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NAVISTAR MAXXFORCE DT9, DT10 MAXXFORCE 11,13,15 DIAGNOSTIC MANUAL

What does this catalog contain?

NAVISTAR MAXXFORCE DT9-DT10-11-13-15 MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR MAXXFORCE DT9-DT10-11-13-15 MANUAL includes:

Numbered table of contents easy to use so that you can find the information you need fast.
Detailed sub-steps expand on repair procedure information.
Numbered instructions guide you through every repair procedure step by step.
Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
Notes, cautions and warnings throughout each chapter pinpoint critical information.
Bold figure number help you quickly match illustrations with instructions.
Detailed illustrations, drawings and photos guide you through every procedure.
Enlarged inset helps you identify and examine parts in detail.

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After payment has been received, a few minutes later.
Lifetime PDF and Access To Download (By Request).
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Searchable Text and Built-in Index For Instant Information Search Bookmarks.
Printable – Pages Or Entire Manual.
Zoomable – Detailed Exploded Diagrams, Picture.

TABLE OF CONTENT OF THE NAVISTAR MAXXFORCE DT9-DT10-11-13-15 MANUAL

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)…………………………….. 8
3.3. SYMPTOM 2 (MEDIUM DUTY): ENGINE NO START / STARTS AND STALLS………………. 16
3.4. SYMPTOM 3 (MEDIUM DUTY): SPN 3719 OR SPN 3936 ACTIVE ONLY OR
FREQUENT REGENS (MORE THAN ONE PARKED REGEN PER DAY)……………………. 23
3.5. SYMPTOM 4 (MEDIUM DUTY): SPN 3719 OR SPN 3936 AND OTHER ACTIVE FAULT
CODES……………………………………………………………………………………….. 34
3.6. SYMPTOM 5 (MEDIUM DUTY) : BLACK SMOKE……………………………………………. 45
4. MAXXFORCE® DT, 9 AND 10 SERVICEMAXX™ SNAPSHOTS……………………………………. 54
4.1. GRAPH 1: AIR MANAGEMENT SYSTEM TEST (GOOD)……………………………………. 54
4.2. GRAPH 2: AIR MANAGEMENT SYSTEM TEST (BAD)………………………………………. 56
4.3. GRAPH 3: 0 TO 60 MPH TEST (ICP DESIRED AND ICP)…………………………………… 57
4.4. GRAPH 4: 0 TO 60 MPH TEST (ENGINE SPEED, ENGINE LOAD, IMP, EBP, AND APP1). . . . 58
4.5. GRAPH 5: NORMAL EXHAUST GAS TEMPERATURES (EFFICIENT DOC AND
UNRESTRICTED AFI) ……………………………………………………………………….. 60
4.6. GRAPH 6: ERRATIC EXHAUST GAS TEMPERATURES ……………………………………. 62
4.7. GRAPH 7: LOW EXHAUST GAS TEMPERATURES (RESTRICTED AFI)……………………. 63
4.8. SOOT LOAD LEVEL VS. EXHAUST GAS TARGET TEMPERATURE CHART. . . . . . . . . . . . . . . . . . . 65
5. AFTERTREATMENT SYSTEM OPERATION……………………………………………………….. 66
5.1. MAXXFORCE® DT, 9 AND 10 ………………………………………………………………… 66
6. COMPONENT DESCRIPTIONS (THEORY OF OPERATION)………………………………………. 69
6.1. MAXXFORCE® DT, 9 AND 10 ………………………………………………………………… 69
7. AFTERTREATMENT SYSTEM FAULT CODES…………………………………………………….. 77
7.1. MAXXFORCE® DT, 9 AND 10 (EPA 10)………………………………………………………. 77
8. AFTERTREATMENT SYSTEM EVENT CHART…………………………………………………….. 80
8.1. MAXXFORCE® DT, 9 AND 10………………………………………………………………… 80
9. MAXXFORCE® 11,13 AND 15 AFTERTREATMENT SYSTEM DIAGNOSTICS…………………….. 81
9.1. START DIAGNOSTICS HERE: ENGINE AND AFTERTREATMENT SYSTEM
OPERATIONAL CHECKS…………………………………………………………………….. 81
9.2. SYMPTOM 1 (HEAVY DUTY): FREQUENT PARKED REGENS WITH NO ACTIVE
FAULT CODES (MORE THAN ONE PARKED REGEN PER DAY)…………………………… 84
9.3. SYMPTOM 2 (HEAVY DUTY): ENGINE NO START / STARTS AND STALLS………………… 92
9.4. SYMPTOM 3 (HEAVY DUTY): SPN 3719 ACTIVE ONLY OR FREQUENT REGENS
(MORE THAN ONE PARKED REGEN PER DAY)……………………………………………. 96
9.5. SYMPTOM 4 (HEAVY DUTY): SPN 3719 AND OTHER ACTIVE FAULT CODES . . . . . . . . . . . . . . 107
9.6. SYMPTOM 5 (HEAVY DUTY): BLACK SMOKE …………………………………………….. 118

10. MAXXFORCE® 11, 13 AND 15 SERVICEMAXX™ SNAPSHOTS………………………………….. 126
10.1. GRAPH 1: AIR MANAGEMENT SYSTEM TEST (GOOD)………………………………….. 126
10.2. GRAPH 2: AIR MANAGEMENT SYSTEM TEST (BAD)…………………………………….. 128
10.3. GRAPHS 3A AND 3B: FUELING DURING ACCELERATION……………………………….. 130
10.4. GRAPHS 4A AND 4B: EXHAUST FLOW DURING ACCELERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.5. GRAPHS 5A AND 5B: BOOST DURING ACCELERATION…………………………………. 135
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. COMPONENT REPLACEMENT…………………………………………………………………… 161
15.1. MAXXFORCE® DT, 9, OR 10 SYSTEMS……………………………………………………. 161
Diesel Particulate Filter Differential Pressure (DPFDP) Tubes and Sensor – Removal………. 161
DPFDP Tubes and Sensor – Installation…………………………………………………….. 162
Temperature Sensor – Removal…………………………………………………………….. 164
Temperature Sensor – Installation…………………………………………………………… 164
Dosing Control Unit (DCU) – Removal………………………………………………………. 166
Dosing Control Unit (DCU) – Installation…………………………………………………….. 166
15.2. MAXXFORCE® 11, 13, OR 15 SYSTEM…………………………………………………….. 168
DPFDP Tubes and Sensor – Removal………………………………………………………. 168
DPFDP Tubes and Sensor – Installation…………………………………………………….. 169
DOC and DPF Temperature Sensor – Removal…………………………………………….. 170
DOC and DPF Temperature Sensor – Installation…………………………………………… 170
Sensor Junction Box – Removal…………………………………………………………….. 172
Sensor Junction Box – Installation…………………………………………………………… 172
16. SINGLE HORIZONTAL / HORIZONTAL…………………………………………………………… 174
16.1. MAXXFORCE® DT, 9, OR 10 ENGINE ……………………………………………………… 174
Diesel Particulate Filter (DPF) (One-Can System) (Except TerraStar®) – Removal. . . . . . . . . . . . . . 174
Diesel Particulate Filter (DPF) (One-Can System) (Except TerraStar®) – Installation. . . . . . . . . . . . 175
Diesel Particulate Filter (DPF) (One-Can System) (TerraStar®) – Removal………………….. 176
Diesel Particulate Filter (DPF) (One-Can System) (TerraStar®) – Installation………………… 177
Diesel Particulate Filter (DPF) (Two-Can System) – Removal……………………………….. 178
Diesel Particulate Filter (DPF) (Two-Can System) – Installation…………………………….. 179
16.2. MAXXFORCE® 11, 13, OR 15 ENGINE……………………………………………………… 180
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 180

17. SINGLE VERTICAL / VERTICAL………………………………………………………………….. 182
17.1. MAXXFORCE® DT, 9, OR 10 ENGINE………………………………………………………. 182
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 182
Diesel Particulate Filter (DPF) – Installation…………………………………………………. 184
17.2. MAXXFORCE® 11, 13, OR 15 ENGINE……………………………………………………… 186
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 186
Diesel Particulate Filter (DPF) – Installation…………………………………………………. 188
18. SINGLE HORIZONTAL / VERTICAL………………………………………………………………. 189
18.1. MAXXFORCE® DT, 9, OR 10 ENGINE………………………………………………………. 189
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 189
Diesel Particulate Filter (DPF) – Installation…………………………………………………. 191
18.2. MAXXFORCE® 11, 13, OR 15 ENGINE……………………………………………………… 192
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 192
Diesel Particulate Filter (DPF) – Installation…………………………………………………. 193
19. UNDER – CAB HORIZONTAL / VERTICAL……………………………………………………….. 194
19.1. MAXXFORCE® DT, 9, OR 10 ENGINE………………………………………………………. 194
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 194
Diesel Particulate Filter (DPF) – Installation…………………………………………………. 196
19.2. MAXXFORCE® 11, 13, OR 15 ENGINE……………………………………………………… 197
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 197
Diesel Particulate Filter (DPF) – Installation…………………………………………………. 199
20. SINGLE HORIZONTAL / DUAL VERTICAL……………………………………………………….. 200
20.1. MAXXFORCE® 11, 13, OR 15 ENGINE……………………………………………………… 200
Diesel Particulate Filter (DPF) – Removal…………………………………………………… 200
Diesel Particulate Filter (DPF) – Installation…………………………………………………. 201
21. REGEN INHIBITORS AND ENTRY CONDITIONS…………………………………………………. 202
21.1. REGEN INHIBITORS……………………………………………………………………….. 202
21.2. ENTRY CONDITIONS………………………………………………………………………. 206
22. DPF AND DOC REUSE GUIDELINES…………………………………………………………….. 209
22.1. MAXXFORCE® DT, 9, AND 10; 11, 13; AND 15……………………………………………… 209
Diesel Particulate Filter (DPF) Inlet – Clean………………………………………………….. 210
Diesel Particulate Filter (DPF) Inlet – Dirty, but Reusable……………………………………. 211
Diesel Particulate Filter (DPF) Inlet – Face Plugged…………………………………………. 212
Diesel Particulate Filter (DPF) – Melted……………………………………………………… 213
Diesel Particulate Filter (DPF) – Cracked but Reusable……………………………………… 214
Diesel Particulate Filter (DPF) Inlet- Ash on Face…………………………………………… 215
Diesel Particulate Filter (DPF) – Excessive Brick Shift……………………………………….. 216
Diesel Particulate Filter (DPF) – Moderate Brick Shift……………………………………….. 217
Diesel Oxidation Catalyst (DOC) Outlet – Dirty but Reusable………………………………… 218
Diesel Oxidation Catalyst (DOC) – Separation………………………………………………. 219
Diesel Oxidation Catalyst (DOC) – Melted…………………………………………………… 220
Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter (DPF) – Damaged Sensor
Port Threads………………………………………………………………………………… 221
23. TORQUE…………………………………………………………………………………………… 222
23.1. TORQUE……………………………………………………………………………………. 222

24. TESTS AND INSPECTIONS……………………………………………………………………….. 223
24.1. DOC EFFICIENCY TEST……………………………………………………………………. 223
Overview…………………………………………………………………………………….. 223
Test Procedure………………………………………………………………………………. 223
24.2. LUG DOWN TEST………………………………………………………………………….. 229
Equipment Condition………………………………………………………………………… 229
Test Setup…………………………………………………………………………………… 229
Test Procedure………………………………………………………………………………. 230
Expected Outcome………………………………………………………………………….. 231
Follow-On Procedure………………………………………………………………………… 231
24.3. 0 TO 60 MPH TEST…………………………………………………………………………. 232
Test Setup…………………………………………………………………………………… 232
Test Procedure………………………………………………………………………………. 233
Expected Outcome………………………………………………………………………….. 234
Follow-On Procedure………………………………………………………………………… 234
25. ABBREVIATIONS AND ACRONYMS……………………………………………………………… 235
26. TERMINOLOGY……………………………………………………………………………………. 244

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