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Navistar MaxxForce DT Manuals
Manuals and User Guides for Navistar MaxxForce DT. We have
2
Navistar MaxxForce DT manuals available for free PDF download: Diagnostic Manual, Operation And Maintenance Manual
Navistar MaxxForce DT Diagnostic Manual (198 pages)
Aftertreatment Symptom-Based Diagnostic and Inspection Manual
Brand:
Navistar
| Category:
Engine
| Size: 5.2 MB
Table of Contents
Table of Contents
3
Foreword
5
Safety Information
6
Safety Terminology
6
Safety Instructions
6
Work Area
6
Vehicle
7
Engine
7
Fire Prevention
7
Batteries
7
Tools
8
Fluids under Pressure
8
Fuel
8
Removal of Tools, Parts, and Equipment
8
Maxxforce Dt, 9 and 10 Aftertreatment System Diagnostics
9
Start Diagnostics Here: Engine and Aftertreatment System
9
Operational Checks
9
Symptom 1 (Medium Duty): Frequent Parked Regens with no Active Fault Codes (more than One Parked Regen Per Day)
12
Signal Values
14
AFI Gasket
18
New Aftertreatment Fuel Injector
18
Early Production AFI Gasket
18
Symptom 2 (Medium Duty): Engine no Start / Starts and Stalls
21
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 Codes
38
Symptom 5 (Medium Duty) : Black Smoke
48
Maxxforce
55
Dt, 9 and 10 Servicemaxx™ Snapshots
55
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 Temperatures
63
Graph 7: Low Exhaust Gas Temperatures (Restricted Afi)
64
Soot Load Level Vs. Exhaust Gas Target Temperature Chart
66
Aftertreatment System Operation
67
Maxxforce ® Dt, 9 and 10
67
Component Descriptions (Theory of Operation)
70
Diesel Oxidation Catalyst (DOC)
70
Diesel Particulate Filter (DPF)
70
Maxxforce ® Dt, 9 and 10
70
Downstream Injection (DSI) Unit
71
Engine Control Module (ECM)
72
Engine Throttle Valve (ETV)
73
Exhaust Back Pressure Valve (EBPV)
74
Exhaust Gas Recirculation (EGR) Valve
75
Pre-Diesel Oxidation Catalyst (PDOC)
76
High and Low Pressure Turbocharger Components
77
Aftertreatment System Fault Codes
79
Maxxforce ® Dt, 9 and 10 (Epa 10)
79
Aftertreatment System Event Chart
82
Maxxforce ® Dt, 9 and 10
82
Maxxforce
83
And 15 Aftertreatment System Diagnostics
83
Start Diagnostics Here: Engine and Aftertreatment System
83
Operational Checks
83
Operational Checks – Start Aftertreatment Diagnostics here
84
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 Stalls
95
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 Codes
108
Symptom 5 (Heavy Duty): Black Smoke
117
Maxxforce
124
And 15 Servicemaxx™ Snapshots
124
Graph 1: Air Management System Test (Good)
124
Graph 2: Air Management System Test (Bad)
126
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
Aftertreatment System Operation
139
Maxxforce
139
And 15
139
Component Descriptions (Theory of Operation)
142
Maxxforce
142
And 13
142
Aftertreatment System Fault Codes
151
Maxxforce 11, 13 and
151
Aftertreatment System Event Chart
155
Maxxforce 11, 13 and
155
Regen Inhibitors and Entry Conditions
156
Check Active Regen Inhibitors
157
Check Parked Regen Inhibitors
158
Parked Regen Checks
159
Entry Conditions
160
DPF Status Test
161
Entry Conditions for a Parked Regen
162
Dpf and Doc Reuse Guidelines
163
Maxxforce Dt, 9, and 10; Maxxforce 11, 13 and
163
Diesel Particulate Filter (DPF) Inlet - Clean
164
Diesel Particulate Filter (DPF) Inlet - Dirty, but Reusable
165
Diesel Particulate Filter (DPF) Inlet - Face Plugged
166
Diesel Particulate Filter (DPF) - Melted
167
Diesel Particulate Filter (DPF) - Cracked but Reusable
168
Diesel Particulate Filter (DPF) Inlet- Ash on Face
169
Diesel Particulate Filter (DPF) - Excessive Brick Shift
170
Diesel Particulate Filter (DPF) - Moderate Brick Shift
171
Diesel Oxidation Catalyst (DOC) Outlet - Dirty but Reusable
172
Diesel Oxidation Catalyst (DOC) - Separation
173
Diesel Oxidation Catalyst (DOC) - Melted
174
Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter (DPF) - Damaged
175
Sensor Port Threads
175
Abbreviations and Acronyms
176
Terminology
185
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Navistar MaxxForce DT Operation And Maintenance Manual (102 pages)
Brand:
Navistar
| Category:
Engine
| Size: 6.75 MB
Table of Contents
Table of Contents
3
Foreword
9
Safety Information
11
Warranty
15
Federal Emission System Warranty
15
Warranty Period
15
Required Maintenance
15
Warranty Repairs and Service
15
Recommended Maintenance or Repair Parts
16
Emergency Repairs
16
What Is Not Covered by Warranty
16
Warranty Rights and Responsibilities
17
California Emission System Warranty
17
Warranty Period
17
Required Maintenance
18
Warranty Repairs and Service
18
Recommended Maintenance or Repair Parts
18
Emergency Repairs
18
What Is Covered by Warranty
19
What Is Not Covered by Warranty
19
Warranty Rights and Responsibilities
20
Section 1 - Engine Systems
21
Engine Serial Number
21
Engine Emission Label
22
Engine Accessory Labels and Identification Plates
22
Engine Specifications
23
Engine Description
25
Engine Features
27
Engine Optional Features
29
Engine Component Locations
32
Component Location - Top
32
Component Location - Front
33
Component Location - Intake Side
34
Component Location - Exhaust Side
35
Component Location - Rear
36
Section 2 - Requirements for Fuel, Engine Oil, and Coolant
37
Fuel
37
Ultra Low Sulfur Diesel (ULSD)
37
Unacceptable Fuel and Blends
37
Acceptable Fuel Blends
38
Use of Higher Biodiesel Fuel Blends (B6 to B20)
38
Unsafe Practices
39
Engine Oil
39
Engine Oil Quality and Service Categories
39
API CJ-4 for High Performance Diesel Engines
39
SAE Oil Viscosity Grades and Temperature Ranges
40
Coolant
41
Coolant Mixtures
41
Extended Life Coolant (ELC) - Red
41
Contamination of Coolant
42
Wait to Start Lamp
43
Section 3 - Instruments, Indicators, and Switches
43
Instrument Panel Gauge Cluster
43
Warning Lights
43
Idle Shutdown Indicator
44
Maintenance Lamp
44
Amber Warning Lamp (AWL)
45
RED Stop Lamp (RSL)
45
High Exhaust System Temperature (HEST) Lamp
46
Diesel Particulate Filter (DPF) Indicator
46
Malfunction Indicator Lamp (MIL)
47
Typical Water Temperature Gauge
48
Oil Pressure Gauge
49
Oil Temperature Gauge
50
Switches
51
Engine Brake ON/OFF Switch
51
Engine Exhaust Brake ON/OFF Toggle Switch
51
Air Cleaner Restriction Indicator
52
Section 4 - Engine Operation
53
Preoperation Checklist
53
Priming the Fuel System
54
Starting the Engine
54
Emergency Starting
56
Operation
57
Suggested Warm-Up Time
57
Idle Speed
57
Extended Idling Periods
58
Exhaust Aftertreatment System
58
Aftertreatment (AFT) High-Soot Auto Engine Shut down
59
Engine Idle Shutdown Timer (Federal-Optional)
59
Engine Idle Shutdown Timer (California-Standard)
60
Cold Weather Operation
61
Cold Ambient Protection (CAP)
62
Hot Weather Operation
62
Engine Shutdown
63
HD-OBD Overview
63
Radiator Shuttle Enable (RSE)
63
Road Speed Limiting (RSL)
63
Road Operation
63
Downhill Operation
64
Section 5 - Maintenance Schedule and Service Procedures
65
Maintenance Schedule
65
Service Procedures
68
Oil Level
68
Coolant Level
69
Water Separator
70
Charge Air Cooler (CAC)
72
External Leakage
72
Air Cleaner Restriction
72
Engine Oil and Filter
73
Centrifuge Filter (if Equipped)
77
Resetting Change Engine Oil Service Interval Message
80
Belt, Air Intake Piping and Clamps
81
Coolant Freeze Point
83
Fuel Filter
83
Fuel Strainer
87
Electrical System
89
Vibration Damper
89
Engine Valve Lash
89
Engine Brake Lash
89
Induction System
89
Extended Life Coolant (ELC) Extender
90
Crankcase Pressure
91
Turbochargers
91
Cleaning Diesel Particulate Filter
91
Service Cooling System
91
Section 6 - Long Term Storage
95
General Information
95
Section 7 - Service Records
97
Maintenance Service Record
97
Daily Care and Report
100
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