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Navistar Diagnostic Tools
Click here to download the Navistar Diagnostic Tools pdf.
Items that are required to diagnose IH electronic engines and multiplexed dashboards:
1. Engine Diagnostic Software (ServiceMaxx, Service Assistant, or Master Diagnostics (MD Fleet)
2. Multiplexed Dashboard diagnostic software (Diamond Logic Builder or Intune)
3. ISIS (service manuals on disc)
4. Communications cable to connect your laptop to the truck (IC4COM or similar)
5. EGED and EGES Diagnostic forms
6. Optional: ABS, Allison, and Instrument panel software, see below:
Diagnostic Equipment:
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Nexiq is now the supplier and all software is distributed through various warehouses such as Chalk’s Truck Parts (800-231-5061), or your local IH dealer.
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ServiceMaxx (engine diagnostic software) PN 828009D9 $850 list AND $200.00 per year renewal fee
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Diamond Logic Builder PN 828005 $775
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IPC PN 850042 $350
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Hydraulic ABS Software PN 850044 $325
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Software is available from IH at list price, or from Nexiq distributors like Chalk’s Truck Parts in Texas (281) 404-5703. You will need a communications cable in addition to the software!
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Note: ZTSE part numbers: Check pricing from your IH dealer.
Diagnostic Software: (note you will also need a communications cable, see below)
- IH Engine Diagnostic Software: ServiceMaxx is the current software for engine diagnostics. All of these programs do a great job at the factory level for diagnostics. They access data and diagnostics on all IH electronic engines- 1994 to current T444E, VT365, DT466E, 530E, DT466 (EGR), DT570, HT570, VT275, and all MaxxForce engines. This software does not work with Cat, Cummins, or Detroit engines. Master Diagnostics will access late engines (2007 up with DPF) but will not access DPF pids used for diagnosing aftertreatment systems. Master Diagnostics (MD Fleet), Service Assistant (SAINT) are excellent OE softwares also, but may not access the exhaust aftertreatment PIDS on 2007 up trucks.
- Diamond Logic Builder PN 828005 $775, Multiplexed dashboard diagnostic software for later IH trucks from 2001 up with the swoopy hood: models 3200, 4100, 4200, 4300, 4400, 7400, 7500, 7600, 7700, 8500, 8600. Intune was the old multiplexed software, which was replaced several years ago with Diamond Logic Builder, which is the new multiplexed software. Instrument Panel Cluster (IPC) is good for 4700/4900 series from '97-02. The multiplexed trucks after that use DLB (or INTUNE, if you happen to have an old copy).
- IPC- Instrument Panel Cluster Diagnostic Software PN 850042 $350 for ’97-01 MD and HD data-driven dash (these trucks read dash info from the J1708 data stream but are not fully multiplexed dashboards) This includes all ’97-2002 4700, 4800, and 4900 models.
- Allison Doc for Allison Transmissions: $695, works with most comm cables (except for late Gen4 reflashing) diagnosticinnovations.com Software PN is J44950-G and is compatible with most comm cables for diagnostics. If you need to do reflashing of Allison controllers, you will need the Dearborn DPA4USB cable kit for flashing the later Gen 5 Allison controllers used from about 2006 on up. http://diagnosticinnovations.com
- Hydraulic ABS diagnostic software PN 850044 $325 for 1998-2002 4700 series trucks (IC3COM/IC4COM ZTSE 4632 cable needed, not Magikey or other common cables!)
- Hydraulic ABS diagnostic software for NGV (2002 up 4200/4400 trucks) Use Wabco Toolbox software, call 800-328-6657 to order. It is compatible with the Magikey cable.
- Bendix Air ABS: Download the free program from http://www.bendix.com/en-us/service/Pages/ABSSoftware.aspx or www.Bendix.com. You will also need any of the comm cables.
Communications Cables:
You will need at least one, and it depends on what you’re working on to determine which cable(s) you’ll need. The biggest question is whether you need to talk to 1998-2002 IH 4700 with Hydraulic ABS. If you do service the 98-02 hydraulic ABS, you need either the IC3COM (serial) or IC4COM (USB) cable. If you don’t service the 98-02 hydraulic ABS, most any cable will work with most any program. The only oddball applications are reflashing late Allison computers, and late Cummins service, which are both cable-specific programs.
Generic type RP1210 compliant cables which work with most software:
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Movimento NAV-Link /NAVCoM: Effective January 1, 2010, Navistar no longer supports the IC3COM and IC4COM, or any other communications cables. The factory supported cable is the Movimento
NAV-Link for most fleets and NAVCoM for dealers.
The NAV-Link will offer communications capabilities consistent with all IH's programs and meet most J1708/J1939 specs for other HD software. https://secure.movimentodl.com/proddetail.php?prod=NAV-Link&cat=1060 The NAVCoM cable will be aimed at dealer use because of its abilities to do independent reprogramming and advanced flight recording characteristics.
- IC4COM Cable kit Part Number ZTSE4632-USB (needed for 98-02 IH Hydraulic ABS, but works with all IH software and most other software). Even though IH is no longer supporting this cable, it is likely to work on most software just fine, especially on older engines. http://international.spx.com or http://www.suenterprise.com/Default.asp, $400-700
- Nexiq MagiKey or USB Link (PN 125032 USB-Link, www.nexiq.com) Works well, and is also available in wireless.
- EZ Tap Wireless: Wireless RP1210 cable for all HD diagnostic software on most J1708/J1939 platforms. Reasonably priced! http://www.xscapeez.com/products.html
- Eaton MD 100 Part Number: VL-Kit-01 $565 www.diagnosticinnovations.com
- Auto Tap for Trucks- software that talks in generic J1708 to most engine/trans/ABS systems, gives codes and limited data stream. $599 and includes the MD100 cable above. This is a good choice for independent garages that work on all makes because it gives you a basic software package and a comm cable that can be used for most IH applications except 98-02 hydraulic ABS. www.autotap.com
I'll forewarn you of what's coming in the future: As software becomes more complex, each software will require its own comm cable due to ever changing communications protocols. This has already happened with Allison Gen5 and Cummins, and is likely to become more widespread. Enjoy the time being where one cable does nearly everything, because that time will end in the future.
Other diagnostic tools you may need:
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Breakout box for Navpak Engines ZTSE 4445 $1502 (’98 -2004 single module ECM)
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Breakout box for ’94-97 (3 box system) use a Ford car (pre-1995) 60 pin breakout box, available from SPX/OTC or Ebay cheap.
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Breakout box for 2005 up DT466/570 EGR engines: 96 pin DLC2 systems, ZTSE 4582A $1343
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Breakout box for ESC (Multiplex computer) ZTSE 4477
Other engine specific tools you’ll need for each engine family:
Note that DT466E and DT466 (EGR) are two completely different engines with a changeover date around 2005 model year.
DT466E/530E, 1996-2004:
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Turbo Training’s Tips and Tricks book for DT466E/530E
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ServiceMaxx, MD Fleet or Service Assistant, and any RP1210 compliant comm cable
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Diagnostic sheets, see chart below to choose which ones, as there are three families- 96-97 3 box, 98-2002 Navpack, and 2002-2004 NGV (The EGED 225 for DT NGV is no longer available from IH on paper due to a printing/supplier glitch. It is available in PDF.)
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ZTSE 4445 breakout box ($1500) will be helpful
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Injector sleeve replacement tools from Iron-Tite call Rich at 440-526-0151
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Fuel suction test quick disconnect: The female Compucheck coupler can be purchased from your IH dealer under P/N 3376859 $24.93 Compucheck fitting PN’s- IH PN# Female ZTSE 4526 Parker PN#PD 242 Male- ZTSE 4542 Parker PN# PD343 Male straight ZTSE 4692
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Compression adapter, Part #: TU-15-25 Price: $115.80- 800-645-1142 Star Products, 5501 21st Street Racine, WI 53406
DT466/570 EGR 2005 up:
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Turbo Training's Tips and Tricks book for DT466/570
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ServiceMaxx, MD Fleet or Service Assistant, and any RP1210 compliant comm cable
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ZTSE 4655 ICP fitting test kit
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EGES-285, EGES-290 Diagnostics sheets, see below
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Fuel Test quick disconnect: The female Compucheck coupler can be purchased from your IH dealer under P/N 3376859 $24.93 Compucheck fitting PN’s- IH PN# Female ZTSE 4526 Parker PN#PD 242 Male- ZTSE 4542 Parker PN# PD343 Male straight ZTSE 4692
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To properly access ECM/IDM voltages and use the Diag Sheets, you’ll need breakout box ZTSE 4582A
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Use a vacuum bleeder to remove air from the cooling system (Air Lift)
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ZTSE 4725 HP oil “puck” tool (needed, but not required)
Navistar Engine Diagnostic Forms
These forms are full color schematics and diagnostic charts, very helpful when performing diagnostics. They are included in ISIS, but not readable or printable.
They are large full color 8 ½” x 17” and come in pads of 40 from your dealer for an inexpensive price.
TSI Number: 04-12-15
TSI Date: April, 2004
Subject File: Engine
I-6 (DT466, 530, 570) Engine Diagnostic Forms
Model Years |
Engine Model |
Engine Serial No. Info |
Publication No. and Form Type |
1987-1992 |
DT/DTI 466 A and B series
|
not available |
CGED-390-2, Diagnostic Analysis Guide |
1987-1992 |
DT/DTI 466 A and B series |
0436665-0690519 |
CGED-365-5, Engine Performance Analysis Guide |
1993 |
DT 408/466 and 530 series |
850017-1193209 |
EGED-115, Performance Analysis Guide |
1995-1997 |
DT 466E and 530E |
931164-1075288 |
EGED-150-1, Performance Diagnostics |
Three Box ECM |
(Three Box System) |
|
EGED-155-1, Electronic Control Diagnostics |
Single Module ECM 4700-4900, 2500, etc non-multiplexed dash |
DT 466E and 530E |
1075289-1194038 |
EGED-180-2, Hard Start Diagnostics |
1997-2002 |
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EGED-185-1, Electronic Control Diagnostics |
NGV Multiplexed truck (4200, 4300, 4400, 7400, 7600, etc) |
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2001-2004 (note EGED225 has been on backorder for years, see PDF) |
DT 466 and DT 530 |
1273511-above |
EGES-220, Mechanical Diagnostics
EGED-225, Electronic Control Diagnostics |
2004-later |
DT 466, DT 570 and HT 570 |
2000001-above |
EGED-285, Electronic Control Diagnostics
EGES-290, Mechanical Diagnostics |
1983-1986 |
9.0 L |
0005565-above |
CGED-335-4, Diagnostic form |
1982-1987 |
6.9 L |
1001-445179 |
CGED-355-5, 6.9 L Engine Performance Analysis
Guide |
1987-1994 |
7.3 L |
500079-1260
423 |
CGED-440-5, 7.3 L Diesel Performance Analysis
Guide CGED-470-4, 7.3 L Solid State Glow Plug
Troubleshooting Guide
|
1993-1997
Three Box System |
T 444E |
000500-6342
33 |
EGED-130-1, Hard Start / No Start & Performance
Diagnostics
EGED-135-1, Electronic Control System Diagnostics |
1997-2003
Single Box Controller |
T 444E |
634234-above |
EGED-195-1, Hard Start / No Start & Performance
Diagnostics
EGED-200-1, Electronic Control System Diagnostics |
2002-2003 |
VT 365 |
0000082-112
359 |
EGED-245, VT-365 Hard Start / No Start &
Performance Diagnostics
EGED-250, VT-365 Engine Performance
Diagnostics
EGED-255, VT-365 Electronic Control System
Diagnostics |
2004-later |
VT 365 |
112360-above |
EGED-245, VT-365 Hard Start / No Start &
Performance Diagnostics
EGED-250, VT-365 Engine Performance
Diagnostics
EGED-255, VT-365 Electronic Control System
Diagnostics |
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