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Serie

Overhaul / Electron

Co

 40E

cs and Diagnostics

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Series 40EEmission Identification

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S

•  

 –  WL == 7.6TA

 –  WN == 8.7TA

• Country of Origin: –  . . .

• Starting Engine Serial Nu

 –  (Sequence Number)

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Series 40Erial Number Description

mber:

on crankcase left side 

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THE FOU

CY

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LE

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INDUC

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ION,COMPRESSION,

POWER,EXHAUST.

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GEN

CONST

RAL

UCTION

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Fuel Supply

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High Pressure Oil

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Inje

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enetrant Crack Check

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Cylinde

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Series 40E

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S i 40E

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iner Bore Measurement

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S i 40E

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iner Flange Bore Depth

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Series 40E

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C

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ankshaft Gear Removal

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Series 40E

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Timing Gear Assembly

Series 40E

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Crankcase

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Front Cover (Front Half)

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Series 40E

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Combustion Air Flow

 

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Series 40E

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Intake

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Manifold / Rocker Cover 

 

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LUBRI

SYS

 ATION

TEM

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1

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Series 40E

Oil Degradatione Interval

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Oil Chan

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15

10PREFERRED

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Oil Change Intervalsil

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• 19,300 km 12,000

• 450 Hours

• 6 Months

Oil Capacity

• . quar s• 26.4 L (28 quarts)

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•  » BELT DRIVEN (SERPENTIN

» THREE RATIOS INDEPEND• : :

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• 1:8:1

 –  DEPENDENT ON ENGINERATING AND APPLICATI

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HPN

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1

 

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1

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er Pump Sub AssemblyWater Pump

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Fan

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2/15 99Water Pump Housing

pWater Pum

Impeller Assembly

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Bearing Shaft

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Out To

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Thermostat Operation

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COOLANT FILTER

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1

Coolant

Series 40E

 Filter With Check ValveValve Spring

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Valve Cage

Valve Body

Filter Element 

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Check Valve

1

Inlet

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REFRACTOMETER

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 HYDROMETER

1

 

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I

Series 40E

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1

Series 40E

Fuel System Flow

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1

Injection Co

Series 40E

trol Pressure Reservoir 

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1

Series 40E

High Pressure Oil Pump

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1

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n Control System Flow

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HEUI INOPER ECTORTION

Series 40E

HEUI Fuel Injector 

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1

Series 40E

EUI Injector Schematic

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Intensifier 

Plunger 

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Poppet Valve

High Pressure

Oil Channel

Fuel Inlet

1

Series 40E

Fill Cycle

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1

Series 40E

Solenoid Energized

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Series 40E25ST0041/2

2/15 99

1

Series 40E

Injection Delay

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Series 40E25ST0041/2

2/15 99

1

Series 40E

Main Injection

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Series 40E25ST0041/2

2/15 99

1

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Heui_i

Series 40E25ST0041/2

2/15 99

ny.exe

1

Series 40E

Injector Harness

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Series 40E25ST0041/2

2/15 99

1

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 ABBRE AND AC IATIONSONYMS

 Abbr  APS Accelerator Position

Sensor 

Series 40E

viations and AcronymsEBP Exhaust Back Pressure

Sensor 

7/18/2019 s40e MASTER

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 ATA American Trucking

 Association

BARO Barometric Pressure

Sensor 

 

Switch

CMP Camshaft Position Sensor 

COL Change Oil Lamp

DDS Drivel ine Disengagement

Series 40E25ST0041/2

2/15 99

Switch

EBPR Exhaust Back Pressure

Regulator 

ECM Electronic Control

Module

 

ECT Engine Coolant

Tem erature Sensor 

EOP Engine Oil Pressure Sensor 

1

 

Sensor 

 Abbr EST Electronic Service Tool

Series 40E

viations and Acronyms 

7/18/2019 s40e MASTER

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HEUI Hydraulically Activated

Electronically Controlled

HPG

 

Hydraulic Pressure

Governing

IAT Intake Air TemperatureSensor 

ICP Injection control Pressure

Sensor 

IPR Injection Pressure Regulator  

Series 40E25ST0041/2

2/15 99

MAP Manifold Absolute Pressure

Sensor 

NPS

OCP

Neutral Position Switch

Overcrank Protection

OWL Oil Water Warning Light

SCCS Speed Command Control

Switch

VREF Voltage Reference

1

7/18/2019 s40e MASTER

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ELECTENGINE RONICONTROL

Series 40E

Processing Information

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Series 40E25ST0041/2

2/15 99

utputs

1

Consoli

ConCon

Series 40E

dated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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Con

Mod

Con

Mod(E(E

EEPEEP

Series 40E25ST0041/2

2/15 99

trol

ule

trol

uleM)M)

OMOM

1

Series 40EECM

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

ConCon

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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Con

Mod

Con

Mod(E(E

EEPEEP

Series 40E25ST0041/2

2/15 99

trol

ule

trol

uleM)M)

OMOM

1

Series 40E

Cam Position Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Series 40ETiming Disk

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Series 40E25ST0041/2

2/15 99

1

ProceInput

Series 40ECam Position Sensor 

Outputsssing

7/18/2019 s40e MASTER

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CMP

Sensor 

Series 40E25ST0041/2

2/15 99

UnitInjectors

IPR

Tachometer 

1

ConsoliCamshaft Position Sensor 

ConConPosition Sensor 

With Idle Validation

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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Con

Mod

Con

Mod(E(E

EEPEEP

Series 40E25ST0041/2

2/15 99

trol

ule

trol

uleM)M)

OMOM

1

 Acc

Series 40Elerator Position Sensor 

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Series 40E25ST0041/2

2/15 99

1

 Acc

Series 40E

lerator Position Sensor 

7/18/2019 s40e MASTER

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ProceIn ut

Series 40E25ST0041/2

2/15 99

Out utsssin

Unit

1

ConsoliCamshaft Position Sensor 

ConConPosition Sensor 

With Idle Validation

I j ti C t l P

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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ModMod

Injection Control Pressure

(E(E

EEPEEP

Series 40E25ST0041/2

2/15 99

uleuleM)M)

OMOM

1

Injection

Series 40Eontrol Pressure Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Injection

ProceInput

Series 40Eontrol Pressure Sensor 

Outputsssing

7/18/2019 s40e MASTER

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ICP

Sensor 

Series 40E25ST0041/2

2/15 99

UnitInjectors

IPR

Warning

Lamp

1

ConsoliCamshaft Position Sensor 

ConConInjection Control Pressure

Position Sensor With Idle Validation

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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ModMod

Injection Control Pressure

(E(E 

EEPEEP

Series 40E25ST0041/2

2/15 99

uleuleM)M)

OMOM

1

Manifold A

Series 40Esolute Pressure Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Manifold A

Series 40Esolute Pressure Sensor 

7/18/2019 s40e MASTER

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MAP

ProceInput

Sensor 

Series 40E25ST0041/2

2/15 99

Unit

Outputssing

Injectors

1

ConsoliCamshaft Position Sensor 

ConConInjection Control Pressure

Position Sensor With Idle Validation

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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ModMod

j

(E(E 

Barometric Pressure

EEPEEP

Series 40E25ST0041/2

2/15 99

uleuleM)M)

OMOM

1

Bar 

Series 40Emetric Pressure Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Bar 

Series 40E

metric Pressure Sensor 

7/18/2019 s40e MASTER

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ProceIn ut

BARO

Sensor 

Series 40E25ST0041/2

2/15 99

Out utsssin

Unit

1

ConsoliCamshaft Position Sensor 

ConConInjection Control Pressure

Position Sensor With Idle Validation

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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ModMod(E(EBarometric Pressure

 

Oil Pressure

EEPEEP

Series 40E25ST0041/2

2/15 99

uleuleM)M)

OMOM

1

Engin

Series 40E

 Oil Pressure Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Eng

ProceInput

Series 40E

ine Oil Pressure Sensor 

Outputsssing

Unit

Injectors

7/18/2019 s40e MASTER

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EOP

Sensor 

Series 40E25ST0041/2

2/15 99

j

Engine

Warning

Lamp

Oil / Water 

Warning

Buzzer 

Lamp

Oil Pressure

1

ConsoliCamshaft Position Sensor 

ConConInjection Control Pressure

Position Sensor With Idle Validation

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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ModMod(E(EBarometric Pressure

 

Oil Pressure

Oil / Coolant Temperature

EEPEEP

Series 40E25ST0041/2

2/15 99

uleuleM)M)

OMOM

1

Engine

Series 40EOil Temperature Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Engine

ProceInput

Series 40EOil Temperature Sensor 

Outputsssing

7/18/2019 s40e MASTER

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EOT

Sensor 

Series 40E25ST0041/2

2/15 99

UnitInjectors

IPR

Temperature

Gauge

1

Engine Cool

Series 40Ent Temperature Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Engine Cool

ProceInput

Series 40Ent Temperature Sensor 

Outputsssing

Unit

Injectors

7/18/2019 s40e MASTER

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ECT

Sensor 

Series 40E25ST0041/2

2/15 99

Engine

Warning

Lamp

Oil / Water 

Warning

Buzzer 

Lamp

Water 

1

Gauge

ConsoliCamshaft Position Sensor 

ConConInjection Control Pressure

Position Sensor With Idle Validation

Series 40Edated Engine Controller 

troltrol

7/18/2019 s40e MASTER

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ModMod(E(EBarometric Pressure

 

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Series 40E25ST0041/2

2/15 99

uleuleM)M)

OMOM

1

Intake

Series 40Eir Temperature Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Intake Ai

PI t

Series 40E

 Temperature Sensor 

O t ti

7/18/2019 s40e MASTER

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ProceIn ut

Series 40E25ST0041/2

2/15 99

Out utsssin

Unit

1

ConsoliCamshaft Position Sensor 

Con

M d

Con

M d

Injection Control Pressure

Position Sensor With Idle Validation

Series 40Edated Engine Controller 

trol

l

trol

l

7/18/2019 s40e MASTER

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ModMod(E(EBarometric Pressure

 

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

Series 40E25ST0041/2

2/15 99

uleuleM)M)

OMOM

1

Series 40ECoolant Level Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Grounding /

Series 40Eoltage Divider Switches

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

((

Series 40Edated Engine Controller 

trol

ule

trol

ule

))

7/18/2019 s40e MASTER

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(E(EBarometric Pressure

 

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

M)M)

OMOM

1

Variable Speed G

Series 40Evernor Throttle Control

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Series 40ECircuits 545 & 541

VIH-to-ECM

Connector 

Bulkhead

Connector 

7/18/2019 s40e MASTER

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5

544

 Speed

5

Set / Decrease

Speed

Series 40E25ST0041/2

2/15 99

3110/K 54545

3211/L

54141

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(E 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)

7/18/2019 s40e MASTER

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(E(EBarometric Pressure

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

M)M)

OMOM

1

Hydraulic Pressur 

Series 40E

 Governing Application

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Series 40E25ST0041/2

2/15 99

1

Hydraulic Pre

PI t

Series 40Esure Governing Sensor 

O t ti

7/18/2019 s40e MASTER

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ProceInput

Series 40E25ST0041/2

2/15 99

Unit

Outputssing

Injectors

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(E 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)

7/18/2019 s40e MASTER

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(E(EBarometric Pressure

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

M)M)

OMOM

1

Self TestInput

Series 40E

elf Test Input Switch

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EB t i P

 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)

7/18/2019 s40e MASTER

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(E(EBarometric Pressure

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

M)M)

OMOM

++--

1

Self TestInput

atteryattery

Power Su

Series 40Epply and Return System

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure

 

Series 40Edated Engine Controller 

trol

ule

trol

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M)M)

7/18/2019 s40e MASTER

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(E(EBarometric Pressure

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

M)M)

OMOM

++-- Cruise/PTO Control

1

atteryattery

Self TestInput

Vehicle Speed LimitingVehicle Speed Sensor 

Series 40EVehicle Speed Sensor 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ProceIn ut

Series 40EVehicle Speed Sensor 

Out utsssin

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Series 40E25ST0041/2

2/15 99

Gauges

Unit

Injectors

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure

 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)

7/18/2019 s40e MASTER

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((Barometric Pressure

Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

))

OMOM

++-- Cruise/PTO Control

CheckEngine

1

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Series 40E

Check Engine Lamp

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)

7/18/2019 s40e MASTER

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

OMOM

Sto

++-- Cruise/PTO Control

CheckEngine

Engine

1

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Series 40E

Stop Engine Lamp

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)

7/18/2019 s40e MASTER

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

1

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Series 40E

Service Engine Lamp

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)

7/18/2019 s40e MASTER

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

1

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Injec

Series 40Etion Pressure Regulator 

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

Injec

ProceInputs

ICP

Sensor 

EOT

Sensor 

Series 40Etion Pressure Regulator 

Outputssing

7/18/2019 s40e MASTER

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CMP

Sensor 

 APS / IVS

BARO

Series 40E25ST0041/2

2/15 99IAT

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Series 40Edated Engine Controller 

trol

ule

trol

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M)M)

7/18/2019 s40e MASTER

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

EST Interface

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

1

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Series 40EEST Interface

7/18/2019 s40e MASTER

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Series 40E25ST0041/2

2/15 99

1

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)Communication, Engine Data Line

7/18/2019 s40e MASTER

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

EST Interface

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

1

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Series 40EEngine Data Line

7/18/2019 s40e MASTER

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Engine

Control Module

Series 40E25ST0041/2

2/15 99

Vehicle Components

on ro o u e

2

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Oil P

Series 40Edated Engine Controller 

trol

ule

trol

ule

M)M)Communication, Engine Data Line

Engine Crank Inhibit Relay

7/18/2019 s40e MASTER

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

EST Interface

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

2

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Engine Cr 

DDS

30

Series 40Eank Inhibit Relay Circuit

Ignition

Switch

85

7/18/2019 s40e MASTER

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30

8787A

Start

RelaySeries 40E25ST0041/2

2/15 99

Engine Crank85

Inhibit Relay

86

ECM

2

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Oil Pressure

Series 40Edated Engine Controller 

trol

ule

trol

ule(VRE) Vehicle Retarder 

M)M)Communication, Engine Data Line

Engine Crank Inhibit Relay

7/18/2019 s40e MASTER

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

EST Interface

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

2

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Series 40EVehicle Retarder 

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Engine

Control Module

Series 40E25ST0041/2

2/15 99

Vehicle Retarder 

e ay or o eno

2

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Oil Pressure

Series 40Edated Engine Controller 

trol

ule

trol

ule(VRE) Vehicle Retarder 

Fan Contro ls

M)M)Communication, Engine Data Line

Engine Crank Inhibit Relay

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Oil Pressure

Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

EST Interface

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

2

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

Series 40EFan / Shutter Control

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Engine

Control Module

Series 40E25ST0041/2

2/15 99

Vehicle Fan / Shutter 

e ay or o eno

2

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Oil Pressure

Series 40Edated Engine Controller 

HEUIHEUI

trol

ule

trol

ule

Fan Controls

(VRE) Vehicle Retarder 

M)M)

EST I t f

Communication, Engine Data Line

Engine Crank Inhibit Relay

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Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

EST Interface

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

2

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

CMPEOP

ECM

IPR EC

Series 40ECM Control Of Injectors

• ECT En ine Coolant

Temperature Sensor 

• ECM Electronic Control Module

• IPR Injection Pressure

Regulator 

• ICP Injection Control Pressure

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ICP

EOT

Injectors

Series 40E25ST0041/2

2/15 99

• MAP Manifold Absolute Pressure

ensor 

• EOT Engine Oil TemperatureSensor 

•   u

• CMP Camshaft Position Sensor 

2

ConsoliCamshaft Position Sensor 

Con

Mod

Con

ModInjection Control Pressure

Position Sensor With Idle Validation

(E(EBarometric Pressure 

Oil Pressure

Series 40Edated Engine Controller 

HEUIHEUI

trol

ule

trol

ule

Fan Contro ls

(VRE) Vehicle Retarder 

M)M)

EST Interface

Communication, Engine Data Line

Engine Crank Inhibit Relay

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Oil / Coolant Temperature

EEPEEP

 Air Temperature Sensor 

Coolant Level

VSG Control

Series 40E25ST0041/2

2/15 99

Hydraulic Pressure Governor 

DiagnosticRequest

In ection Pressure Re ulator 

EST Interface

OMOM

Sto

ServiceEngine

++-- Cruise/PTO Control

Engine

CheckEngine

2

atteryattery Vehicle Speed LimitingVehicle Speed Sensor 

Self TestInput

WI

FEAT

ING

RES

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FEAT RES

• The electronic control

different voltage valu

• 5 volts

 –  Sensor inputs

• 12 / 24 volts

Series 40EWiring Features

 s stem re uires

s to operate.

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• 12 / 24 volts

 –  Vehicle charging syst

• 100+ volts

 –  Injector solenoid oper 

Series 40E25ST0041/2

2/15 99

m

tion

2

Wi

Covered Circuit Length

0 to 49 mm

50 to 151 mm

 305 to 609 mm

Series 40Ee Length Requirements

Maximum Deviation

5.0 mm

7.5 mm

.15.0 mm

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610 to 914 mm

915 to 1219 mm1220 to 1224 mm

1225 to 1829 mm

1830 and reater Series 40E25ST0041/2

2/15 99

17.5 mm

20.0 mm22.5 mm

25.0 mm

5 + .25 mm for every 300 mm

2

ncremen grea er an mm

Cond

Quantity of Wires to be Covered

Up to 3

4 to 5

6 to 7

8 to 10

Series 40Eit Diameter for 18 AWG

Recommended Conduit Diameter 

6 mm

9 mm

10 mm

13 mm

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8 to 10

11 to 17

18 to 21

22 to 28

27 to 37

Series 40E25ST0041/2

2/15 99

  o

13 mm

16 mm

19 mm

22 mm

25 mm

2

 mm

Wire Gauge

14 AWG

16 AWG

Series 40E

Terminal Load Criteria

Must Withstand Applied Load

222 N

133 N

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16 AWG

18 AWG

Series 40E25ST0041/2

2/15 99

133 N

89 N

2

CEOPECM

IPR

ICP

Series 40EEngine Harness

P

 

ECM

•CT  Solenoids

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EOT

MAP

Injectors

Series 40E25ST0041/2

2/15 99

2

Vehi

•

•

Series 40E

cle Interface Harness

 

Power ECM

 ECM

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•

•

Series 40E25ST0041/2

2/15 99

 

Communication To TheECM

ECM Outputs

2

WIRE C

EXE

IMPING

CISE

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Termin

Part Number  Description

2003343C1

 ATS Connector

BAPS Connector

1689464C1

Packard 12020156 Main Power Relay

2041419C1 VIH-to-ECM Connect

Series 40El Installation Technique

Installation Refer to

erminal  A 3.7.4.1

erminal B 3.7.4.2

Terminal

or Terminal

 A 3.7.4.1

C 3.7.4.3

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2041420C1 VIH-to-ECM Connect

Packard 12066614 Main Power Relay

235135053 J1708 / J1587 Data L

Series 40E25ST0041/2

2/15 99

a n onnec23515462

or Terminal C 3.7.4.3

Terminal A 3.7.4.1

ink Terminal D

. . .

3.7.4.4

2

. . .*r erm na

Terminal

Series 40E

Push To Seat Terminal

Connector Assembly

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Series 40E25ST0041/2

2/15 99

 

2

Seal Positioning

Series 40EPush To Seat Terminals

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Series 40E25ST0041/2

2/15 99

2

Contact

Cable Core Wings

Series 40E

Push To Seat Terminals

Insulation Wings

Seal

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g

Series 40E25ST0041/2

2/15 99

2

Series 40E

Push To Seat Terminals

Cable

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TerminalSeries 40E25ST0041/2

2/15 99

Seal

2

Series 40E

Pull To Seat Terminal

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Pull-To-Seat

Connector 

Series 40E25ST0041/2

2/15 99

2

J 387

Or Equi

Series 40EPull To Seat Terminal

06

alent

Cable

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TerminalSeries 40E25ST0041/2

2/15 99

2

Crimp

Series 40Eool for Augat Terminals

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Series 40E25ST0041/2

2/15 99

2

Pull-to-

Terminal (14 and 16 ga Wire),

Series 40ESeat Terminal Method C

18 ga GXL Wire

16 ga GXL Wire

14 ga GXL Wire

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Series 40E25ST0041/2

2/15 99

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

2

Guidelines for Ac

60-pin Terminal Detail Crim

14 AWG Insulation 3.2

14 AWG Conductor 

16 AWG Insulation

1.

2.

Series 40Eeptable Terminal Crimp

p Height

3.48 mm

Crimp Width

2 mm

2.44 mm

3.48 mm

0 mm

0 mm

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16 AWG Conductor 1.

 

18 AWG Conductor  1.

.

Series 40E25ST0041/2

2/15 99

2.44 mm4 mm

. mm

4 mm 2.05 mm

2

Deuts

Series 40Ech Terminal Positioning

0.8 mm

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6.0 mm

Series 40E25ST0041/2

2/15 99

2

Deut

Series 40Ech Terminal Installation

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Series 40E25ST0041/2

2/15 99

25.4 mm

2

Series 40EDeutsch Terminal

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Unlocked Posit ion

Series 40E25ST0041/2

2/15 99

Locked Position

2

Series 40EDeutsch Removal Tool

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Series 40E25ST0041/2

2/15 99

2

Canno

Latch

Locator 

Latch

Locator 

Series 40En Connector Crimp Tool

 

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Locator 

Color 

Code Turret

Index

Mark

Series 40E25ST0041/2

2/15 99

Lock Pin

2

Dial

Series 40E

Cannon Connector 

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Series 40E25ST0041/2

2/15 99

2

Cannon Connector E

Series 40E

ploded View (Plug End)

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Series 40E25ST0041/2

2/15 99

2

Cannon Expl

Series 40Eoded View (Socket End)

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Series 40E25ST0041/2

2/15 99

2

Ca

Insertion

Shoulder 

oo

Guide Pin

Series 40Ennon Terminal Insertion

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Series 40E25ST0041/2

2/15 99

2

Cannon

Socket

Extraction End

Series 40Eonnector Removal Tool

Handle

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Lock Ring

Series 40E25ST0041/2

2/15 99

 

2

WIRE S

GUID

LICING

LINES

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Tool

Heat Gun

Sn 60 solder with rosin core flux

Wire Stripper 

Splice Clips

Series 40ESplicing Tools

Part Number 

----

----

Kent-Moore J 35615 or equivalent

DDC P/N 0597428 or equivalent

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p p

Heat Shrink Tubing

Series 40E25ST0041/2

2/15 99

q

Refer to Section 3.7.7.5

2

Series 40ESplicing Straight Leads

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Series 40E25ST0041/2

2/15 99

2

Recommended Spli

oo

Heat Gun

Wire Stripper 

Splice Clips

Heat Shrink Tubing

Series 40Eing Tools Alt. Method 1

ar um er  

----

Kent-Moore J-35615 or equivalent

23519359 or equivalent

Refer to Section 3.7.7.5

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Terminal Crimper for 16 and 18 AWG

Terminal Crimper for 14 and 12 AWG

Terminal Crimper for 10 AWG

Series 40E25ST0041/2

2/15 99

Kent-Moore J-38125-6

2

Splicing Strai

Series 40Eght Leads Alt. Method 1

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Series 40E25ST0041/2

2/15 99

2

Recommended Spli

oo

Heat Gun

Wire Stripper 

Splice Clips

Heat Shrink Tubing

Series 40Eing Tools Alt. Method 2

ar um er  

----

Kent-Moore J-35615 or equivalent

0597428 or equivalent

Refer to Section 3.7.7.5

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Terminal Crimper for 16 and 18 AWG

Terminal Crimper for 14 and 12 AWG

Terminal Crimper for 10 AWG

Series 40E25ST0041/2

2/15 99

Kent-Moore J-38125-6

2

Splicing Straigh

Shrink Tubing

Series 40E

t Leads Alt. Method 2

Splice Clip, P/N 597428 

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6mm (.25”

Both En

Series 40E25ST0041/2

2/15 99

Min.

ds

2

Strai

 Apply Twoayers o ape

Series 40En Relief of Spliced Joint

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Minimum

Both EndsGeneri

Insulat

Series 40E25ST0041/2

2/15 99

 

 

Minimum

Both Endsd

2

65 mm MinimumBetween Splices

Series 40Etaggering Wire Splices

Tape Spliced

Wires Together 

orrect Method

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Series 40E25ST0041/2

2/15 99

2

Incorrect Method

•  insulation by about 6mm

Series 40EShrink Wrap

 on both sides of the splice

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Series 40E25ST0041/2

2/15 99

2

DIG

MULTI

TAL

ETER

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•

sui

on

Series 40EDigital Multimeter 

 

table for diagnostic work

Navistar electronics

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Series 40E25ST0041/2

2/15 99

2

Di

Manual Range

Replace

Battery

Series 40Egital Multimeter Display

Touch Hold

Measurement

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Series 40E25ST0041/2

2/15 99

 

Range Indicato

2

 

Series 40EDVOM Pushbuttons

Manual / AutoRange Select

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Series 40E25ST0041/2

2/15 99

2

Series 40ECurrent Measurement

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Series 40E25ST0041/2

2/15 99

2

Series 40EVoltage Measurement

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Series 40E25ST0041/2

2/15 99

2

Series 40Eesistance Measurement

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Series 40E25ST0041/2

2/15 99

2

ELECT

SERVIC

RONIC

E TOOL

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Series 40EElectronic Service Tool

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Series 40E25ST0041/2

2/15 99

2

Ele

Series 40Etronic Service Tool Map

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Series 40E25ST0041/2

2/15 99

2

EN

DIAGNHARD STAR

INE

STICS/ NO START

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HARD STAR  / NO START

Series 40Eiagnostics Preparation

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Series 40E25ST0041/2

2/15 99

2

Series 40Eiagnostics Preparation

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Series 40E25ST0041/2

2/15 99

2

Series 40ED-200 Test Kit

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Series 40E25ST0041/2

2/15 99

2

1. Sufficient Clean

• ree o a er- c ng an

• Correct grade of fuel

Method

Series 40EFuel Quality

 Fuel

 c ou ng

Check

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Method

Visual

Series 40E25ST0041/2

2/15 99

Check

2

2. Visual Inspecti

• Inspect for leaks

• Inspect for loose conn

Method

Series 40EVisual Inspection

n

Electrical

ctions, etc.

Check

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Method

Visual

Series 40E25ST0041/2

2/15 99

Check

2

• Check engine crankca

3. CHECK ENGIN

• Check for contaminant• Correct Grade / Viscos

• Miles / Hours on oil

• Check oil pressure on

Series 40EEngine Oil Level

e oil level

 OIL LEVEL

 (fuel, coolant)ty

ash gauge

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Visual

Series 40E25ST0041/2

2/15 99

2

Inta

• Ins ect hoses and i i

4. Intake / Exhaus

• Check fi lter minder • Inspect exhaust syste

Method

Series 40Eke / Exhaust Restriction

n

 Restriction

Check

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Method

Visual

Series 40E25ST0041/2

2/15 99

Check

2

Series 40EInlet Restriction Gauge

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Series 40E25ST0041/2

2/15 99

2

5. EST TOOL - FA

• ns a ec ron c erv

 Active

Inactive

Series 40E

EST Tool Fault Codes

LT CODES

e oo

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Inactive

See Electronic Diagno

Series 40E25ST0041/2

2/15 99

tic Form for codes

2

6a. EST - ENGINE

• e ec an ar es r  

Menu

Faults

Found

Series 40EEngine Off Tests

OFF TESTS

om e ng ne es

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Repair fault codes befo

Series 40E25ST0041/2

2/15 99

re continuing

2

6b. EST - INJECT

NOTE: Standard Test mu

• Select Injector Test fro

 

Test.

Faults

Series 40EInjector “ Buzz Test”

R “ BUZZ TEST”

t be performed first, in

m the Engine Off Test

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oun

See Electronic Diagno

Series 40E25ST0041/2

2/15 99

tic Form for codes

2

7. STI BUTTON - F

NOTE: Perform this test i

• Depress and hold “ En

then turn the ignition s

 

position.

Faults

Series 40EFlash Codes

LASH CODES

 a EST is not available or

ine Diagnostics” switch,

witch to the “ ON”

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Faults

Found

Refer to Electronic DiSeries 40E25ST0041/2

2/15 99code(s) are set

nostic form if fault

2

Series 40Eelf Test Input Switch

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Series 40E25ST0041/2

2/15 99

2

8. EST TOOL - DAT• Select and enter the follo

in a custom data list.

• Monitor the data while cr 

secon s m n mum

Data Sp

 

Eng. RPM

 vo

130 RP

Series 40EEST - Data List

 LISTing data as the first 3 lines

nking the engine for 20

ec  Actual

 m n.

 min.

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If voltage is low, refer to

If no RPM is noted rechec

 

Series 40E25ST0041/2

2/15 99 If ICP pressure is low, ref 

CM diagnostics

k fault codes

  .

2

r to Test 10

9a. ECM VOLTAG

NOTE: Perform this test i

• Check while cranking the

• Measure with DVOM at th

 

Pins: (21+ & 1-) (22+ & 2-) (

Instrument Spe

Series 40EECM Voltage

 a EST is not available or

engine

ree locations with breakout

4+ & 23-)

c Actual

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DVOM &

Breakout box7 vol

minim

Series 40E25ST0041/2

2/15 99 If voltage is low, refer

ts

um

2

o ECM diagnostics

Series 40EECM Voltage

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Series 40E25ST0041/2

2/15 99

2

• Minimum 130 RPM en

9b. ENGINE CRA

secon s

• Measure with breakou

ECM @ pins 51+ & 19-

Instrument Sp

DVOM 26

Series 40EEngine Cranking RPM

ine cranking speed for 20

KING RPM

 box engine harness on

c Actual

z

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51+ & 19- Mini

If no fre uenc rechecSeries 40E25ST0041/2

2/15 99

um

k fault codes

2

Series 40EEngine Cranking RPM

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Series 40E25ST0041/2

2/15 99

2

Inj

• Minimum 130 RPM cra

9c. Injection Cont

• Measure with breakou

Harness on ECM @ pi

“ tee” signal (green) &

Instrument Sp

DVOM 1 v

Series 40Eection Control Pressure

nk speed for 20 seconds

ol Pressure

 box connected to Engine

s 16+ & 19- or breakout

ground (black)

c Actual

lt

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16+ & 19- Mini

If ICP pressure is low, r 

Series 40E25ST0041/2

2/15 99

um

efer to Test 10

2

Inj

Series 40Eection Control Pressure

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Series 40E25ST0041/2

2/15 99

2

Inj

J-43103

Series 40Eection Control Pressure

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Series 40E25ST0041/2

2/15 99

2

10. LOW ICP PRES• Remove EOT sensor and

reinstall EOT

• Remove high pressure h

•  Attach adapter and ICP s

• Monitor pressure while c

EST

1 volt miDVOM

500 PSI

Series 40ELow ICP Pressure Test

URE TESTcheck for oil in reservoir and

se from oil manifold

nsor to the hose

anking engine

n.

in.

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If pressure is within speci

pressure oil leak

Series 40E25ST0041/2

2/15 99

 

If pressure is sti ll low repl

fications check for high

2

 ace IPR and retest

Series 40EOil Reservoir Check

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Series 40E25ST0041/2

2/15 99

2

Fuel Pu

• Measure at bleeder va

11. Fuel Pump Pre

• Minimum 130 RPM cra

Instrument Sp

0 - 160 PSI

Gauge20

mini

Series 40Emp Pressure (Cranking)

ve on fi lter head

ssure

nk speed for 20 seconds

c Actual

SI

um

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If pressure is low, rep

strainer and retest

Series 40E25ST0041/2

2/15 99

  ,

Restriction Test 2b (o

ace fuel fi lter, clean fuel

2

 

Performance Diagnostics)

Fuel PuSeries 40E

mp Pressure (Cranking)

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Series 40E25ST0041/2

2/15 99

2

EN

DIAGNPERFORMANC

INE

STICS DIAGNOSTICS

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Series 40Eiagnostics Preparation

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Series 40E25ST0041/2

2/15 99

2

Series 40ED-200 Test Kit

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Series 40E25ST0041/2

2/15 99

2

1. CHECK ENGIN

 

• Check for contaminant

• Correct Grade / Viscos

Method

Vi l

Series 40EEngine Oil Level

 OIL LEVEL

 

(fuel, coolant)

ty

Check

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Visual

Series 40E25ST0041/2

2/15 99

2

S

• Drain sample from tan

• Ins ect fuel for contam

.

• Measure fuel pressure• Measure pressure at hi

nstrument p

0 - 160 PSI

30

mini@ Hig

Series 40Eufficient Fuel / Pressure

(s)

ination

 

at fuel fi lter bleeder gh idle

c ctua

SI

umidle

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If pressure is low repla

Series 40E25ST0041/2

2/15 99s ra ner an re es

If pressure is st ill low,

e fuel fi lter, clean fuel

2

roceed with step 2b

Tr 

2b. TRANSFER PU• Measure at fuel fi lter inlet

Instrument p

0 - 30” Hg Less t

”

  ,

and fuel tank

Series 40Ensfer Pump Restriction

P RESTRICTION @ High idle

c  Actual

han

 

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and fuel tank.

If restrict ion is < 8” Hg., r 

Series 40E25ST0041/2

2/15 99

fer to Diagnostic Manual 11-10

2

Tr Series 40E

nsfer Pump Restriction

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Series 40E25ST0041/2

2/15 99

2

3. EST TOOL - FA

• ns a ec ron c erv

 Active

Inactive

Series 40EEST Tool Fault Codes

LT CODES

e oo

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See Electronic Diagno

Series 40E25ST0041/2

2/15 99

tic Form for codes

2

4a. EST - ENGINE

• e ec an ar es r  

Menu

Faults

Found

Series 40EEngine Off Tests

OFF TESTS

om e ng ne es

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Repair fault codes, bef 

Series 40E25ST0041/2

2/15 99

re continuing

2

4b. EST - INJECT

NOTE: Standard Test mu

• Select Injector Test fro

 

Test.

Faultsoun

Series 40EInjector “ Buzz Test”

R “ BUZZ TEST”

t be performed first, in

m the Engine Off Test

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See Electronic Diagno

Series 40E25ST0041/2

2/15 99

tic Form for codes

2

5. STI BUTTON - F

NOTE: Perform this test i

• Depress and hold “ En

then turn the ignition s

 

position.

Faults

Found

Series 40EFlash Codes

LASH CODES

 a EST is not available or

ine Diagnostics” switch,

witch to the “ ON”

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Refer to Electronic DiSeries 40E25ST0041/2

2/15 99code(s) are set

nostic form if fault

2

Series 40Eelf Test Input Switch

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Series 40E25ST0041/2

2/15 99

2

• Measure at Hi h idle a

6. INTAKE RESTRI

• Use manometer or ma

Instrument

Manometer or 

S

12.5

Series 40EIntake Restriction

d no load

CTION

nehelic

 Actualec

 H O

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Series 40E25ST0041/2

2/15 99

2

7a. EST - ENGINE

• e ec an ar es r  

Test Menu

Faults

Found

Series 40EEngine Running Test

RUNNING TEST

om e ng ne unn ng

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Refer to Electronic Di

Series 40E25ST0041/2

2/15 99

 

gnostic form if fault

2

Injector Tes

7b. EST TOOL - IN

NOTE: Standard Test mu

• Select Injector Test fro

 

Faultsoun

Series 40E (Cylinder Contribution)

JECTOR TEST

t be performed first, in

m the Engine Running

.

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Refer to Electronic DiSeries 40E25ST0041/2

2/15 99 code(s) are set

nostic form if fault

2

• Measure fuel pressure

8. FUEL PRESSU

• Measure pressure at f 

Instrument Sp

0 - 160 PSI

Gauge30

mini

If pressure is low repl

t i d t t

Series 40EFuel Pressure Full Load

at fuel fi lter bleeder 

E (FULL LOAD)

ll load rated speed

c Actual

SI

um

ace fuel fi lter, clean fuel

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strainer and retest

Series 40E25ST0041/2

2/15 99

 

2

 

Fuel PSeries 40E

ump Pressure Full Load

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Series 40E25ST0041/2

2/15 99

3

Inj

9. ICP PRESSURE• Monitor ICP pressure and

tool in data list mode. Or

Data Sp

Low Idle PSI /

High Idle

Full Load

PSI /

PSI /

If pressure is low or unst

and retest

Series 40Eection Control Pressure

 engine RPM with the EST

use breakout tee and DVOM

ec  Actual

olts

olts

olts

ble disconnect ICP sensor

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and retest

If roblem is resolved, ref 

Series 40E25ST0041/2

2/15 99

If pressure is still low or uretest

er to ICP dia nosis

3

nstable, replace IPR and

Inj

J-43103

Series 40Eection Control Pressure

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Series 40E25ST0041/2

2/15 99

3

• Monitor boost pressur 

10. BOOST PRES

  oo n a a s m

• Or use dash tach andEST tool is not availab

• Measure at full load ra

Spec

PSI @ RPM

Series 40EBoost Pressure

e and engine RPM with the

URE

e.

- 30 PSI gauge and “ T” ifle

ted speed

 Actual

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Series 40E25ST0041/2

2/15 99

3

Series 40EBoost Pressure

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Series 40E25ST0041/2

2/15 99

3

•

11. CRANKCASE

J-39267• Measure at High Idle n

Instrument Sp

”- 2

Magnehelic

Gauge

<

H

Series 40ECrankcase Pressure

RESSURE

 

load RPM

c Actual

”

0

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Gauge H2

Series 40E25ST0041/2

2/15 99

0

3

Series 40ECrankcase Pressure

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Series 40E25ST0041/2

2/15 99

3

P

• If guideline data was otests, engine operation

testing is required

Series 40Eerformance Diagnostics

tained during the first 11is satisfactory. No further

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testing is required

Series 40E25ST0041/2

2/15 99

3

•  Apply regulated suppl

12. WASTEGATE

• Inspect for leakage

• Inspect movement

Instrument Sp

- ”

Gauge28 ± 2

Series 40EWastegate Actuator 

 to actuator 

CTUATOR

c Actual

 PSI

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Series 40E25ST0041/2

2/15 99

3

Series 40EWastegate Actuator 

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Series 40E25ST0041/2

2/15 99

3

• Visually inspect exha

13. EXHAUST RE

• Measure at a point 3 t

outlet• Measure at full load &

Instrument Sp

Ma nehelic ”0 - 60” H20

 

Series 40EExhaust Restriction

st system for damage

TRICTION

 6 inches after turbo

rated speed

c Actual

2

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Series 40E25ST0041/22/15 99

3

Series 40EExhaust Restriction

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Series 40E25ST0041/22/15 99

3

• Engine off: Hot or Col

14. VALVE CLEAR

Feeler gauge

Series 40EValve Clearance

d

 ANCE

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Series 40E25ST0041/22/15 99

3

Crankshaft Position#1 Piston at TDC Compression

#6 Piston at TDC Compression

INT

1EXH

2

INT

3

Front

Series 40EValve Adjustment

 Adjust Valves

EXH INT

INT

7

INT INT

EXH

6

EXH

EXH

10

EXH

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Series 40E25ST0041/22/15 99

3

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