Navistar International MaxxForce DT 9 & 10 (EPA 10) Engines Official Diagnostic Manual

Navistar International MaxxForce DT 9 & 10 (EPA 10) Engines Official Diagnostic Manual

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This is the COMPLETE Official Diagnostic Manual for the Navistar International MaxxForce DT 9 & 10 (EPA 10) Engines, MaxxForce 11, 13 & 15 (EPA 10) Engines.

This manual contains detailed diagnostic information, service and repair information, technical specifications, service codes, observable symptoms for Navistar International Engine.

This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 

Models And Serials :

Aftertreatment Symptom-Based Diagnostic & Inspection Manual –
MaxxForce DT, 9 & 10 (EPA 10) , MaxxForce 11, 13 & 15 (EPA 10)

CONTENTS : 

1. FOREWORD…………………………………………………..1
2. SAFETY INFORMATION……………………………….2
3. MAXXFORCE® DT, 9 AND 10 AFTERTREATMENT SYSTEM DIAGNOSTICS……5
3.1. START DIAGNOSTICS HERE: ENGINE AND AFTERTREATMENT SYSTEM
OPERATIONAL CHECKS…5
3.2. SYMPTOM 1 (MEDIUM DUTY): FREQUENT PARKED REGENS WITH NO ACTIVE
FAULT CODES (MORE THAN ONE PARKED REGEN PER DAY)…9
3.3. SYMPTOM 2 (MEDIUM DUTY): ENGINE NO START / STARTS AND STALLS……19
3.4. SYMPTOM 3 (MEDIUM DUTY): SPN 3719 OR SPN 3936 ACTIVE ONLY OR
FREQUENT REGENS (MORE THAN ONE PARKED REGEN PER DAY)……………………. 27
3.5. SYMPTOM 4 (MEDIUM DUTY): SPN 3719 OR SPN 3936 AND OTHER ACTIVE FAULT
CODES………………………..39
3.6. SYMPTOM 5 (MEDIUM DUTY) : BLACK SMOKE………………………………..49
4. MAXXFORCE® DT, 9 AND 10 SERVICEMAXX™ SNAPSHOTS…………….57
4.1. GRAPH 1: AIR MANAGEMENT SYSTEM TEST (GOOD)………………………57
4.2. GRAPH 2: AIR MANAGEMENT SYSTEM TEST (BAD)…………………………..59
4.3. GRAPH 3: 0 TO 60 MPH TEST (ICP DESIRED AND ICP)………………………60
4.4. GRAPH 4: 0 TO 60 MPH TEST (ENGINE SPEED, ENGINE LOAD, IMP, EBP, AND APP1)..61
4.5. GRAPH 5: NORMAL EXHAUST GAS TEMPERATURES (EFFICIENT DOC AND
UNRESTRICTED AFI)..63
4.6. GRAPH 6: ERRATIC EXHAUST GAS TEMPERATURES …………………………….65
4.7. GRAPH 7: LOW EXHAUST GAS TEMPERATURES (RESTRICTED AFI)……66
4.8. SOOT LOAD LEVEL VS. EXHAUST GAS TARGET TEMPERATURE CHART… 68
5. AFTERTREATMENT SYSTEM OPERATION……………………………………………………….. 69
5.1. MAXXFORCE® DT, 9 AND 10 ………………………………………………………………………. 69
6. COMPONENT DESCRIPTIONS (THEORY OF OPERATION)…………………………….72
6.1. MAXXFORCE® DT, 9 AND 10 …………………………………………………………………72
7. AFTERTREATMENT SYSTEM FAULT CODES……………………………………………….81
7.1. MAXXFORCE® DT, 9 AND 10 (EPA 10)…………………………………………………..81
8. AFTERTREATMENT SYSTEM EVENT CHART………………………………………………84
8.1. MAXXFORCE® DT, 9 AND 10………………………………………………………………… 84
9. MAXXFORCE® 11,13 AND 15 AFTERTREATMENT SYSTEM DIAGNOSTICS….85
9.1. START DIAGNOSTICS HERE: ENGINE AND AFTERTREATMENT SYSTEM
OPERATIONAL CHECKS….85
9.2. SYMPTOM 1 (HEAVY DUTY): FREQUENT PARKED REGENS WITH NO ACTIVE
FAULT CODES (MORE THAN ONE PARKED REGEN PER DAY)…………………………… 89
9.3. SYMPTOM 2 (HEAVY DUTY): ENGINE NO START / STARTS AND STALLS…..97
9.4. SYMPTOM 3 (HEAVY DUTY): SPN 3719 ACTIVE ONLY OR FREQUENT REGENS
(MORE THAN ONE PARKED REGEN PER DAY)…………103
9.5. SYMPTOM 4 (HEAVY DUTY): SPN 3719 AND OTHER ACTIVE FAULT CODES….112
9.6. SYMPTOM 5 (HEAVY DUTY): BLACK SMOKE ……………………………………………. 121
10. MAXXFORCE® 11, 13 AND 15 SERVICEMAXX™ SNAPSHOTS………………….129
10.1. GRAPH 1: AIR MANAGEMENT SYSTEM TEST (GOOD)…………………………….129
10.2. GRAPH 2: AIR MANAGEMENT SYSTEM TEST (BAD)………………………………..131
10.3. GRAPH 3: LUG DOWN TEST (ENGINE SPEED, FRP, AND FRPD)……………..133
10.4. GRAPH 4: LUG DOWN TEST (ENGINE SPEED AND TC1TOP)…………………..135
10.5. GRAPH 5: LUG DOWN TEST (ENGINE SPEED, APP1, VEHICLE SPEED, AND IMP)..136
10.6. GRAPH 6: NORMAL EXHAUST GAS TEMPERATURES (EFFICIENT DOC AND
UNRESTRICTED AFI)..138
10.7. GRAPH 7: INVERTED EXHAUST GAS TEMPERATURES (INEFFICIENT DOC)..140
10.8. GRAPH 8: LOW EXHAUST GAS TEMPERATURES (RESTRICTED AFI)……………..142
11. AFTERTREATMENT SYSTEM OPERATION………………………………………………..144
11.1. MAXXFORCE® 11, 13 AND 15 ……………………………………………………………..144
12. COMPONENT DESCRIPTIONS (THEORY OF OPERATION)……………………147
12.1. MAXXFORCE® 11 AND 13 ………………………………………………………………….. 147
13. AFTERTREATMENT SYSTEM FAULT CODES……………………………………………..156
13.1. MAXXFORCE® 11, 13 AND 15……………………………………………………………….156
14. AFTERTREATMENT SYSTEM EVENT CHART……………………………………………..160
14.1. MAXXFORCE® 11, 13 AND 15……………………………………………………………….160
15. REGEN INHIBITORS AND ENTRY CONDITIONS………………………………………161
15.1. REGEN INHIBITORS…………………………………………………………………………………. 161
15.2. ENTRY CONDITIONS……………………………………………………………………………….. 165
16. DPF AND DOC REUSE GUIDELINES…………………………………………………………..168
16.1. MAXXFORCE® DT, 9, AND 10; MAXXFORCE® 11, 13 AND 15………..168
Diesel Particulate Filter (DPF) Inlet – Clean………………………………………………….. 169
Diesel Particulate Filter (DPF) Inlet – Dirty, but Reusable…………………………….170
Diesel Particulate Filter (DPF) Inlet – Face Plugged…………………………………..171
Diesel Particulate Filter (DPF) – Melted……………………………………………………… 172
Diesel Particulate Filter (DPF) – Cracked but Reusable……………………………..173
Diesel Particulate Filter (DPF) Inlet- Ash on Face……………………………………….174
Diesel Particulate Filter (DPF) – Excessive Brick Shift…………………………………175
Diesel Particulate Filter (DPF) – Moderate Brick Shift………………………………..176
Diesel Oxidation Catalyst (DOC) Outlet – Dirty but Reusable…………………..177
Diesel Oxidation Catalyst (DOC) – Separation……………………………………………. 178
Diesel Oxidation Catalyst (DOC) – Melted…………………………………………………… 179
Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter (DPF) – Damaged Sensor
Port Threads………….180
17. ABBREVIATIONS AND ACRONYMS……………………………………………………181
18. TERMINOLOGY……………………………………………………………………………………. 190

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