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DIAGNOSTIC MANUAL

1. New Aftertreatment Fuel Injector

(AFI) gasket

2. Early production AFI gasket

Figure 22

AFI Gasket

Step

Action

Decision

CAUTION

Do not remove the nozzle injector from the
doser housing.

Spray pattern test is no

longer a visual check for Aftertreatment
Fuel Injector (AFI) replacement.

Perform Aftertreatment Fuel Injector (AFI) visual inspection.
Remove AFI (see Engine Service Manual) and check for the
following:

Visual Checks:

•

Correct AFI gasket is installed (Figure 22)

•

AFI and bore unrestricted and free of carbon buildup

•

AFI tip free of cracks and other damage

Did AFI pass all visual checks?

Yes: Install AFI, and go to step 10

No: Correct failed visual check(s).
After repairs are complete, install AFI
and go to step 10.

https://www.truck-manuals.net/

Содержание MaxxForce DT

Страница 1: ...Revision 5 EPA 10 US Canada October 2014 DIAGNOSTIC MANUAL Aftertreatment Symptom Based Diagnostic and Inspection Manual MaxxForce DT 9 and 10 EPA 10 MaxxForce 11 13 and 15 EPA 10 Navistar Inc 2701 Na...

Страница 2: ...https www truck manuals net...

Страница 3: ...5 GRAPH 5 NORMAL EXHAUST GAS TEMPERATURES EFFICIENT DOC AND UNRESTRICTED AFI 57 4 6 GRAPH 6 ERRATIC EXHAUST GAS TEMPERATURES 59 4 7 GRAPH 7 LOW EXHAUST GAS TEMPERATURES RESTRICTED AFI 60 4 8 SOOT LOAD...

Страница 4: ...14 1 MAXXFORCE 11 13 AND 15 151 15 REGEN INHIBITORS AND ENTRY CONDITIONS 152 15 1 REGEN INHIBITORS 152 15 2 ENTRY CONDITIONS 156 16 DPF AND DOC REUSE GUIDELINES 159 16 1 MAXXFORCE DT 9 AND 10 MAXXFOR...

Страница 5: ...vances Procedures specifications and parts defined in published technical service literature may be altered Technical service literature is revised periodically If a technical publication is ordered t...

Страница 6: ...ion and Note Warning A warning describes actions necessary to prevent or eliminate conditions hazards and unsafe practices that can cause personal injury or death Caution A caution describes actions n...

Страница 7: ...before removing panels housing covers and caps If an engine or vehicle is not safe to operate tag the ignition key Fire Prevention Make sure charged fire extinguishers are in the work area NOTE Check...

Страница 8: ...ssure Follow approved procedures only Fuel Do not over fill the fuel tank Overfill creates a fire hazard Do not smoke in the work area Do not refuel the tank when the engine is running Removal of Tool...

Страница 9: ...m Operational Checks Operational Checks Start Aftertreatment Diagnostics Here Step Action Decision 1 Verify the following engine systems are in satisfactory condition Engine Oil Park vehicle on level...

Страница 10: ...cracks or internal damage without removing the DPF from the vehicle and is used to test basic functionality of the diesel particulate filter This is to be done prior to removing the DPF 1 The transmi...

Страница 11: ...om 2 Medium Duty Engine No Start Starts and Stalls page 17 Step Action Decision 5 Using Electronic Service Tool EST with ServiceMaxx software check Diagnostic Trouble Code DTC list for SPN 3719 FMI 0...

Страница 12: ...ad Test Specific Session and verify Load Test Specific Session is unchecked 2 Go to Sessions Performance and select the record snapshot icon from the toolbar 3 Go to Tests KOER Tests Air Management Te...

Страница 13: ...cision 2A Check for engine performance issues Perform 0 to 60 MPH Test procedure below 1 Using EST go to Sessions Performance 2 Find an open stretch of road where minimum speed limit is 50 mph or high...

Страница 14: ...Signal Values ICP desired ICP Injection Pressure Regulator IPR valve control Compare snapshot to Graph 3 and associated Graph Analysis page 54 Is ICP system operating as per Graph 3 Graph Analysis Yes...

Страница 15: ...ne Speed Engine Load Intake Manifold Pressure IMP Exhaust Back Pressure EBP Accelerator Pedal Position 1 APP1 Compare snapshot to Graph 4 and associated Graph Analysis page 55 Is AMS operating as per...

Страница 16: ...nlet Temperature DPFIT Diesel Particulate Filter Outlet Temperature DPFOT DPF Soot Load Compare snapshot to Graph 5 6 and 7 page 57 Which graph does snapshot most closely match Graph 5 Diagnostics com...

Страница 17: ...F DOC and PDOC reusable Yes Install removed aftertreatment system components and go to step 6 No Replace failed component s After repairs are complete go to step 6 Step Action Decision 6 Determine roo...

Страница 18: ...ctor AFI replacement Perform Aftertreatment Fuel Injector AFI visual inspection Remove AFI See Engine Service Manual and check for the following Visual Checks Correct AFI gasket is installed Figure 1...

Страница 19: ...ion 10 Verify exhaust gas temperatures are within specification 1 Using Electronic Service Tool EST with ServiceMaxx software go to Tests KOER Aftertreatment Tests Onboard Filter Cleanliness Test OBFC...

Страница 20: ...epairs 1 Verify engine coolant temperature is greater than 180 F 82 C and lube oil temperature is greater than 176 F 80 C 2 Using EST with ServiceMaxx software go to Tests and deselect Load Test Speci...

Страница 21: ...gine does not start wait 2 to 3 minutes and crank engine again for a maximum of 20 seconds 5 Stop recording 6 Use the playback feature in ServiceMaxx and graph TC1TOP and Diesel Particulate Filter Dif...

Страница 22: ...his is normal and the DPF should NOT be replaced Is the DPF contaminated Yes Remove Pre Diesel Oxidation Catalyst PDOC Diesel Oxidation Catalyst DOC and then and then go to step 4 No Go to step 5 Step...

Страница 23: ...tertreatment system components and then go to step 7 Step Action Decision 6 Determine root cause of exhaust system contamination See Engine Symptoms Diagnostics section in Engine Diagnostic Manual Aft...

Страница 24: ...or clamp After repairs are complete go to step 9 Step Action Decision 9 Check for a failed Air Management System AMS actuator 1 Using EST with ServiceMaxx software go to Tests Load Test Specific Sessi...

Страница 25: ...sion 10A Check for engine performance issues Perform 0 to 60 MPH Test procedure below 1 Using EST go to Sessions Performance 2 Find an open stretch of road where minimum speed limit is 50 mph or highe...

Страница 26: ...tion in Engine Diagnostic Manual After repairs are complete retest for original problem Step Action Decision 10C Check for Air Management System AMS issue Using EST with ServiceMaxx software use the p...

Страница 27: ...repairs 1 Verify engine coolant temperature is greater than 180 F 82 C and lube oil temperature is greater than 176 F 80 C 2 Using EST with ServiceMaxx software go to Tests and deselect Load Test Spec...

Страница 28: ...g Electronic Service Tool EST with ServiceMaxx software check Diagnostic Trouble Code DTC list to determine which of the following fault codes is active SPN 3719 3936 FMI 0 15 or 16 Which fault code i...

Страница 29: ...es go to Step 11 Step Action Decision 4 Do three Onboard Filter Cleanliness Tests OBFCT to decrease soot load of Diesel Particulate Filter DPF Using EST go to Tests KOER Aftertreatment Tests Onboard F...

Страница 30: ...ymptom 5 Medium Duty Black smoke page 44 No Go to step 11 Step Action Decision 7 Determine if Diesel Particulate Filter DPF Pre Diesel Oxidation Catalyst PDOC and Diesel Oxidation Catalyst DOC are con...

Страница 31: ...to step 11 Step Action Decision 11 Check for a failed Air Management System AMS actuator 1 Using EST with ServiceMaxx software go to Tests Load Test Specific Session and verify Load Test Specific Sess...

Страница 32: ...cision 11A Check for engine performance issues Perform 0 to 60 MPH Test procedure below 1 Using EST go to Sessions Performance 2 Find an open stretch of road which will safely allow full acceleration...

Страница 33: ...tion in Engine Diagnostic Manual After repairs are complete retest for original problem Step Action Decision 11C Check for Air Management System AMS issue Using EST with ServiceMaxx software use the p...

Страница 34: ...from the toolbar When OBFCT is complete stop recording Use the playback feature and graph the following signal values from OBFCT Signal Values Diesel Oxidation Catalyst Inlet Temperature DOCIT Diesel...

Страница 35: ...ctor AFI replacement Perform Aftertreatment Fuel Injector AFI visual inspection Remove AFI see Engine Service Manual and check for the following Visual Checks Correct AFI gasket is installed Figure 2...

Страница 36: ...rtreatment Tests Onboard Filter Cleanliness Test OBFCT 2 Go to Sessions Performance and select the record snapshot icon from the toolbar When OBFCT is complete stop recording Use the playback feature...

Страница 37: ...for system repairs 1 Verify engine coolant temperature is greater than 180 F 82 C and lube oil temperature is greater than 176 F 80 C 2 Using EST with ServiceMaxx software go to Tests and deselect Lo...

Страница 38: ...2 Step Action Decision 2 Using Electronic Service Tool EST with ServiceMaxx software check Diagnostic Trouble Code DTC list to determine which of the following fault codes is active SPN 3719 FMI 0 15...

Страница 39: ...de go to Step 11 Step Action Decision 5 Do three Onboard Filter Cleanliness Tests OBFCT to decrease soot load of Diesel Particulate Filter DPF Using EST go to Tests KOER Aftertreatment Tests Onboard F...

Страница 40: ...mptom 5 Medium Duty Black smoke page 44 No Go to step 12 Step Action Decision 8 Determine if Diesel Particulate Filter DPF Pre Diesel Oxidation Catalyst PDOC and Diesel Oxidation Catalyst DOC are cont...

Страница 41: ...o step 12 Step Action Decision 12 Check for a failed Air Management System AMS actuator 1 Using EST with ServiceMaxx software go to Tests Load Test Specific Session and verify Load Test Specific Sessi...

Страница 42: ...sion 12A Check for engine performance issues Perform 0 to 60 MPH Test procedure below 1 Using EST go to Sessions Performance 2 Find an open stretch of road where minimum speed limit is 50 mph or highe...

Страница 43: ...tion in Engine Diagnostic Manual After repairs are complete retest for original problem Step Action Decision 12C Check for Air Management System AMS issue Using EST with ServiceMaxx software use the p...

Страница 44: ...eanliness Test When OBFCT is complete stop recording Use the playback feature and graph the following signal values from OBFCT Signal Values Diesel Oxidation Catalyst Inlet Temperature DOCIT Diesel Pa...

Страница 45: ...ctor AFI replacement Perform Aftertreatment Fuel Injector AFI visual inspection Remove AFI see Engine Service Manual and check for the following Visual Checks Correct AFI gasket is installed Figure 4...

Страница 46: ...reatment Tests Onboard Filter Cleanliness Test OBFCT 2 Go to Sessions Performance and select the record snapshot icon from the toolbar When OBFCT is complete stop recording Use the playback feature an...

Страница 47: ...epairs 1 Verify engine coolant temperature is greater than 180 F 82 C and lube oil temperature is greater than 176 F 80 C 2 Using EST with ServiceMaxx software go to Tests and deselect Load Test Speci...

Страница 48: ...ll vehicle operational checks page 5 Step Action Decision 1 Diesel Particulate Filter DPF Snap Acceleration Test Quick Test This procedure checks the DPF for cracks or internal damage without removing...

Страница 49: ...and loose parts End of diagnostics Step Action Decision 4 Check for a Failed Air Management System AMS actuator 1 Using an Electronic Service Tool EST with ServiceMaxx software go to Tests Load Test...

Страница 50: ...performance issues Perform 0 to 60 MPH Test procedure below 1 Using Electronic Service Tool EST with ServiceMaxx software go to Sessions Performance 2 Find an open stretch of road where minimum speed...

Страница 51: ...nostics section in Engine Diagnostic Manual After repairs are complete go to Step 10A Step Action Decision 5C Check for Air Management System AMS issue On the Electronic Service Tool EST with ServiceM...

Страница 52: ...board Filter Cleanliness Test When OBFCT is complete stop recording Use the playback feature and graph the following signal values from OBFCT Diesel Oxidation Catalyst Inlet Temperature DOCIT Diesel P...

Страница 53: ...ertreatment Fuel Injector AFI visual inspection Remove the AFI doser housing from the turbo outlet pipe see Engine Service Manual and perform the following visual checks Correct AFI gasket is installe...

Страница 54: ...are complete go to step 10 No Go to step 10 Step Action Decision 10 Verify exhaust gas temperatures are within specification 1 Using Electronic Service Tool EST with ServiceMaxx software go to Tests...

Страница 55: ...Red 3 Exhaust Gas Recirculation EGR valve position percent Purple Figure 5 Graph 1 Air Management System Test Good Graph Analysis This graph shows normal operation of the Air Management System AMS du...

Страница 56: ...a stabilized high point and a stabilized low point then compare to the table below Engine MAF Mean Value MMV Difference Tolerance MaxxForce DT 215 230 HP 690 1000 Less than 690 Fails AMS Test MaxxFor...

Страница 57: ...itoring the effects each actuator has on Intake Manifold Pressure IMP IMP is normally between 2 psi 14 kPa to 6 psi 41 kPa on engine ramp up during AMT If the Exhaust Gas Recirculation EGR valve is no...

Страница 58: ...oes not give pass or fail results It only allows the user to validate ICP and Injection Control Pressure Desired ICPD signal values under load As engine rpm increases ICP should steadily increase Low...

Страница 59: ...peed Engine Load IMP EBP and APP1 Graph Analysis This graph shows the Intake Manifold Pressure IMP signal value operating as designed This test does not give pass or fail results It only allows the us...

Страница 60: ...0 rpm 2 Verify Exhaust Back Pressure EBP is less than 70 psi 414 kPa with APP1 signal value at 99 6 and engine speed between 1800 rpm to 2200 rpm NOTE IMP signal value may be as low as 29 psi 221 kPa...

Страница 61: ...r Inlet Temperature DPFIT degrees Fahrenheit Blue 3 Diesel Particulate Filter Outlet Temperature DPFOT degrees Fahrenheit Green Figure 9 Graph 5 Normal Exhaust Gas Temperatures Efficient DOC AND Unres...

Страница 62: ...at approximate target temperature for current soot load level See Soot Load Level vs Exhaust Gas Target Temperature Chart page 62 2 Verify Diesel Oxidation Catalyst Inlet Temperature DOCIT signal valu...

Страница 63: ...m occur when the Diesel Oxidation Catalyst becomes contaminated or an issue with the Aftertreatment Fuel Injector AFI is present This test does not give pass or fail results It only allows the user to...

Страница 64: ...erature DPFOT degrees Fahrenheit Green Figure 11 Graph 7 Low Exhaust Gas Temperatures Restricted AFI Graph Analysis This graph shows low exhaust gas temperatures indicating a restricted Aftertreatment...

Страница 65: ...at approximate target temperature for current soot load level See Soot Load Level vs Exhaust Gas Target Temperature Chart page 62 2 Verify Diesel Oxidation Catalyst Inlet Temperature DOCIT signal val...

Страница 66: ...49 2 1090 F 588 C 50 66 3 1075 F 579 C 67 83 4 1050 F 566 C 84 99 5 1025 F 552 C 100 116 6 1000 F 538 C 117 132 7 975 F 524 C 133 149 8 900 F 482 C 150 169 9 860 F 460 C 170 184 10 850 F 454 C 185 19...

Страница 67: ...Diesel Oxidation Catalyst Outlet Temperature DOCOT and Diesel Particulate Filter Outlet Temperature DPFOT Monitors Diesel Particulate Filter Differential Pressure DPFDP Controls engine operating param...

Страница 68: ...ke Vehicle Speed Sensor VSS Driveline Disconnect Switch DDS Power Take Off Switch PTO Diesel Oxidation Catalyst DOC Diesel Particulate Filter DPF Diesel Oxidation Catalyst Outlet Temperature DOCOT sen...

Страница 69: ...ETV Warning Indicators Inlet Air Heater IAH Aftertreatment Control Module ACM Aftertreatment Fuel Inlet Sensor AFTFIS Aftertreatment Fuel Pressure 2 AFTFP2 sensor Aftertreatment Fuel Shutoff Valve AFT...

Страница 70: ...Oxidizes hydrocarbons and carbon monoxide CO in exhaust stream Provides heat for exhaust system warm up Diesel Particulate Filter DPF The DPF does the following Captures and temporarily stores carbon...

Страница 71: ...he clean side of the low pressure fuel system and will provide a metered amount of fuel to the Aftertreatment Fuel Injector AFI The DSI unit provides pressurized fuel injection pulses to the AFI The A...

Страница 72: ...he Engine Control Module ECM monitors and controls engine operation to ensure maximum performance and adherence to emissions standards The ECM performs the following functions Provide reference voltag...

Страница 73: ...e s air intake path through the CAC to help heat the exhaust aftertreatment during regeneration and to assist when heavy EGR is requested The electronic portion of the ETV contains a microprocessor th...

Страница 74: ...ure Valve EBPV The Exhaust Back Pressure Valve EBPV controls the position of the exhaust valve increasing or decreasing exhaust gas back pressure and temperature to allow the Diesel Oxidation Catalyst...

Страница 75: ...System MaxxForce DT 9 and 10 Engines Exhaust Gas Recirculation EGR Valve The EGR valve receives the desired valve position from the ECM for exhaust gas recirculation The EGR valve regulates the flow o...

Страница 76: ...improve exhaust emissions Allows for more efficient operation of the aftertreatment system 1 PDOC back bracket attaches to engine 2 PDOC bracket 3 Exhaust Flange Gasket 4 11 x 20 x 24 mm spacer 3 5 M...

Страница 77: ...ly 11 Low pressure turbine outlet 12 High pressure compressor housing 13 High pressure turbine inlet 14 Low pressure turbine housing 15 Low pressure bearing housing 16 Low pressure compressor housing...

Страница 78: ...ides high charge air pressure to improve engine performance and to help reduce emissions Exhaust gas flow The HP turbocharger is connected directly to the exhaust manifold through the HP turbine inlet...

Страница 79: ...4 DPFOT signal Out of Range LOW DPFOT signal circuit short to GND Failed DPFOT sensor 3246 7 DPFOT not warming along with engine Biased DPFOT circuit or sensor 3246 20 DPF over temperature possible f...

Страница 80: ...t OPEN or short to PWR Failed AFTFIS 3480 4 AFTFP1 signal Out of Range LOW AFTFP1 signal circuit short to GND Failed AFTFIS 3482 3 AFT Fuel Shutoff Valve short to PWR AFTFSV circuit OPEN or short to P...

Страница 81: ...EN or short to PWR SIG GND circuit OPEN Failed DPFOT sensor 4765 4 DOCIT signal Out of Range LOW DOCIT signal circuit short to GND Failed DPFOT sensor 4765 7 DOCIT not increasing with engine temperatu...

Страница 82: ...DIAGNOSTIC MANUAL AFTERTREATMENT SYSTEM EVENT CHART 8 1 MAXXFORCE DT 9 AND 10 78 https www truck manuals net...

Страница 83: ...ystem These illuminated warning lamps may indicate an engine mechanical or performance concern Tools Required Electronic Service Tool EST with ServiceMaxx software Interface cable RP1210B compliant su...

Страница 84: ...l fuel gauge look into fuel tanks to verify fuel level and make sure fuel levels are equal in both tanks Fuel quality Obtain a fuel sample and check for water waxing icing sediment gasoline Diesel Exh...

Страница 85: ...e 113 No Go to Symptom 1 Heavy Duty Frequent Parked Regens with No Active Codes More than one parked regen per day page 83 Step Action Decision 4 Using Electronic Service Tool EST with ServiceMaxx sof...

Страница 86: ...c Trouble Code DTC list for SPN 3719 FMI 0 or 16 DPF Soot Load Is SPN 3719 FMI 0 or SPN 3719 FMI 16 the only fault code s active Yes Go to Symptom 3 Heavy Duty SPN 3719 Active Only or Frequent Regens...

Страница 87: ...ement System AMS actuator 1 Using Electronic Service Tool EST with ServiceMaxx software go to Tests Load Test Specific Session and verify Load Test Specific Session is unchecked 2 Go to Sessions Perfo...

Страница 88: ...celerator pedal fully to the floor and accelerate to rated engine speed After Lug Down Test is complete stop recording and save snapshot Go to step 2B Step Action Decision 2B Check for low fuel rail p...

Страница 89: ...n Engine Diagnostic Manual After repairs are complete retest for original problem Step Action Decision 2D Check for an Intake Manifold Pressure IMP issue Use the playback feature in ServiceMaxx and gr...

Страница 90: ...closely match Graph 6 Diagnostics complete Graph 7 Go to step 4 Graph 8 Go to step 7 Step Action Decision 4 Determine if DPF or DOC is contaminated Remove the DPF and DOC see Exhaust System Service M...

Страница 91: ...Let the engine idle for 5 minutes while monitoring O2S Temperature signal value Is O2S Temperature signal value greater than 1400 F 760 C Yes Go to step 8 No Repair O2S or circuit See Electronic Contr...

Страница 92: ...tor AFI replacement Perform Aftertreatment Fuel Injector AFI visual inspection Remove AFI see Engine Service Manual and check for the following Visual Checks Correct AFI gasket is installed Figure 22...

Страница 93: ...Step Action Decision 12 Verify exhaust gas temperatures are within specification 1 Using Electronic Service Tool EST with ServiceMaxx software go to Sessions Performance and select the record snapsho...

Страница 94: ...een diagnosed and repaired Has root cause for frequent regens been diagnosed and repaired Yes Diagnostics complete No Go back to step 1 of Engine and Aftertreatment System Operational Checks page 80 t...

Страница 95: ...articulate Filter Differential Pressure DPFDP signal values 5 Verify DPFDP and TC1TOP are within specification DPFDP signal value should be less than 1 psi 7 kPa and TC1TOP signal value should be less...

Страница 96: ...are the DPF DOC and PDOC reusable Yes Go to step 6 No Replace failed component s After repairs are complete go to step 6 Step Action Decision 5 Determine if removed aftertreatment system components ne...

Страница 97: ...r clamp After repairs are complete go to step 8 Step Action Decision 8 Check for a failed Air Management System AMS actuator 1 Using Electronic Service Tool EST with ServiceMaxx software go to Tests L...

Страница 98: ...celerator pedal fully to the floor and accelerate to rated engine speed After Lug Down Test is complete stop recording and save snapshot Go to step 9B Step Action Decision 9B Check for low fuel rail p...

Страница 99: ...completed correctly and the proper decision was made Step Action Decision 9D Check for an Intake Manifold Pressure IMP issue Use the playback feature in ServiceMaxx and graph the following signal valu...

Страница 100: ...bar Then go to Tests KOER Aftertreatment Tests Onboard Filter Cleanliness Test Is SPN 3719 still active after OBFCT is complete Yes Go to step 2 No Go to step 6 Step Action Decision 2 Determine if Die...

Страница 101: ...s section in Engine Diagnostic Manual After repairs are complete go to step 7 Step Action Decision 6 Diesel Particulate Filter DPF Snap Acceleration Test Quick Test This procedure checks the DPF for c...

Страница 102: ...Go to Tests KOER Tests Air Management Test When Air Management Test is complete stop recording Use the playback feature in ServiceMaxx and graph the following signal values Signal Values Engine Speed...

Страница 103: ...celerator pedal fully to the floor and accelerate to rated engine speed After Lug Down Test is complete stop recording and save snapshot Go to step 8B Step Action Decision 8B Check for low fuel rail p...

Страница 104: ...n Engine Diagnostic Manual After repairs are complete retest for original problem Step Action Decision 8D Check for an Intake Manifold Pressure IMP issue Use the playback feature in ServiceMaxx and gr...

Страница 105: ...o step 10 Step Action Decision 10 Check Oxygen Sensor O2S operation Start the engine and allow to reach normal operating temperature Using EST with ServiceMaxx software go to Sessions Performance Let...

Страница 106: ...r AFI replacement Perform Aftertreatment Fuel Injector AFI visual inspection Remove AFI see Engine Service Manual and check for the following Visual Checks Correct AFI gasket is installed Figure 23 AF...

Страница 107: ...ce and select the record snapshot icon from the toolbar 2 Go to Tests KOER Aftertreatment Tests Onboard Filter Cleanliness Test When OBFCT is complete stop recording Use the playback feature and graph...

Страница 108: ...snapshot icon from the toolbar Then go to Tests KOER Aftertreatment Tests Onboard Filter Cleanliness Test Is SPN 3719 still active after OBFCT is complete Yes Go to step 3 No Go to step 7 Step Action...

Страница 109: ...ection in Engine Diagnostic Manual After repairs are complete go to step 8 Step Action Decision 7 Diesel Particulate Filter DPF Snap Acceleration Test Quick Test This procedure checks the DPF for crac...

Страница 110: ...o to Tests KOER Tests Air Management Test When Air Management Test is complete stop recording Use the playback feature in ServiceMaxx and graph the following signal values Signal Values Engine Speed I...

Страница 111: ...celerator pedal fully to the floor and accelerate to rated engine speed After Lug Down Test is complete stop recording and save snapshot Go to step 9B Step Action Decision 9B Check for low Fuel Rail P...

Страница 112: ...Engine Diagnostic Manual After repairs are complete retest for original problem Step Action Decision 9D Check for an Intake Manifold Pressure IMP issue Use the playback feature in ServiceMaxx and gra...

Страница 113: ...to step 11 Step Action Decision 11 Check Oxygen Sensor O2S operation Start the engine and allow to reach normal operating temperature Using EST with ServiceMaxx software go to Sessions Performance Let...

Страница 114: ...tor AFI replacement Perform Aftertreatment Fuel Injector AFI visual inspection Remove AFI see Engine Service Manual and check for the following Visual Checks Correct AFI gasket is installed Figure 24...

Страница 115: ...Action Decision 16 Verify exhaust gas temperatures are within specification 1 Using Electronic Service Tool EST with ServiceMaxx software go to Sessions Performance and select the record snapshot icon...

Страница 116: ...egens symptom Has root cause for frequent regens been diagnosed and repaired Yes Diagnostics complete No Go back to step 1 of Engine and Aftertreatment System Operational Checks page 80 to verify engi...

Страница 117: ...off and chock the wheels to prevent vehicle from moving in either direction NOTE Before beginning the following step based diagnostics perform all vehicle operational checks page 80 Step Action Decisi...

Страница 118: ...fault code s Using Electronic Service Tool EST with ServiceMaxx software go to Tests KOER Aftertreatment Tests Onboard Filter Cleanliness Test While OBFCT is running check the following components fo...

Страница 119: ...repair failed actuator See Performance Diagnostics section in Engine Diagnostic Manual After repairs are complete retest for original problem WARNING To prevent personal injury or death do not exceed...

Страница 120: ...cs section in Engine Diagnostic Manual After repairs are complete retest for original problem Step Action Decision 5C Verify aftertreatment system is free of restrictions Using Electronic Service Tool...

Страница 121: ...roblem Step Action Decision 6 Verify exhaust gas temperatures are within specification 1 Using Electronic Service Tool EST with ServiceMaxx software go to Sessions Performance and select the record sn...

Страница 122: ...eplacement Perform Aftertreatment Fuel Injector AFI visual inspection Remove AFI See Engine Service Manual and check for the following Visual Checks Correct AFI gasket is installed Figure 25 AFI and b...

Страница 123: ...tep Action Decision 10 Verify exhaust gas temperatures are within specification 1 Using Electronic Service Tool EST with ServiceMaxx software go to Tests KOER Aftertreatment Tests Onboard Filter Clean...

Страница 124: ...alysis This graph shows normal operation of the Air Management System AMS during the Air Management Test AMT The AMT does not give pass or fail results It only allows the user to validate the AMS by m...

Страница 125: ...lue drops NOTE MaxxForce 11 ONLY AFT regen status stays Not Active NOTE Turbocharger 1 Wastegate Control TC1WC does not affect engine performance and is removed from post production engines If engine...

Страница 126: ...agement Test AMT The AMT does not give pass or fail results It only allows the user to validate the AMS by monitoring the effects each actuator has on Intake Manifold Pressure IMP sensor IMP is normal...

Страница 127: ...aph IMP does not drop when TC2WC is commanded ON NOTE MaxxForce 11 ONLY AFT regen status stays Not Active NOTE Turbocharger 1 Wastegate Control TC1WC does not affect engine performance and is removed...

Страница 128: ...RP and FRPD Graph Analysis This graph shows a fuel management system operating as designed This test does not give pass or fail results It only allows the user to validate Fuel Rail Pressure FRP and F...

Страница 129: ...i 219 943 kPa at full load 2 Verify FRP signal value is within a 1000 psi 6 895 kPa range of FRPD signal value during acceleration NOTE Analyze Lug Down Test signal values only during engine accelerat...

Страница 130: ...rating as designed unrestricted This test does not give pass or fail results It only allows the user to validate Turbocharger 1 Turbine Outlet Pressure TC1TOP signal value under load High TC1TOP will...

Страница 131: ...gned This test does not give pass or fail results It only allows the user to validate IMP signal value under load Engine power band is typically between 1300 to 1700 rpm with peak power occurring arou...

Страница 132: ...kPa to 43 psi 296 kPa with Accelerator Pedal Position 1 APP1 signal value at 99 6 and engine speed between 1300 rpm to 1700 rpm NOTE Analyze Lug Down Test signal values only during engine acceleration...

Страница 133: ...en 4 Diesel Oxidation Catalyst DOC at operating temperature and stabilized 5 Diesel Oxidation Catalyst Inlet Temperature DOCIT degrees Fahrenheit Purple Figure 31 Graph 6 Normal Exhaust Gas Temperatur...

Страница 134: ...Diesel Particulate Filter Outlet Temperature DPFOT signal values are greater than 900 F 482 C 2 Verify Diesel Oxidation Catalyst Inlet Temperature DOCIT signal value is between 550 F 287 C to 800 F 4...

Страница 135: ...Inefficient DOC Graph Analysis This graph shows inverted exhaust gas temperatures indicating an inefficient Diesel Oxidation Catalyst DOC Inverted temperatures in the exhaust stream occur when the Die...

Страница 136: ...OCOT indicating inverted exhaust gas temperatures 2 Verify Diesel Oxidation Catalyst Inlet Temperature DOCIT signal value is between 550 F 287 C to 800 F 427 C NOTE It is normal to see Diesel Oxidatio...

Страница 137: ...ted AFI Graph Analysis This graph shows low exhaust gas temperatures indicating a restricted Aftertreatment Fuel Injector AFI Low temperatures in the exhaust stream occur when Diesel Oxidation Catalys...

Страница 138: ...F 482 C In this graph DOCOT and DPFOT are less than 900 F 482 C 2 Verify Diesel Oxidation Catalyst Inlet Temperature DOCIT signal value is between 550 F 287 C to 800 F 427 C NOTE It is normal to see...

Страница 139: ...Diesel Oxidation Catalyst Outlet Temperature DOCOT and Diesel Particulate Filter Outlet Temperature DPFOT Monitors Diesel Particulate Filter Differential Pressure DPFDP Controls engine operating para...

Страница 140: ...l Position APP sensor Park brake Vehicle Speed Sensor VSS Driveline Disconnect Switch DDS Power Take Off Switch PTO Diesel Oxidation Catalyst DOC Diesel Particulate Filter DPF Diesel Oxidation Catalys...

Страница 141: ...Valve ETV Warning Indicators Inlet Air Heater IAH Aftertreatment Fuel Inlet Sensor AFTFIS Aftertreatment Fuel Pressure 2 AFTFP2 sensor Aftertreatment Fuel Shutoff Valve AFTFSV Aftertreatment Fuel Dose...

Страница 142: ...the Low Pressure LP turbocharger wastegate control port High Pressure HP turbocharger wastegate control port the Exhaust Back Pressure Valve EBPV control port and the Turbocharger 1 Turbine Outlet Pre...

Страница 143: ...zes hydrocarbons and carbon monoxide CO in exhaust stream Provides heat for exhaust system warm up Diesel Particulate Filter DPF The DPF does the following Captures and temporarily stores carbon based...

Страница 144: ...e 11 and 13 Engines Downstream Injection DSI Unit The DSI unit is connected to the clean side of the low pressure fuel system and will provide a metered amount of fuel to the AFI The DSI unit provides...

Страница 145: ...ECM 96 pin E1 terminal Figure 38 ECM MaxxForce 11 and 13 Engines Engine Control Module ECM The Engine Control Module ECM monitors and controls engine operation to ensure maximum performance and adher...

Страница 146: ...s air intake path through the CAC to help heat the exhaust aftertreatment during regeneration and to assist when heavy EGR is requested The electronic portion of the ETV contains a microprocessor tha...

Страница 147: ...Typical Exhaust Back Pressure Valve EBPV The Exhaust Back Pressure Valve EBPV controls the position of the exhaust valve increasing or decreasing exhaust gas back pressure and temperature to allow the...

Страница 148: ...on MaxxForce 11 and 13 Engines Right Rear Engine Exhaust Gas Recirculation EGR Valve The EGR valve receives the desired valve position from the ECM for exhaust gas recirculation The EGR valve regulate...

Страница 149: ...improve exhaust emissions Allows for more efficient operation of the aftertreatment system 1 PDOC back bracket attaches to engine 2 PDOC bracket 3 Exhaust Flange Gasket 4 11 x 20 x 24 mm spacer 3 5 M1...

Страница 150: ...ght side of the engine Intake air flow Filtered air enters the LP compressor where it is compressed and directed to the LPCAC if equipped Cooled LP air enters the HP compressor where it is further com...

Страница 151: ...OW Sensor circuit fault or missing DPF Biased DPFDP sensor or circuit Cracked DPF DPFDP sensor pressure hoses reversed DPFDP sensor hose before filter leaking or disconnected 3471 1 Fuel Pressure 1 be...

Страница 152: ...T Fuel Doser sticking Open AFI stuck Open 3556 7 AFT Fuel Injector not responding as expected DSI failed system validation cycle Biased AFTFIS or circuit Biased Aftertreatment Fuel Pressure 2 AFTFP2 s...

Страница 153: ...ting up during exhaust injection Diesel Oxidation Catalyst DOC failure face plugged 4766 20 DOC Outlet Temperature above maximum desired Aftertreatment Fuel Injector AFI plugged or sticking Engine ove...

Страница 154: ...DIAGNOSTIC MANUAL Coolant leak to exhaust 5319 31 DPF incomplete Regeneration High DPFDP after DPF regen High ash level in DPF 150 https www truck manuals net...

Страница 155: ...DIAGNOSTIC MANUAL AFTERTREATMENT SYSTEM EVENT CHART 14 1 MAXXFORCE 11 13 AND 15 151 https www truck manuals net...

Страница 156: ...any of the following conditions Inhibitors do not match their expected value Entry conditions have not been met Active fault code s To view the status of Regen inhibitors use an Electronic Service To...

Страница 157: ...Check Expected Results Comment AFT Regen Inhibit Status Not Inhibited If inhibited correct the cause Check switches and any DTC that may be causing the Regen inhibit Red Stop Alert Lamp Off If On Rege...

Страница 158: ...ault Parking brake switch On If Off set parking brake if switch does not turn On then diagnose circuit fault Brake Pedal switch Off If On and foot is off pedal then diagnose circuit fault Accelerator...

Страница 159: ...482 F 250 C to 572 F 300 C If below 482 F 250 C using Electronic Service Tool EST with ServiceMaxx software run the KOER Air Management Test If above 572 F 300 C check for proper ETV operation and if...

Страница 160: ...nditions for an Active Regen When the ECM determines the soot level threshold is reached the system triggers DPF Regen NOTE Short trips or stop and go driving could prevent a successful Regen The foll...

Страница 161: ...ngine Running Engine Coolant Temperature is above or at least 170 F 75 C Vehicle stationary Inhibit DTCs must not be active Go to Regen Inhibitors page 152 PTO not active switch must be off Regen inhi...

Страница 162: ...not on Engine Coolant Temperature is above or at least 170 F 75 C Vehicle speed not rolling Inhibiting DTCs must not be active Go to Regen Inhibitors page 152 Regen Inhibit switch not active switch mu...

Страница 163: ...and 13 EPA 10 non Selective Catalyst Reduction SCR aftertreatment systems When inspecting aftertreatment systems with SCR reference the appropriate Exhaust Aftertreatment Service Manual with DPF and S...

Страница 164: ...Inlet Clean Figure 46 Diesel Particulate Filter DPF Inlet Clean Appearance Black soot or gray ash can be seen on the face of the DPF and within the channels Cause The system is working properly Action...

Страница 165: ...irty but Reusable Figure 47 Diesel Particulate Filter DPF Inlet Dirty but Reusable Appearance Black soot or gray ash on the face of the DPF and within the channels Cause The system is working properly...

Страница 166: ...Filter DPF Inlet Face Plugged Appearance The DPF is completely covered with black soot or gray ash Cause Excessive soot generation Action Determine and repair the root cause of excessive soot generat...

Страница 167: ...or deformed DPF cells Cause Excessive exhaust gas temperatures Action Determine the cause of excessive exhaust gas temperatures Refer to the appropriate Engine Diagnostic Manual for diagnostic proced...

Страница 168: ...sable Appearance Surface cracking on either face of the DPF Action The DPF can be reused NOTE Surface cracking on either face of the Diesel Particulate Filter DPF substrate is normal and acceptable If...

Страница 169: ...Filter DPF Inlet Ash on Face Figure 51 Diesel Particulate Filter DPF Inlet Ash on Face Appearance Buildup of ash on the inlet face of the DPF Cause Normal system operation Action Properly service and...

Страница 170: ...rick Shift Appearance The DPF brick has shifted past the DPFOT sensor causing damage to the DPF substrate Cause Excessive soot accumulation caused by a base engine concern resulting in higher than nor...

Страница 171: ...h the DPFOT sensor port bung but has not damaged the DPF substrate Cause Excessive soot accumulation caused by a base engine concern resulting in higher than normal exhaust back pressure Action Determ...

Страница 172: ...DOC Outlet Dirty but Reusable Figure 54 Diesel Oxidation Catalyst DOC Outlet Dirty but Reusable Appearance Black soot or gray ash on the face of the DOC Cause The system is working properly Action The...

Страница 173: ...DOC Separation A DOC separation Figure 55 Diesel Oxidation Catalyst DOC Separation Appearance DOC separation between the substrate and housing Cause Occurs during the manufacturing process Action The...

Страница 174: ...or deformed DOC cells Cause Excessive exhaust gas temperatures Action Determine the cause of excessive exhaust gas temperatures Refer to the appropriate Engine Diagnostic Manual for diagnostic proced...

Страница 175: ...el Oxidation Catalyst DOC or Diesel Particulate Filter DPF Damaged Sensor Port Threads Appearance The DOC or DPF differential pressure or temperature sensor port threats are damaged Cause Seized threa...

Страница 176: ...uel Pressure AFS Aftertreatment Fuel Supply AFT Aftertreatment AFTFD Aftertreatment Fuel Doser AFTFIT Aftertreatment Fuel Inlet Temperature AFTFIS Aftertreatment Fuel Inlet Sensor AFTFP Aftertreatment...

Страница 177: ...dy Controller BCS Boost Control Solenoid BDC Bottom Dead Center bhp Brake Horsepower BOO Brake On Off BTDC Before Top Dead Center C Celsius CAC Charge Air Cooler CACOT Charge Air Cooler Outlet Tempera...

Страница 178: ...Diesel Oxidation Catalyst Inlet Temperature DOCOT Diesel Oxidation Catalyst Outlet Temperature DPF Diesel Particulate Filter DPFDP Diesel Particulate Filter Differential Pressure DPFIT Diesel Particu...

Страница 179: ...e 3 EMI Electromagnetic Interference EOP Engine Oil Pressure EOT Engine Oil Temperature EPA Environmental Protection Agency ESN Engine Serial Number EST Electronic Service Tool ETC Engine Throttle Con...

Страница 180: ...r hour gal min U S Gallons per minute GCW Gross Combined Weight GCWR Gross Combined Weight Rating GVW Gross Vehicle Weight H2O Water HC Hydrocarbons HCI Hydrocarbon Injection HEST High Exhaust System...

Страница 181: ...anifold Pressure IMT Intake Manifold Temperature in Inch inHg Inch of mercury INJs Injectors IPR Injection Pressure Regulator ISC Interstage Cooler ITV Intake Throttle Valve J1939H J1939 Data Link Hig...

Страница 182: ...ow MAP Manifold Absolute Pressure MAP IAT Manifold Absolute Pressure Inlet Air Temperature mi Mile MIL Malfunction Indicator Lamp mm Millimeter mpg Miles per gallon mph Miles per hour MSDS Material Sa...

Страница 183: ...square inch absolute psig Pounds per square inch gauge pt Pint PTO Power Takeoff PWM Pulse Width Modulate PWR Power voltage qt Quart RAM Random Access Memory rpm Revolutions per minute SIG GND Signal...

Страница 184: ...l TCM Transmission Control Module TDC Top Dead Center V Volt VBAT or B Battery Voltage VGT Variable Geometry Turbo VIN Vehicle Identification Number VREF Reference Voltage VSS Vehicle Speed Sensor WTS...

Страница 185: ...the exhaust system to increase temperature of the exhaust gases Aftertreatment AFT system A part of the exhaust system that processes engine exhaust to meet emission requirements and traps particulate...

Страница 186: ...e decisions Calibration values are stored in ROM and put into the processor during programming to allow the engine to operate within certain parameters Camshaft Position CMP sensor A magnetic pickup s...

Страница 187: ...es the crankshaft connecting rods and allied parts Crankcase breather A vent for the crankcase to release excess interior air pressure Crankcase Oil Separator Speed CCOSS sensor The CCOSS sensor sends...

Страница 188: ...of the exhaust gases and is necessary for DPF regeneration Dual Stage Turbocharger An assembly of two turbochargers low pressure and high pressure in series to provide a wide range of charge air press...

Страница 189: ...tch ON and the engine OFF Engine Oil Pressure EOP sensor A variable capacitance sensor that measures oil pressure Engine Oil Temperature EOT sensor A thermistor sensor that measures oil temperature En...

Страница 190: ...sensor Exhaust manifold Exhaust gases flow through the exhaust manifold to the turbocharger exhaust inlet and are directed to the EGR cooler Exhaust Manifold Pressure EMP sensor A variable capacitanc...

Страница 191: ...a special section of low tension cable designed to open the circuit when subjected to an extreme current overload SAE J1156 APR86 Gross Combined Weight Rating GCWR Maximum combined weight of towing ve...

Страница 192: ...control pressure Inlet Air Heater IAH The IAH is primarily used to assist in starting the engine during cold weather In addition it helps to reduce white smoke emissions by heating the incoming air I...

Страница 193: ...ntrol of the EGR valve and ITV The ECM monitors the MAF signal so that the ECM can control the EGR and intake throttle systems Magnehelic Gauge A gauge that measures pressure in inches of water Magnet...

Страница 194: ...signal Efficient method of providing power between fully on and fully off Random Access Memory RAM Computer memory that stores information Information can be written to and read from RAM Input informa...

Страница 195: ...t may not have hard failures but may be exhibiting abnormal operating performance Identify a particular event or condition that will be reported Report a component and non standard failure mode Tachom...

Страница 196: ...rolled by signals from the ECM in response to engine speed required fuel quantity boost exhaust back pressure and altitude The TC1WC actuator is part of the turbocharger assembly NOTE TC1WC does not a...

Страница 197: ...lowing through a circuit or portion of the circuit current multiplied by resistance Voltage ignition Voltage supplied by the ignition switch when the key is ON Water In Fuel WIF sensor A switch sensor...

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