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Navistar MaxxForce 9 Diagnostic Manual
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DIAGNOSTIC
MANUAL
Step
Action
Decision
13
V
erify
root
cause
of
frequent
regens
has
been
diagnosed
and
repaired.
Has
root
cause
for
frequent
regens
been
diagnosed
and
repaired?
Y
es:
Diagnostics
complete
No:
Go
back
to
step
1
of
Engine
and
Aftertreatment
System
Operational
Checks
page
80
to
verify
engine
systems
are
in
satisfactory
condition.
90
https://www.truck-manuals.net/
93
95
Table of Contents
Default Chapter
3
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 9 Specifications
General
Brand
Navistar
Model
MaxxForce 9
Category
Engine
Language
English
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