oil Pump

Series 40E25ST0041/2 2/15 99

12

Series 40E Injectio on Control System Flow

Series 40E25ST0041/2 2/15 99

12

HEUI INJJECTOR OPERA ATION

Series 40E HEUI Fuel Injector

Series 40E25ST0041/2 2/15 99

13

Series 40E H HEUI Injector Schematic

Poppet Valve Intensifier Piston Plunger

High Pressure Oil Channel Fuel Inlet

Series 40E25ST0041/2 2/15 99

13

Series 40E Fill Cycle

Series 40E25ST0041/2 2/15 99

13

Series 40E Solenoid Energized

Series 40E25ST0041/2 2/15 99

13

Series 40E Injection Delay

Series 40E25ST0041/2 2/15 99

13

Series 40E Main Injection

Series 40E25ST0041/2 2/15 99

13

Heui_iny.exe

Series 40E25ST0041/2 2/15 99

13

Series 40E Injector Harness

Series 40E25ST0041/2 2/15 99

13

ABBREV VIATIONS AND ACR RONYMS

Series 40E Abbre eviations and Acronyms APS

Accelerator Position Sensor

ATA

American Trucking Association

Exhaust aust Back ac Pressure essu e Sensor EBPR Exhaust Back Pressure Regulator EBP

BARO Barometric Pressure Sensor

ECM

Electronic Control Module

BNO

Brake Normally Open Switch

ECI

Engine Crank Inhibit

CMP

Camshaft Position Sensor

ECT

Engine Coolant Temperature Sensor

COL

Change Oil Lamp

EOP

Engine Oil Pressure Sensor

DDS

Driveline Disengagement g g Switch

EOT

Engine Oil Temperature Sensor

Series 40E25ST0041/2 2/15 99

13

Series 40E Abbre eviations and Acronyms EST S

Electronic ect o c Se Service ce Tool oo

IVS

Idle Validation Switch

HEUI

Hydraulically Activated Electronically Controlled Unit Injector

MAP

Manifold Absolute Pressure Sensor

NPS

Neutral Position Switch

OCP

Overcrank Protection Oil Water Warning Light

HPG

Hydraulic Pressure Governing

IAT

Intake Air Temperature Sensor

OWL

ICP

Injection j control Pressure Sensor

SCCS Speed Command Control Switch

IPR

Injection Pressure Regulator

VREF Voltage Reference

Series 40E25ST0041/2 2/15 99

14

ELECTRONIC ENGINE CONTROL C

Series 40E Processing Information

Input

Processing

O Outputs

Series 40E25ST0041/2 2/15 99

14

Series 40E Consolidated Engine Controller Electrronic Control Mod dule (EC CM)

EEPR ROM

Series 40E25ST0041/2 2/15 99

14

Series 40E ECM

Series 40E25ST0041/2 2/15 99

14

Series 40E Consolidated Engine Controller Camshaft Position Sensor

Electrronic Control Mod dule (EC CM)

EEPR ROM

Series 40E25ST0041/2 2/15 99

14

Series 40E Cam Position Sensor

Series 40E25ST0041/2 2/15 99

14

Series 40E Timing Disk

Series 40E25ST0041/2 2/15 99

14

Series 40E Cam Position Sensor Input

Processing

Outputs Unit Injectors

CMP Sensor

EC CM

IPR

Tachometer

Series 40E25ST0041/2 2/15 99

14

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation

Electrronic Control Mod dule (EC CM)

EEPR ROM

Series 40E25ST0041/2 2/15 99

14

Series 40E Acce elerator Position Sensor

Series 40E25ST0041/2 2/15 99

15

Series 40E Acce elerator Position Sensor

Input put

APS

Proce ocess ssing g

EC CM

Outputs Unit Injectors

IPR

Series 40E25ST0041/2 2/15 99

15

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure

Electrronic Control Mod dule (EC CM)

EEPR ROM

Series 40E25ST0041/2 2/15 99

15

Series 40E Injection Control C Pressure Sensor

Series 40E25ST0041/2 2/15 99

15

Series 40E Injection Control C Pressure Sensor Input

Processing

Outputs Unit Injectors

ICP Sensor

EC CM

IPR

Engine Warning Lamp Series 40E25ST0041/2 2/15 99

15

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure

Electrronic Control Mod dule (EC CM)

EEPR ROM

Series 40E25ST0041/2 2/15 99

15

Series 40E Manifold Ab bsolute Pressure Sensor

Series 40E25ST0041/2 2/15 99

15

Series 40E Manifold Ab bsolute Pressure Sensor

Input

Processing

MAP Sensor

EC CM

Output Unit Injectors

Series 40E25ST0041/2 2/15 99

15

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

EEPR ROM

Series 40E25ST0041/2 2/15 99

15

Series 40E Baro ometric Pressure Sensor

Series 40E25ST0041/2 2/15 99

15

Series 40E Baro ometric Pressure Sensor

Input put

BARO Sensor

Proce ocess ssing g

EC CM

Outputs Unit Injectors

IPR

Series 40E25ST0041/2 2/15 99

16

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure

EEPR ROM

Series 40E25ST0041/2 2/15 99

16

Series 40E Engine e Oil Pressure Sensor

Series 40E25ST0041/2 2/15 99

16

Series 40E Eng gine Oil Pressure Sensor Input

Processing

Outputs Unit Injectors

EOP Sensor

Engine Warning Lamp EC CM

Warning Buzzer Oil / Water Lamp Oil Pressure Gauge

Series 40E25ST0041/2 2/15 99

16

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM

Series 40E25ST0041/2 2/15 99

16

Series 40E Engine Oil Temperature Sensor

Series 40E25ST0041/2 2/15 99

16

Series 40E Engine Oil Temperature Sensor Input

Processing

Outputs Unit Injectors

EOT Sensor

EC CM

IPR

Oil Temperature Gauge Series 40E25ST0041/2 2/15 99

16

Series 40E Engine Coola ant Temperature Sensor

Series 40E25ST0041/2 2/15 99

16

Series 40E Engine Coola ant Temperature Sensor Input

Processing

Outputs Unit Injectors

ECT Sensor

Engine Warning Lamp EC CM

Warning Buzzer Oil / Water Lamp

Series 40E25ST0041/2 2/15 99

Water Temperature Gauge

16

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor

Series 40E25ST0041/2 2/15 99

16

Series 40E Intake Air A Temperature Sensor

Series 40E25ST0041/2 2/15 99

17

Series 40E Intake Airr Temperature Sensor

Input put

IAT

Proce ocess ssing g

EC CM

Outputs Unit Injectors

IPR

Series 40E25ST0041/2 2/15 99

17

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Coolant Level

Series 40E25ST0041/2 2/15 99

17

Series 40E Coolant Level Sensor

Series 40E25ST0041/2 2/15 99

17

Series 40E Grounding / Voltage V Divider Switches

Series 40E25ST0041/2 2/15 99

17

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Coolant Level VSG Control

Series 40E25ST0041/2 2/15 99

17

Series 40E Variable Speed Go overnor Throttle Control

Series 40E25ST0041/2 2/15 99

17

Series 40E Circuits 545 & 541 Bulkhead Connector Resume / Increase Speed

5 545

10/K

VIH-to-ECM Connector

545

31

544 5 541

11/L

541

32

Set / Decrease Speed

Series 40E25ST0041/2 2/15 99

17

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Coolant Level VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

17

Series 40E Hydraulic Pressure e Governing Application

Series 40E25ST0041/2 2/15 99

17

Series 40E Hydraulic Pres ssure Governing Sensor

Input

Processing

HPG

EC CM

Output Unit Injectors

Series 40E25ST0041/2 2/15 99

18

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Coolant Level VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

Self Test Input

18

Series 40E S Test Input Switch Self

Series 40E25ST0041/2 2/15 99

18

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Coolant Level VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery Self Test Input

18

Series 40E Power Supply and Return System

Series 40E25ST0041/2 2/15 99

18

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Coolant Level VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

18

Series 40E Vehicle Speed Sensor

Series 40E25ST0041/2 2/15 99

18

Series 40E Vehicle Speed Sensor

Input put

VSS

Proce ocess ssing g

Outputs

Gauges EC CM Unit Injectors

Series 40E25ST0041/2 2/15 99

18

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

18

Series 40E Check Engine Lamp

Series 40E25ST0041/2 2/15 99

18

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Air Temperature Sensor Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

19

Series 40E Stop Engine Lamp

Series 40E25ST0041/2 2/15 99

19

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

19

Series 40E Service Engine Lamp

Series 40E25ST0041/2 2/15 99

19

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

19

Series 40E Injec ction Pressure Regulator

Series 40E25ST0041/2 2/15 99

19

Series 40E Injec ction Pressure Regulator Inputs

Processing

Output

ICP Sensor EOT Sensor CMP Sensor

EC CM

IPR

APS / IVS MAP BARO Series 40E25ST0041/2 2/15 99

IAT

19

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure

EST Interface

Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

19

Series 40E EST Interface

Series 40E25ST0041/2 2/15 99

19

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM) Communication, Engine Data Line

Oil Pressure

EST Interface

Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

19

Series 40E Engine Data Line

Engine Control Module

Vehicle Components C t l Module Control M d l

Series 40E25ST0041/2 2/15 99

20

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure

Engine Crank Inhibit Relay Communication, Engine Data Line EST Interface

Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

20

Series 40E Engine Crrank Inhibit Relay Circuit Ignition Switch

DDS

85

30

Engine Crank Inhibit Relay 86

87A

87

Start Relay

ECM

Series 40E25ST0041/2 2/15 99

20

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure

(VRE) Vehicle Retarder

Engine Crank Inhibit Relay Communication, Engine Data Line EST Interface

Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

20

Series 40E Vehicle Retarder

Engine Control Module

Vehicle Retarder R l or Solenoid Relay S l id

Series 40E25ST0041/2 2/15 99

20

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure

Fan Controls (VRE) Vehicle Retarder

Engine Crank Inhibit Relay Communication, Engine Data Line EST Interface

Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

20

Series 40E Fan / Shutter Control

Engine Control Module

Vehicle Fan / Shutter R l or Solenoid Relay S l id

Series 40E25ST0041/2 2/15 99

20

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure

HEUI Fan Controls (VRE) Vehicle Retarder

Engine Crank Inhibit Relay Communication, Engine Data Line EST Interface

Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

20

Series 40E E ECM Control Of Injectors EOP

CMP

ECM

IPR

ECT T ICP

EOT

Injectors

•

ECT

• •

ECM IPR

• •

ICP MAP

•

EOT

• •

EOP CMP

Engine g Coolant Temperature Sensor Electronic Control Module Injection Pressure Regulator Injection Control Pressure Manifold Absolute Pressure S Sensor Engine Oil Temperature Sensor Engine Oil Pressure Press re Sensor Camshaft Position Sensor

MAP Series 40E25ST0041/2 2/15 99

20

Series 40E Consolidated Engine Controller Camshaft Position Sensor Accelerator Position Sensor With Idle Validation Injection Control Pressure Manifold Absolute Pressure Barometric Pressure

Electrronic Control Mod dule (EC CM)

Oil Pressure

HEUI Fan Controls (VRE) Vehicle Retarder

Engine Crank Inhibit Relay Communication, Engine Data Line EST Interface

Oil / Coolant Temperature

Injection ject o Pressure essu e Regulator egu ato

EEPR ROM Service Engine

Air Temperature Sensor

Stop p Engine

Coolant Level Check Engine

VSG Control

Hydraulic Pressure Governor Series 40E25ST0041/2 2/15 99

Diagnostic Request

+ B tt Battery

Cruise/PTO Control Vehicle Speed Limiting Vehicle Speed Sensor

Self Test Input

20

WIR RING FEATU URES

Series 40E Wiring Features • The electronic controll system y requires q different voltage value es to operate. • 5 volts – Sensor inputs

• 12 / 24 volts – Vehicle charging syste em

• 100+ volts – Injector solenoid opera ation

Series 40E25ST0041/2 2/15 99

21

Series 40E Wirre Length Requirements Covered Circuit Length

Maximum Deviation

0 to 49 mm

5.0 mm

50 to 151 mm

7.5 mm

152 to 304 mm

12 5 mm 12.5

305 to 609 mm

15.0 mm

610 to 914 mm

17.5 mm

915 to 1219 mm

20.0 mm

1220 to 1224 mm

22.5 mm

1225 to 1829 mm

25.0 mm

1830 and g greater

25 + .25 mm for every 300 mm 2 i increment greater than 1830 mm

Series 40E25ST0041/2 2/15 99

21

Series 40E Condu uit Diameter for 18 AWG Quantity of Wires to be Covered Recommended Conduit Diameter Up to 3

6 mm

4 to 5

9 mm

6 to 7

10 mm

8 to 10

13 mm

11 to 17

16 mm

18 to 21

19 mm

22 to 28

22 mm

27 to 37

25 mm

38 to 40

30 mm

Series 40E25ST0041/2 2/15 99

21

Series 40E Terminal Load Criteria Wire Gauge

Must Withstand Applied Load

14 AWG

222 N

16 AWG

133 N

18 AWG

89 N

Series 40E25ST0041/2 2/15 99

21

Series 40E Engine Harness EOP

CM MP

ECM

IPR

E ECT

• Sensor Input To The ECM • Drive Injector Solenoids

ICP EOT

Injectors MAP Series 40E25ST0041/2 2/15 99

21

Series 40E Vehicle Interface Harness • OEM Supplied • Power ECM • Sensor Input To The ECM • Auxiliary Systems Communication To The ECM • ECM Outputs Series 40E25ST0041/2 2/15 99

21

WIRE CR RIMPING EXER RCISE

Series 40E Termina al Installation Technique Part Number

Description n

Installation Technique

Refer to Section

1689464C1

ATS Connector Terminal T

A

3.7.4.1

2003343C1

BAPS Connector Terminal T

B

3.7.4.2

Packard 12020156

Main Power Relay Terminal

A

3.7.4.1

2041419C1

VIH-to-ECM Connecttor Terminal

C

3.7.4.3

VIH-to-ECM Connector Terminal

C

3.7.4.3

Main Power Relay Terminal

A

3.7.4.1

12103881

HPS Connector T Terminal

B

3742 3.7.4.2

235135053

J1708 / J1587 Data Link L Terminal

D

3.7.4.4

*

3 11 3 1 3.11.3.1

2041420C1 Packard 12066614

23516830 Series 40E25ST0041/2 23515462 2/15 99

M i VIH Connecto Main C tor Terminal T i l

21

Series 40E Push To Seat Terminal Terminal

Connector Assembly

Terminal Lock

Series 40E25ST0041/2 2/15 99

21

Series 40E Seal Positioning Push To Seat Terminals

Series 40E25ST0041/2 2/15 99

22

Series 40E Push To Seat Terminals Contact

Cable Core Wings

Insulation Wings

Seal

Series 40E25ST0041/2 2/15 99

22

Series 40E Push To Seat Terminals

Cable

Terminal

Seal

Series 40E25ST0041/2 2/15 99

22

Series 40E Pull To Seat Terminal Seal

Pull-To-Seat Connector Series 40E25ST0041/2 2/15 99

22

Series 40E Pull To Seat Terminal J 38706 Or Equiv valent

Cable

Terminal Series 40E25ST0041/2 2/15 99

22

Series 40E Crimp Tool T for Augat Terminals

Series 40E25ST0041/2 2/15 99

22

Series 40E Pull-to-Seat Terminal Method C 18 ga GXL Wire 16 ga GXL Wire Terminal (14 and 16 ga Wire), P/N: 2041420C1

14 ga GXL Wire Terminal (18 ga Wire), P/N: 2041419C1

Series 40E25ST0041/2 2/15 99

22

Series 40E Guidelines for Acc ceptable Terminal Crimp Crim mp Height

Crimp Width

14 AWG Insulation

3.2 22 mm

3.48 mm

14 AWG Conductor

1.5 50 mm

2.44 mm

16 AWG Insulation

2.9 90 mm

3.48 mm

16 AWG Conductor

1.3 34 mm

2.44 mm

18 AWG Insulation

25 2.5 59 mm

2 84 mm 2.84

18 AWG Conductor

1.2 24 mm

2.05 mm

60-pin Terminal Detail

Series 40E25ST0041/2 2/15 99

22

Series 40E Deutsch Terminal Positioning

0.8 mm

6.0 mm

Series 40E25ST0041/2 2/15 99

22

Series 40E Deuts sch Terminal Installation

25.4 mm

Series 40E25ST0041/2 2/15 99

22

Series 40E Deutsch Terminal

Unlocked Position

Locked Position

Series 40E25ST0041/2 2/15 99

23

Series 40E Deutsch Removal Tool

Series 40E25ST0041/2 2/15 99

23

Series 40E Cannon Connector Crimp Tool Latch

Crimp Tool

Locator

Latch Locator Locator Color Code

Turret Index Mark Lock Pin

Series 40E25ST0041/2 2/15 99

Dial

23

Series 40E Cannon Connector

Series 40E25ST0041/2 2/15 99

23

Series 40E Cannon Connector Ex xploded View (Plug End)

Series 40E25ST0041/2 2/15 99

23

Series 40E Cannon Exploded View (Socket End)

Series 40E25ST0041/2 2/15 99

23

Series 40E Cannon Terminal Insertion Insertion T l Tool Guide Pin Shoulder

Series 40E25ST0041/2 2/15 99

23

Series 40E Cannon Connector C Removal Tool

Socket Extraction End Handle

Lock Ring

Pin Extraction End Series 40E25ST0041/2 2/15 99

23

WIRE SP PLICING GUIDE ELINES

Series 40E Splicing Tools Tool

Part Number

Heat Gun

----

Sn 60 solder with rosin core flux

----

Wire Stripper

Kent-Moore J 35615 or equivalent

Splice Clips

DDC P/N 0597428 or equivalent

Heat Shrink Tubing

Refer to Section 3.7.7.5

Series 40E25ST0041/2 2/15 99

23

Series 40E Splicing Straight Leads

Clip

Series 40E25ST0041/2 2/15 99

24

Series 40E Recommended Splic cing Tools Alt. Method 1 T l Tool Heat Gun Wire Stripper

P t Number Part N b ---Kent-Moore J-35615 or equivalent

Splice Clips

23519359 or equivalent

Heat Shrink Tubing

Refer to Section 3.7.7.5

Terminal Crimper for 16 and 18 AWG

Kent-Moore J-38125-6

Terminal Crimper for 14 and 12 AWG Terminal Crimper for 10 AWG Series 40E25ST0041/2 2/15 99

24

Series 40E Splicing Straiight Leads Alt. Method 1

Series 40E25ST0041/2 2/15 99

24

Series 40E Recommended Splic cing Tools Alt. Method 2 T l Tool Heat Gun Wire Stripper

P t Number Part N b ---Kent-Moore J-35615 or equivalent

Splice Clips

0597428 or equivalent

Heat Shrink Tubing

Refer to Section 3.7.7.5

Terminal Crimper for 16 and 18 AWG

Kent-Moore J-38125-6

Terminal Crimper for 14 and 12 AWG Terminal Crimper for 10 AWG Series 40E25ST0041/2 2/15 99

24

Series 40E Splicing Straight Leads Alt. Method 2 Splice Clip, P/N 597428 or Equivalent

Shrink Tubing

6mm (.25”)) Min. Both En nds Series 40E25ST0041/2 2/15 99

24

Series 40E Strain Relief of Spliced Joint Apply Two L Layers off Tape T

45 mm Minimum Both Ends

Generic c Insulate ed Splice Arrea

25 mm Minimum Both Ends

Series 40E25ST0041/2 2/15 99

24

Series 40E S Staggering Wire Splices

65 mm Minimum Between Splices

Series 40E25ST0041/2 2/15 99

C Correct Method

Tape Spliced Wires Together

Incorrect Method

24

Series 40E Shrink Wrap • The Heat Shrink Wrap mu ust overlap the wire insulation by about 6mm on both sides of the splice

Series 40E25ST0041/2 2/15 99

24

DIGIITAL MULTIM METER

Series 40E Digital Multimeter • Analog Multimeters are not suiitable for diagnostic work on Navistar electronics

Series 40E25ST0041/2 2/15 99

24

Series 40E Diigital Multimeter Display Touch Hold Manual Range Measurement Units

Replace Battery

Range Indicator Zero Function Series 40E25ST0041/2 2/15 99

25

Series 40E DVOM Pushbuttons Zero Function

Manual / Auto Range Select

Smooth / Backlight

Series 40E25ST0041/2 2/15 99

25

Series 40E Current Measurement

Series 40E25ST0041/2 2/15 99

25

Series 40E Voltage Measurement

Series 40E25ST0041/2 2/15 99

25

Series 40E R Resistance Measurement

Series 40E25ST0041/2 2/15 99

25

ELECTRONIC SERVICE TOOL

Series 40E Electronic Service Tool

Series 40E25ST0041/2 2/15 99

25

Series 40E Elec ctronic Service Tool Map

Series 40E25ST0041/2 2/15 99

25

ENG GINE DIAGNO OSTICS HARD START T / NO START

Series 40E D Diagnostics Preparation

Series 40E25ST0041/2 2/15 99

25

Series 40E D Diagnostics Preparation

Series 40E25ST0041/2 2/15 99

26

Series 40E D-200 Test Kit

Series 40E25ST0041/2 2/15 99

26

Series 40E Fuel Quality 1. Sufficient Clean n Fuel • •

Free off Water-Icing F W t I i and d clouding l di Correct grade of fuel

Method

Check

Visual

Series 40E25ST0041/2 2/15 99

26

Series 40E Visual Inspection 2. Visual Inspectio on • •

Inspect for leaks Inspect for loose conne ections, etc. Fuel

Oil

Method

Coolant

Electrical

Air

Check

Visual

Series 40E25ST0041/2 2/15 99

26

Series 40E Engine Oil Level 3. CHECK ENGINE E OIL LEVEL • • • • •

Check engine crankcas se oil level Check for contaminants s (fuel, coolant) Correct Grade / Viscosiity Miles / Hours on oil Check oil pressure on dash d gauge Method

Check

Visual Series 40E25ST0041/2 2/15 99

26

Series 40E Inta ake / Exhaust Restriction 4. Intake / Exhaustt Restriction • • •

Inspect p hoses and pipi p p ng g Check filter minder Inspect exhaust system m

Method

Check

Visual

Series 40E25ST0041/2 2/15 99

26

Series 40E Inlet Restriction Gauge

Series 40E25ST0041/2 2/15 99

26

Series 40E EST Tool Fault Codes 5. EST TOOL - FAU ULT CODES •

I t ll Electronic Install El t i Servic S ice Tool T l

Active Inactive See Electronic Diagnos stic Form for codes Series 40E25ST0041/2 2/15 99

26

Series 40E Engine Off Tests 6a. EST - ENGINE OFF TESTS •

Select S l t Standard St d d Test T t fr from the th Engine E i Off Test T t Menu

Faults Found

Repair fault codes befo ore continuing Series 40E25ST0041/2 2/15 99

26

Series 40E Injector “Buzz Test” 6b. EST - INJECTO OR “BUZZ TEST” NOTE: Standard Test mus st be performed first, in order to gain acces ss to the Injector Buzz Test. • Select Injector Test from m the Engine Off Test Menu Faults F Found d See Electronic Diagnos stic Form for codes Series 40E25ST0041/2 2/15 99

26

Series 40E Flash Codes 7. STI BUTTON - FLASH CODES NOTE: Perform this test iff a EST is not available or is inoperative •

Depress and hold “Eng gine Diagnostics” switch, then turn the ignition sw witch to the “ON” position. Faults Found

Series 40E25ST0041/2 2/15 99

agnostic g form if fault Refer to Electronic Dia code(s) are set

27

Series 40E S Test Input Switch Self

Series 40E25ST0041/2 2/15 99

27

Series 40E EST - Data List 8. EST TOOL - DATA A LIST • •

Series 40E25ST0041/2 2/15 99

Select and enter the follow wing data as the first 3 lines in a custom data list. Monitor the data while cra anking the engine for 20 seconds d minimum i i Data

Sp pec

Bat voltage

7 volts lts min. i

Eng. RPM

130 RPM M min.

ICP pressure

500 PS SI min. min

Actual

If voltage is low, refer to ECM E diagnostics If no RPM is noted rechec ck fault codes If ICP pressure is low, refe er to Test 10

27

Series 40E ECM Voltage 9a. ECM VOLTAGE E NOTE: Perform this test iff a EST is not available or is inoperative • •

Check while cranking the engine Measure with DVOM at three locations with breakout box connected at chassis s harness connector on ECM Pins: (21+ & 1-) (22+ & 2-) (2 24+ & 23-)

Series 40E25ST0041/2 2/15 99

Instrument

Spec c

DVOM & Breakout box

7 vollts minim mum

Actual

If voltage is low, refer to t ECM diagnostics

27

Series 40E ECM Voltage

Series 40E25ST0041/2 2/15 99

27

Series 40E Engine Cranking RPM 9b. ENGINE CRAN NKING RPM • •

Minimum 130 RPM eng gine cranking speed for 20 seconds d Measure with breakoutt box engine harness on ECM @ pins 51+ & 19Instrument

Spe ec

DVOM 51+ & 19-

H 26 Hz mum Minim

Actual

If no frequency, q y, recheck fault codes Series 40E25ST0041/2 2/15 99

27

Series 40E Engine Cranking RPM

Series 40E25ST0041/2 2/15 99

27

Series 40E Injection Control Pressure 9c. Injection Contrrol Pressure • •

Minimum 130 RPM cra ank speed for 20 seconds Measure with breakoutt box connected to Engine Harness on ECM @ pin ns 16+ & 19- or breakout “tee” signal (green) & ground (black) Instrument

Spe ec

DVOM 16+ & 19-

olt 1 vo mum Minim

Actual

If ICP pressure is low, refer r to Test 10 Series 40E25ST0041/2 2/15 99

27

Series 40E Injection Control Pressure

Series 40E25ST0041/2 2/15 99

27

Series 40E Injection Control Pressure

J-43103

Series 40E25ST0041/2 2/15 99

27

Series 40E Low ICP Pressure Test 10. LOW ICP PRESS SURE TEST • • • •

Series 40E25ST0041/2 2/15 99

Remove EOT sensor and check for oil in reservoir and reinstall EOT Remove high pressure ho ose from oil manifold Attach adapter and ICP se ensor to the hose Monitor pressure while crranking engine

Instrument

Spec

EST

500 PSI min. m

DVOM

1 volt min.

Actual

If pressure is within speciifications check for high pressure oil leak if pressure is still low veriify that the pump is rotating If pressure is still low repllace IPR and retest

28

Series 40E Oil Reservoir Check

Series 40E25ST0041/2 2/15 99

28

Series 40E Fuel Pump Pressure (Cranking) 11. Fuel Pump Pre essure • •

Series 40E25ST0041/2 2/15 99

Measure at bleeder vallve on filter head Minimum 130 RPM cra ank speed for 20 seconds Instrument

Spe ec

0 - 160 PSI Gauge

P 20 PSI minim mum

Actual

If pressure is low, repllace fuel filter, clean fuel strainer and retest If pressure is still low, low, perform Transfer Pump Restriction Test 2b (off Performance Diagnostics)

28

Series 40E Fuel Pump Pressure (Cranking)

Series 40E25ST0041/2 2/15 99

28

ENG GINE DIAGNO OSTICS PERFORMANCE E DIAGNOSTICS

Series 40E D Diagnostics Preparation

Series 40E25ST0041/2 2/15 99

28

Series 40E D-200 Test Kit

Series 40E25ST0041/2 2/15 99

28

Series 40E Engine Oil Level 1. CHECK ENGINE E OIL LEVEL • • •

Check engine crankcas se oil level Check for contaminants s (fuel, coolant) Correct Grade / Viscosiity

Method

Check

Visual

Series 40E25ST0041/2 2/15 99

28

Series 40E S Sufficient Fuel / Pressure 2 SUFFICIENT FUEL / PRESSURE 2. • • • •

Series 40E25ST0041/2 2/15 99

Drain sample from tank k(s) Inspect fuel for contam mination Measure fuel pressure at fuel filter bleeder Measure pressure at high idle I t Instrument t

S ec Spe

0 - 160 PSI Gauge

30 PSI P minim mum @ High h idle

A t l Actual

If pressure is low replac ce fuel filter, clean fuel strainer and retest If pressure is still low, proceed p with step 2b

28

Series 40E Tra ansfer Pump Restriction 2b. TRANSFER PUM MP RESTRICTION •

Measure at fuel filter inlett @ High idle

Instrument 0 - 30” Hg Vacuum gauge

S ec Spe

Actual

Less than 8” Hg 8 H

If restriction is high high, check for blockage between pump and fuel tank. efer to Diagnostic Manual 11-10 If restriction is < 8” Hg., re Series 40E25ST0041/2 2/15 99

28

Series 40E Tra ansfer Pump Restriction

Series 40E25ST0041/2 2/15 99

29

Series 40E EST Tool Fault Codes 3. EST TOOL - FAU ULT CODES •

I t ll Electronic Install El t i Servic S ice Tool T l

Active Inactive See Electronic Diagnos stic Form for codes Series 40E25ST0041/2 2/15 99

29

Series 40E Engine Off Tests 4a. EST - ENGINE OFF TESTS •

Select S l t Standard St d d Test T t fr from the th Engine E i Off Test T t Menu

Faults Found

Repair fault codes, befo ore continuing Series 40E25ST0041/2 2/15 99

29

Series 40E Injector “Buzz Test” 4b. EST - INJECTO OR “BUZZ TEST” NOTE: Standard Test mus st be performed first, in order to gain acces ss to the Injector Buzz Test. • Select Injector Test from m the Engine Off Test Menu Faults F Found d See Electronic Diagnos stic Form for codes Series 40E25ST0041/2 2/15 99

29

Series 40E Flash Codes 5. STI BUTTON - FLASH CODES NOTE: Perform this test iff a EST is not available or is inoperative •

Depress and hold “Eng gine Diagnostics” switch, then turn the ignition sw witch to the “ON” position. Faults Found

Series 40E25ST0041/2 2/15 99

agnostic g form if fault Refer to Electronic Dia code(s) are set

29

Series 40E S Test Input Switch Self

Series 40E25ST0041/2 2/15 99

29

Series 40E Intake Restriction 6. INTAKE RESTRIICTION • •

Measure at High g idle an nd no load Use manometer or mag gnehelic

Instrument Manometer or Magnehelic

Sp pec

Actual

12.5” ” H2O

Series 40E25ST0041/2 2/15 99

29

Series 40E Engine Running Test 7a. EST - ENGINE RUNNING TEST •

Select S l t Standard St d d Test T t fr from the th Engine E i Running R i Test Menu Faults Found

Refer to Electronic Dia agnostic form if fault code(s) are set Series 40E25ST0041/2 2/15 99

29

Series 40E Injector Testt (Cylinder Contribution) 7b. EST TOOL - INJECTOR TEST NOTE: Standard Test mus st be performed first, in order to gain acces ss to the Injector Test Test. •

Select Injector Test from m the Engine Running Menu Faults F Found d

Series 40E25ST0041/2 2/15 99

Refer to Electronic Dia agnostic g form if fault code(s) are set

29

Series 40E Fuel Pressure Full Load 8. FUEL PRESSUR RE (FULL LOAD) • •

Measure fuel pressure at fuel filter bleeder Measure pressure at fu ull load rated speed Instrument

Spe ec

0 - 160 PSI Gauge

P 30 PSI minim mum

Actual

If pressure is low repla ace fuel filter, clean fuel strainer and retest If pressure is still low perform test 2B Series 40E25ST0041/2 2/15 99

29

Series 40E Fuel Pump Pressure Full Load

Series 40E25ST0041/2 2/15 99

30

Series 40E Injection Control Pressure 9. ICP PRESSURE •

Series 40E25ST0041/2 2/15 99

Monitor ICP pressure and d engine RPM with the EST tool in data list mode. Or use breakout tee and DVOM

Data

Spec

Low Idle

v PSI / volts

High Idle

v PSI / volts

Full Load

PSI / volts v

Actual

If pressure is low or unsta able disconnect ICP sensor and retest problem is resolved,, reffer to ICP diagnosis g If p If pressure is still low or unstable, u replace IPR and retest

30

Series 40E Injection Control Pressure

J-43103

Series 40E25ST0041/2 2/15 99

30

Series 40E Boost Pressure 10. BOOST PRESS SURE • • •

Monitor boost pressurre and engine RPM with the EST tool t l in i data d t list li t mo ode. d Or use dash tach and 0 - 30 PSI gauge and “T” if EST tool is not availab ble Measure at full load rated speed Spec

Actual

PSI @ RPM

Series 40E25ST0041/2 2/15 99

30

Series 40E Boost Pressure

Series 40E25ST0041/2 2/15 99

30

Series 40E Crankcase Pressure 11. CRANKCASE PRESSURE P • •

Measure at road draft tube with orifice tool J-39267 Measure at High Idle no o load RPM Instrument

Spe ec

0 - 60” H20 Magnehelic Gauge

< 8” 8 H20

Actual

Series 40E25ST0041/2 2/15 99

30

Series 40E Crankcase Pressure

Series 40E25ST0041/2 2/15 99

30

Series 40E Performance Diagnostics

STOP • If guideline data was ob btained during the first 11 tests, engine operation is satisfactory. No further testing is required Series 40E25ST0041/2 2/15 99

30

Series 40E Wastegate Actuator 12. WASTEGATE ACTUATOR A • • •

Apply regulated supply y to actuator Inspect for leakage Inspect movement

Instrument

Spe ec

0 - 60 60” PSI Gauge

28 ± 2 PSI

Actual

Series 40E25ST0041/2 2/15 99

30

Series 40E Wastegate Actuator

Series 40E25ST0041/2 2/15 99

30

Series 40E Exhaust Restriction 13. EXHAUST RES STRICTION • • •

Visually inspect exhau ust system for damage Measure at a point 3 to o 6 inches after turbo outlet Measure at full load & rated speed Instrument

Spe ec

Magnehelic 0 - 60” H20

< 33 33” H20

Actual

Series 40E25ST0041/2 2/15 99

31

Series 40E Exhaust Restriction

Series 40E25ST0041/2 2/15 99

31

Series 40E Valve Clearance 14. VALVE CLEARA ANCE •

Engine off: Hot or Cold

Instrument

Spe ec

Actual

Feeler gauge

Series 40E25ST0041/2 2/15 99

31

Series 40E Valve Adjustment Adjust j Valves

Crankshaft Position #1 Piston at TDC Compression #6 Piston at TDC Compression

INT EXH INT 1 3 2

EXH 10

EXH INT 6 7 EXH INT 5 4

EXH INT 8 9

INT EXH 12 11

Front

Series 40E25ST0041/2 2/15 99

31