Description

NAVISTAR Exhaust Aftertreatment System with SCR 9900 SERVICE MANUAL

What does this catalog contain?

NAVISTAR SCR 9900 SERVICE 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 SCR 9900 SERVICE 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.

What will you get when you get this service catalog?

After payment has been received, a few minutes later.
Lifetime PDF and Access To Download (By Request).
Compatible With Windows, Mac, IOS, Android and Other Systems.
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 SCR 9900 SERVICE MANUAL

DESCRIPTION……………………………………………………………………………………….. 1
1.1. THEORY OF OPERATION…………………………………………………………………….. 7
………………………………………………………………………………………………… 7
1.2. SWITCHBACK / HORIZONTAL………………………………………………………………… 8
1.3. VERTICAL / VERTICAL……………………………………………………………………….. 9
1.4. IN-LINE……………………………………………………………………………………….. 10
2. GENERAL SERVICE INFORMATION……………………………………………………………….. 11
2.1. EXHAUST AFTERTREATMENT SYSTEM MODIFICATIONS………………………………… 12
2.2. GASKETS AND FASTENERS………………………………………………………………… 13
2.3. DIESEL PARTICULATE FILTER (DPF) INDEXING…………………………………………… 13
2.4. DPF AND DOC CLEANING…………………………………………………………………… 13
2.5. DPF GENERAL INSPECTION……………………………………………………………….. 14
DPF Inspection Points………………………………………………………………………… 15
2.6. DOC GENERAL INSPECTION……………………………………………………………….. 18
DOC Inspection Points……………………………………………………………………….. 18
2.7. DPF / DOC THREAD REPAIR………………………………………………………………… 22
12 MM Thread Replacement…………………………………………………………………. 22
14 MM Thread Replacement…………………………………………………………………. 26
2.8. DOC AND DPF REUSE GUIDELINES……………………………………………………….. 30
General Information…………………………………………………………………………… 30
Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted………………………………………. 31
Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged……………………………………….. 32
Diesel Particulate Filter (DPF) Inlet / Outlet – New……………………………………………. 33
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1)……………………………………… 34
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2)……………………………………… 35
Diesel Particulate Filter (DPF) Inlet – Clean………………………………………………….. 36
Diesel Particulate Filter (DPF) Inlet – Gouged………………………………………………… 37
Diesel Particulate Filter (DPF) Inlet – Ash…………………………………………………….. 38
Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings……………………………………….. 39
Diesel Particulate Filter (DPF) Outlet – Soot Stains…………………………………………… 40
Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process…………………… 41
Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains ………………………………. 42
Diesel Particulate Filter (DPF) Outlet – Face Cracked………………………………………… 43
Diesel Particulate Filter (DPF) Outlet – Coolant Staining……………………………………… 44
Diesel Particulate Filter (DPF) Outlet – Melted……………………………………………….. 45
2.9. DECOMPOSITION REACTOR TUBE CLEANING……………………………………………. 46
2.10. DIESEL EXHAUST FLUID (DEF) DOSING VALVE CLEANING………………………………. 47
2.11. DEF SUPPLY MODULE FILTER INSPECTION………………………………………………. 49
2.12. DIESEL EXHAUST FLUID (DEF) SYSTEM CONTAMINATION………………………………. 51
2.13. DEF SYSTEM DECONTAMINATION PROCEDURE…………………………………………. 54
2.14. DIESEL EXHAUST FLUID (DEF) REFRACTOMETER TOOL………………………………… 55
2.15. DIESEL EXHAUST FLUID (DEF) DOSING SYSTEM REUSE GUIDELINES…………………. 58
2.16. DIESEL EXHAUST FLUID (DEF) TANK DRAINING………………………………………….. 61
3. SWITCHBACK / HORIZONTAL……………………………………………………………………… 62
3.1. CUMMINS ISX15 AND ISB6.7 OR NAVISTAR® N13, N9, AND N10 ENGINES. . . . . . . . . . . . . . . . . . . 62
Switchback / Horizontal – Removal…………………………………………………………… 62
Switchback / Horizontal – Installation…………………………………………………………. 64
Diesel Exhaust Fluid (DEF) Dosing Valve – Removal…………………………………………. 65
Diesel Exhaust Fluid (DEF) Dosing Valve – Installation………………………………………. 66

Decomposition Reactor Tube – Removal…………………………………………………….. 67
Decomposition Reactor Tube – Installation…………………………………………………… 68
Aftertreatment Assembly Mounting Bracket – Removal………………………………………. 69
Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly
Mounting Bracket – Installation……………………………………………………………….. 70
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . 71
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation………………….. 71
Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal…………………………….. 73
Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation…………………………… 73
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal (If
Equipped)…………………………………………………………………………………….. 74
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If
Equipped)…………………………………………………………………………………….. 74
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped). . . . . . . . . . 75
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped). . . . . . . . 75
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal. . . . . . . . . . . . . . 76
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation. . . . . . . . . . . . 76
(DPF) Temperature Sensors and Module – Removal…………………………………………. 78
Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation……………….. 78
Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal………………………….. 80
Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation………………………… 81
Diesel Particulate Filter (DPF) High Pressure Tube – Removal………………………………. 82
Diesel Particulate Filter (DPF) High Pressure Tube – Installation…………………………….. 82
Diesel Particulate Filter (DPF) Low Pressure Tube – Removal……………………………….. 83
Diesel Particulate Filter (DPF) Low Pressure Tube – Installation……………………………… 83
4. VERTICAL / VERTICAL …………………………………………………………………………….. 84
4.1. NAVISTAR® N13 ENGINE…………………………………………………………………….. 84
Vertical / Vertical……………………………………………………………………………… 84
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal… 85
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield –
Installation……………………………………………………………………………………. 85
Power Distribution Module (PDM) – Removal………………………………………………… 86
Power Distribution Module (PDM) – Installation………………………………………………. 86
Aftertreatment Control Module (ACM) – Removal…………………………………………….. 87
Aftertreatment Control Module (ACM) – Installation…………………………………………… 87
5. IN–LINE……………………………………………………………………………………………… 88
5.1. CUMMINS ISB6.7 OR NAVISTAR® N9 AND N10 ENGINES………………………………….. 88
In-Line………………………………………………………………………………………… 88
6. DIESEL EXHAUST FLUID (DEF) SYSTEM…………………………………………………………. 89
6.1. CUMMINS ISX15 AND ISB6.7 OR NAVISTAR® N13, N9, AND N10 ENGINES. . . . . . . . . . . . . . . . . . . 89
Diesel Exhaust Fluid (DEF) Tank – Removal…………………………………………………. 89
Diesel Exhaust Fluid (DEF) Tank – Installation……………………………………………….. 92
Power Distribution Module (PDM) – Removal………………………………………………… 93
Power Distribution Module (PDM) – Installation………………………………………………. 93
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal…………………………………. 94
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation………………………………. 97
Diesel Exhaust Fluid (DEF) Tank Lines – Removal…………………………………………… 98
Diesel Exhaust Fluid (DEF) Tank Lines – Installation………………………………………… 100

Diesel Exhaust Fluid (DEF) Supply Module – Removal……………………………………… 101
Diesel Exhaust Fluid (DEF) Supply Module – Installation……………………………………. 102
Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal……………………………….. 103
Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation……………………………… 103
Aftertreatment Control Module (ACM) – Removal…………………………………………… 104
Aftertreatment Control Module (ACM) – Installation…………………………………………. 105
Diesel Exhaust Fluid (DEF) Tank Bracket – Removal……………………………………….. 106
Diesel Exhaust Fluid (DEF) Tank Bracket – Installation……………………………………… 107
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal……………………………… 108
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation……………………………. 109
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal………………………………….. 110
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation………………………………… 111
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal. . . . . . . . . . . . . . . . . . . . . . . . 112
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation…………………. 114
Diesel Exhaust Fluid (DEF) System…………………………………………………………. 115
7. ACRONYM LIST…………………………………………………………………………………… 116
TORQUE……………………………………………………………………………………………….. 117

Moreover

This is the same manual used by the dealers to diagnose and troubleshoot your vehicle.
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