Table Of Contents - Navistar MaxxForce DT Diagnostic Manual

Table of Contents

Table Of Contents3
Foreword5
Safety Information6
Safety Terminology6
Safety Instructions6
Work Area6
Vehicle7
Engine7
Fire Prevention7
Batteries7
Tools8
Fluids Under Pressure8
Fuel8
Removal Of Tools, Parts, And Equipment8
Maxxforce Dt, 9 And 10 Aftertreatment System Diagnostics9
Start Diagnostics Here: Engine And Aftertreatment System9
Operational Checks9
Symptom 1 (Medium Duty): Frequent Parked Regens With No Active Fault Codes (More Than One Parked Regen Per Day)12
Signal Values14
Afi Gasket18
New Aftertreatment Fuel Injector18
Early Production Afi Gasket18
Symptom 2 (Medium Duty): Engine No Start / Starts And Stalls21
Symptom 3 (Medium Duty): Spn 3719 Or Spn 3936 Active Only Or Frequent Regens (More Than One Parked Regen Per Day)28
Symptom 4 (Medium Duty): Spn 3719 Or Spn 3936 And Other Active Fault Codes38
Symptom 5 (Medium Duty) : Black Smoke48
Maxxforce55
Dt, 9 And 10 Servicemaxx™ Snapshots55
Graph 1: Air Management System Test (Good)55
Graph 2: Air Management System Test (Bad)57
Graph 3: 0 To 60 Mph Test (Icp Desired And Icp)58
Graph 4: 0 To 60 Mph Test (Engine Speed, Engine Load, Imp, Ebp, And App1)59
Graph 5: Normal Exhaust Gas Temperatures (Efficient Doc And Unrestricted Afi)61
Graph 6: Erratic Exhaust Gas Temperatures63
Graph 7: Low Exhaust Gas Temperatures (Restricted Afi)64
Soot Load Level Vs. Exhaust Gas Target Temperature Chart66
Aftertreatment System Operation67
Maxxforce ® Dt, 9 And 1067
Component Descriptions (Theory Of Operation)70
Diesel Oxidation Catalyst (Doc)70
Diesel Particulate Filter (Dpf)70
Downstream Injection (Dsi) Unit71
Engine Control Module (Ecm)72
Engine Throttle Valve (Etv)73
Exhaust Back Pressure Valve (Ebpv)74
Exhaust Gas Recirculation (Egr) Valve75
Pre-Diesel Oxidation Catalyst (Pdoc)76
High And Low Pressure Turbocharger Components77
Aftertreatment System Fault Codes79
Maxxforce ® Dt, 9 And 10 (Epa 10)79
Aftertreatment System Event Chart82
And 15 Aftertreatment System Diagnostics83
Operational Checks – Start Aftertreatment Diagnostics Here84
Symptom 1 (Heavy Duty): Frequent Parked Regens With No Active Fault Codes (More Than One Parked Regen Per Day)87
Symptom 2 (Heavy Duty): Engine No Start / Starts And Stalls95
Symptom 3 (Heavy Duty): Spn 3719 Active Only Or Frequent Regens (More Than One Parked Regen Per Day)100
Symptom 4 (Heavy Duty): Spn 3719 And Other Active Fault Codes108
Symptom 5 (Heavy Duty): Black Smoke117
And 15 Servicemaxx™ Snapshots124
Graph 3: Lug Down Test (Engine Speed, Frp, And Frpd)128
Graph 4: Lug Down Test (Engine Speed And Tc1Top)130
Graph 5: Lug Down Test (Engine Speed, App1, Vehicle Speed, And Imp)131
Graph 6: Normal Exhaust Gas Temperatures (Efficient Doc And Unrestricted Afi)133
Graph 7: Inverted Exhaust Gas Temperatures (Inefficient Doc)135
Graph 8: Low Exhaust Gas Temperatures (Restricted Afi)137
And 15139
And 13142
Maxxforce 11, 13 And151
Regen Inhibitors And Entry Conditions156
Check Active Regen Inhibitors157
Check Parked Regen Inhibitors158
Parked Regen Checks159
Entry Conditions160
Dpf Status Test161
Entry Conditions For A Parked Regen162
Dpf And Doc Reuse Guidelines163
Maxxforce Dt, 9, And 10; Maxxforce 11, 13 And163
Diesel Particulate Filter (Dpf) Inlet - Clean164
Diesel Particulate Filter (Dpf) Inlet - Dirty, But Reusable165
Diesel Particulate Filter (Dpf) Inlet - Face Plugged166
Diesel Particulate Filter (Dpf) - Melted167
Diesel Particulate Filter (Dpf) - Cracked But Reusable168
Diesel Particulate Filter (Dpf) Inlet- Ash On Face169
Diesel Particulate Filter (Dpf) - Excessive Brick Shift170
Diesel Particulate Filter (Dpf) - Moderate Brick Shift171
Diesel Oxidation Catalyst (Doc) Outlet - Dirty But Reusable172
Diesel Oxidation Catalyst (Doc) - Separation173
Diesel Oxidation Catalyst (Doc) - Melted174
Diesel Oxidation Catalyst (Doc) Or Diesel Particulate Filter (Dpf) - Damaged175
Sensor Port Threads175
Abbreviations And Acronyms176
Terminology185