Navistar MaxxForce 15 User Manual

DIAGNOSTICMANUAL0000003081 AftertreatmentSymptom-BasedDiagnosticandInspectionManual-MaxxForce
®
DT,9and10(EPA10),MaxxForce
®
11,13and15(EPA10)Revision5
EPA10-US,CanadaOctober2014
DIAGNOSTICMANUAL
AftertreatmentSymptom-BasedDiagnosticandInspectionManual
MaxxForce
®
DT,9and10(EPA10)
MaxxForce
®
11,13and15(EPA10)
Navistar,Inc.
2701NavistarDrive,Lisle,IL60532USA
©2014Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.
https://www.truck-manuals.net/

Navistar MaxxForce 15 Specifications

General

Brand	Navistar
Model	MaxxForce 15
Category	Engine
Language	English

Summary

FOREWORD

SAFETY INFORMATION

Safety Terminology

Defines Warning, Caution, and Note terms for safety context.

Safety Instructions

General safety practices for work area and personal protective equipment.

MAXXFORCE® DT, 9 AND 10 AFTERTREATMENT SYSTEM DIAGNOSTICS

3.1. START DIAGNOSTICS HERE: ENGINE AND AFTERTREATMENT SYSTEM OPERATIONAL CHECKS

Initial checks for engine and aftertreatment system operational status before further diagnostics.

3.2. SYMPTOM 1 (MEDIUM DUTY): FREQUENT PARKED REGENS WITH NO ACTIVE FAULT CODES (MORE THAN ONE PARKED REGEN PER DAY)

Step 1 Check for a failed Air Management System (AMS) actuator.

Diagnosing the AMS actuator using ServiceMaxx™ software and specific tests.

3.3. SYMPTOM 2 (MEDIUM DUTY): ENGINE NO START / STARTS AND STALLS

Step 1 Check for an exhaust system restriction by performing the following Exhaust System Restriction Test:

Procedure to test for exhaust system restriction using specific diagnostic tools and values.

3.4. SYMPTOM 3 (MEDIUM DUTY): SPN 3719 OR SPN 3936 ACTIVE ONLY OR FREQUENT REGENS (MORE THAN ONE PARKED REGEN PER DAY)

Step 1 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 3719/3936 FMI 0, 15, or 16.

Identifying active fault codes related to SPN 3719/3936 using diagnostic software.

3.5. SYMPTOM 4 (MEDIUM DUTY): SPN 3719 OR SPN 3936 AND OTHER ACTIVE FAULT CODES

Step 1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, check Diagnostic Trouble Code (DTC) list for active fault code(s) other than SPN 3719 (DPF soot load).

Initial check for active fault codes other than SPN 3719 using diagnostic software.

3.6. SYMPTOM 5 (MEDIUM DUTY) : BLACK SMOKE

Step 1 Diesel Particulate Filter (DPF) Snap Acceleration Test (Quick Test).

Performing a snap acceleration test to check the DPF for cracks or internal damage.

4. MAXXFORCE® DT, 9 AND 10 SERVICEMAXX™ SNAPSHOTS

4.1. GRAPH 1: AIR MANAGEMENT SYSTEM TEST (GOOD)

Analysis of a good Air Management System test graph from ServiceMaxx™ software.

4.2. GRAPH 2: AIR MANAGEMENT SYSTEM TEST (BAD)

Graph Analysis:

Explains a bad Air Management System test graph and its implications for the aftertreatment system.

4.3. GRAPH 3: 0 TO 60 MPH TEST (ICP DESIRED AND ICP)

Graph Analysis

Analysis of ICP and ICPD signal values during a 0-60 MPH test for system validation.

4.4. GRAPH 4: 0 TO 60 MPH TEST (ENGINE SPEED, ENGINE LOAD, IMP, EBP, AND APP1)

Graph Analysis

Analysis of engine speed, load, IMP, EBP, and APP1 during a 0-60 MPH test.

4.5. GRAPH 5: NORMAL EXHAUST GAS TEMPERATURES (EFFICIENT DOC AND UNRESTRICTED AFI)

Graph Analysis:

Analysis of normal exhaust gas temperatures indicating an efficient DOC and unrestricted AFI.

4.6. GRAPH 6: ERRATIC EXHAUST GAS TEMPERATURES

Graph Analysis:

Analysis of erratic exhaust gas temperatures indicating a contaminated DOC or faulty AFI.

4.7. GRAPH 7: LOW EXHAUST GAS TEMPERATURES (RESTRICTED AFI)

Graph Analysis:

Analysis of low exhaust gas temperatures indicating a restricted AFI due to restricted fuel flow.

4.8. SOOT LOAD LEVEL VS. EXHAUST GAS TARGET TEMPERATURE CHART

AFTERTREATMENT SYSTEM OPERATION

5.1. MAXXFORCE® DT, 9 AND 10

Describes the functions of the aftertreatment system for specific engine models.

COMPONENT DESCRIPTIONS (THEORY OF OPERATION)

6.1. MAXXFORCE® DT, 9 AND 10

Details the function of the Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).

AFTERTREATMENT SYSTEM FAULT CODES

7.1. MAXXFORCE® DT, 9 AND 10 (EPA 10)

Lists common aftertreatment system fault codes (SPN/FMI) and their possible causes.

AFTERTREATMENT SYSTEM EVENT CHART

8.1. MAXXFORCE® DT, 9 AND 10

Illustrates the sequence of events and operator responses for aftertreatment system issues.

MAXXFORCE® 11,13 AND 15 AFTERTREATMENT SYSTEM DIAGNOSTICS

9.1. START DIAGNOSTICS HERE: ENGINE AND AFTERTREATMENT SYSTEM OPERATIONAL CHECKS

Initial checks for engine and aftertreatment system operational status before further diagnostics.

9.2. SYMPTOM 1 (HEAVY DUTY): FREQUENT PARKED REGENS WITH NO ACTIVE FAULT CODES (MORE THAN ONE PARKED REGEN PER DAY)

Step 1 Check for a failed Air Management System (AMS) actuator.

Diagnosing the AMS actuator using ServiceMaxx™ software and specific tests.

9.3. SYMPTOM 2 (HEAVY DUTY): ENGINE NO START / STARTS AND STALLS

Step 3 Diesel Particulate Filter (DPF) Snap Acceleration Test (Quick Test).

Performing a snap acceleration test to check the DPF for cracks or internal damage.

9.4. SYMPTOM 3 (HEAVY DUTY): SPN 3719 ACTIVE ONLY OR FREQUENT REGENS (MORE THAN ONE PARKED REGEN PER DAY)

Step 1 Do Onboard Filter Cleanliness Test (OBFCT) to clear SPN 3719 active fault code(s).

Clearing SPN 3719 fault codes using the OBFCT test via diagnostic software.

9.5. SYMPTOM 4 (HEAVY DUTY): SPN 3719 AND OTHER ACTIVE FAULT CODES

Step 1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, check Diagnostic Trouble Code (DTC) list for active fault code(s) other than SPN 3719 (DPF soot load).

Checking for active fault codes other than SPN 3719 using diagnostic software.

9.6. SYMPTOM 5 (HEAVY DUTY): BLACK SMOKE

Step 7 Diesel Particulate Filter (DPF) Snap Acceleration Test (Quick Test).

Performing a snap acceleration test to check the DPF for cracks or internal damage.

MAXXFORCE® 11, 13 AND 15 SERVICEMAXX™ SNAPSHOTS

10.1. GRAPH 1: AIR MANAGEMENT SYSTEM TEST (GOOD)

Analysis of a good Air Management System test graph from ServiceMaxx™ software.

10.2. GRAPH 2: AIR MANAGEMENT SYSTEM TEST (BAD)

Graph Analysis:

Explains a bad Air Management System test graph and its implications for the aftertreatment system.

10.3. GRAPH 3: LUG DOWN TEST (ENGINE SPEED, FRP, AND FRPD)

Graph Analysis:

Analysis of FRP and FRPD signal values during a Lug Down Test for system validation.

10.4. GRAPH 4: LUG DOWN TEST (ENGINE SPEED AND TC1TOP)

Graph Analysis:

Analysis of engine speed and TC1TOP signal values during a Lug Down Test.

10.6. GRAPH 6: NORMAL EXHAUST GAS TEMPERATURES (EFFICIENT DOC AND UNRESTRICTED AFI)

Graph Analysis:

Analysis of normal exhaust gas temperatures indicating an efficient DOC and unrestricted AFI.

10.7. GRAPH 7: INVERTED EXHAUST GAS TEMPERATURES (INEFFICIENT DOC)

Graph Analysis:

Analysis of inverted exhaust gas temperatures indicating an inefficient DOC.

10.8. GRAPH 8: LOW EXHAUST GAS TEMPERATURES (RESTRICTED AFI)

Graph Analysis:

Analysis of low exhaust gas temperatures indicating a restricted AFI due to restricted fuel flow.

AFTERTREATMENT SYSTEM OPERATION

11.1. MAXXFORCE® 11, 13 AND 15

Describes the functions of the aftertreatment system for specific engine models.

COMPONENT DESCRIPTIONS (THEORY OF OPERATION)

12.1. MAXXFORCE® 11 AND 13

Details the Air Control Valve (ACV) assembly and its critical role in aftertreatment system operation.

AFTERTREATMENT SYSTEM FAULT CODES

13.1. MAXXFORCE® 11, 13 AND 15

Lists common aftertreatment system fault codes (SPN/FMI) and their possible causes.

AFTERTREATMENT SYSTEM EVENT CHART

14.1. MAXXFORCE® 11, 13 AND 15

Illustrates the sequence of events and operator responses for aftertreatment system issues.

REGEN INHIBITORS AND ENTRY CONDITIONS

15.1. REGEN INHIBITORS

Explains conditions that inhibit regeneration and how to check them.

15.2. ENTRY CONDITIONS

Lists the required conditions for an active regeneration cycle to occur.

DPF AND DOC REUSE GUIDELINES

16.1. MAXXFORCE® DT, 9, AND 10; MAXXFORCE® 11, 13 AND 15

Guidelines for reusing Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).