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MaxxForce 9 DT
DIAGNOSTIC MANUAL
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Navistar MaxxForce 9 DT, MaxxForce 10 DT, MaxxForce 11, MaxxForce 13, MaxxForce 15 DIAGNOSTIC MANUAL

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

TABLEOFCONTENTS

TABLEOFCONTENTS
1.FOREWORD........................................................................................................1
2.SAFETYINFORMATION..........................................................................................2
3.MAXXFORCE
®
DT,9AND10AFTERTREATMENTSYSTEMDIAGNOSTICS............................5
3.1.STARTDIAGNOSTICSHERE:ENGINEANDAFTERTREATMENTSYSTEM
OPERATIONALCHECKS.................................................................................5
3.2.SYMPTOM1(MEDIUMDUTY):FREQUENTP ARKEDREGENSWITHNOACTIVE
FAUL TCODES(MORETHANONEPARKEDREGENPERDAY)...................................8
3.3.SYMPTOM2(MEDIUMDUTY):ENGINENOST ART/STARTSANDSTALLS...................17
3.4.SYMPTOM3(MEDIUMDUTY):SPN3719ORSPN3936ACTIVEONLYOR
FREQUENTREGENS(MORETHANONEPARKEDREGENPERDAY).........................24
3.5.SYMPTOM4(MEDIUMDUTY):SPN3719ORSPN3936ANDOTHERACTIVEFAULT
CODES.....................................................................................................34
3.6.SYMPTOM5(MEDIUMDUTY):BLACKSMOKE....................................................44
4.MAXXFORCE
®
DT,9AND10SERVICEMAXX™SNAPSHOTS...........................................51
4.1.GRAPH1:AIRMANAGEMENTSYSTEMTEST(GOOD)...........................................51
4.2.GRAPH2:AIRMANAGEMENTSYSTEMTEST(BAD)..............................................53
4.3.GRAPH3:0TO60MPHTEST(ICPDESIREDANDICP)..........................................54
4.4.GRAPH4:0TO60MPHTEST(ENGINESPEED,ENGINELOAD,IMP,EBP ,ANDAPP1)....55
4.5.GRAPH5:NORMALEXHAUSTGASTEMPERATURES(EFFICIENTDOCAND
UNRESTRICTEDAFI)...................................................................................57
4.6.GRAPH6:ERRA TICEXHAUSTGASTEMPERATURES...........................................59
4.7.GRAPH7:LOWEXHAUSTGASTEMPERA TURES(RESTRICTEDAFI).........................60
4.8.SOOTLOADLEVELVS.EXHAUSTGAST ARGETTEMPERATURECHART...................62
5.AFTERTREATMENTSYSTEMOPERATION.................................................................63
5.1.MAXXFORCE
®
DT,9AND10...........................................................................63
6.COMPONENTDESCRIPTIONS(THEORYOFOPERATION)..............................................66
6.1.MAXXFORCE
®
DT,9AND10...........................................................................66
7.AFTERTREATMENTSYSTEMFAULTCODES..............................................................75
7.1.MAXXFORCE
®
DT,9AND10(EPA10)................................................................75
8.AFTERTREATMENTSYSTEMEVENTCHART..............................................................78
8.1.MAXXFORCE
9.MAXXFORCE
®
DT,9AND10...........................................................................78
®
11,13AND15AFTERTREA TMENTSYSTEMDIAGNOSTICS..........................79
9.1.STARTDIAGNOSTICSHERE:ENGINEANDAFTERTREATMENTSYSTEM
OPERATIONALCHECKS................................................................................79
9.2.SYMPTOM1(HEAVYDUTY):FREQUENTPARKEDREGENSWITHNOACTIVE
FAUL TCODES(MORETHANONEPARKEDREGENPERDAY).................................83
9.3.SYMPTOM2(HEA VYDUTY):ENGINENOSTART/STARTSANDSTALLS.....................91
9.4.SYMPTOM3(HEAVYDUTY):SPN3719ACTIVEONLYORFREQUENTREGENS
(MORETHANONEPARKEDREGENPERDAY)....................................................96
9.5.SYMPTOM4(HEA VYDUTY):SPN3719ANDOTHERACTIVEFAULTCODES..............104
9.6.SYMPTOM5(HEA VYDUTY):BLACKSMOKE.....................................................1 13
i
TABLEOFCONTENTS
TABLEOFCONTENTS(CONT.)
10.MAXXFORCE
®
11,13AND15SERVICEMAXX™SNAPSHOTS.........................................120
10.1.GRAPH1:AIRMANAGEMENTSYSTEMTEST(GOOD).........................................120
10.2.GRAPH2:AIRMANAGEMENTSYSTEMTEST(BAD)............................................122
10.3.GRAPH3:LUGDOWNTEST(ENGINESPEED,FRP ,ANDFRPD).............................124
10.4.GRAPH4:LUGDOWNTEST(ENGINESPEEDANDTC1TOP).................................126
10.5.GRAPH5:LUGDOWNTEST(ENGINESPEED,APP1,VEHICLESPEED,ANDIMP)........127
10.6.GRAPH6:NORMALEXHAUSTGASTEMPERATURES(EFFICIENTDOCAND
UNRESTRICTEDAFI)..................................................................................129
10.7.GRAPH7:INVERTEDEXHAUSTGASTEMPERATURES(INEFFICIENTDOC)...............131
10.8.GRAPH8:LOWEXHAUSTGASTEMPERATURES(RESTRICTEDAFI).......................133
11.AFTERTREATMENTSYSTEMOPERA TION................................................................135
11.1.MAXXFORCE
®
11,13AND15........................................................................135
12.COMPONENTDESCRIPTIONS(THEORYOFOPERATION).............................................138
12.1.MAXXFORCE
®
11AND13.............................................................................138
13.AFTERTREATMENTSYSTEMFAULTCODES.............................................................147
13.1.MAXXFORCE
®
11,13AND15.........................................................................147
14.AFTERTREATMENTSYSTEMEVENTCHART............................................................151
14.1.MAXXFORCE
®
11,13AND15.........................................................................151
15.REGENINHIBITORSANDENTRYCONDITIONS..........................................................152
15.1.REGENINHIBITORS...................................................................................152
15.2.ENTRYCONDITIONS..................................................................................156
16.DPFANDDOCREUSEGUIDELINES.......................................................................159
16.1.MAXXFORCE
®
DT,9,AND10;MAXXFORCE
®
11,13AND15....................................159
16.1.1.DieselParticulateFilter(DPF)Inlet-Clean...............................................160
16.1.2.DieselParticulateFilter(DPF)Inlet-Dirty,butReusable................................161
16.1.3.DieselParticulateFilter(DPF)Inlet-FacePlugged......................................162
16.1.4.DieselParticulateFilter(DPF)-Melted....................................................163
16.1.5.DieselParticulateFilter(DPF)-CrackedbutReusable..................................164
16.1.6.DieselParticulateFilter(DPF)Inlet-AshonFace........................................165
16.1.7.DieselParticulateFilter(DPF)-ExcessiveBrickShift....................................166
16.1.8.DieselParticulateFilter(DPF)-ModerateBrickShift....................................167
16.1.9.DieselOxidationCatalyst(DOC)Outlet-DirtybutReusable............................168
16.1.10.DieselOxidationCatalyst(DOC)-Separation............................................169
16.1.11.DieselOxidationCatalyst(DOC)-Melted.................................................170
16.1.12.DieselOxidationCatalyst(DOC)orDieselParticulateFilter(DPF)-Damaged
SensorPortThreads.......................................................................171
17.ABBREVIATIONSANDACRONYMS........................................................................172
18.TERMINOLOGY.................................................................................................181
ii
DIAGNOSTICMANUAL

FOREWORD

Navistar,Inc.iscommittedtocontinuousresearchanddevelopmenttoimproveproductsandintroduce technologicaladvances.Procedures,specications,andpartsdenedinpublishedtechnicalserviceliterature maybealtered.
Technicalserviceliteratureisrevisedperiodically.Ifatechnicalpublicationisordered,thelatestrevision willbesupplied.
NOTE–Toordertechnicalserviceliterature,contactyourInternationaldealer.
1
DIAGNOSTICMANUAL

SAFETYINFORMATION

Thismanualprovidesgeneralandspecicmaintenanceproceduresessentialforreliableengineoperation andyoursafety .Sincemanyvariationsinprocedures,tools,andservicepartsareinvolved,adviceforall possiblesafetyconditionsandhazardscannotbestated.
Readsafetyinstructionsbeforedoinganyserviceandtestproceduresfortheengineorvehicle.Seerelated applicationmanualsformoreinformation.
DisregardforSafetyInstructions,Warnings,Cautions,andNotesinthismanualcanleadtoinjury,deathor damagetotheengineorvehicle.

SafetyT erminology

Threetermsareusedtostressyoursafetyandsafeoperationoftheengine:Warning,Caution,andNote.
Warning:Awarningdescribesactionsnecessarytopreventoreliminateconditions,hazards,andunsafe practicesthatcancausepersonalinjuryordeath.
Caution:Acautiondescribesactionsnecessarytopreventoreliminateconditionsthatcancausedamageto theengineorvehicle.
Note:Anotedescribesactionsnecessaryforcorrect,efcientengineorvehicleoperation.

SafetyInstructions

WorkArea

•Keepworkareaclean,dry ,andorganized.
•Keeptoolsandpartsofftheoor.
•Makesuretheworkareaisventilatedandwelllit.
•Makesurearstaidkitisavailable.

SafetyEquipment

•Usecorrectliftingdevices.
•Usesafetyblocksandstands.

ProtectiveMeasures

•Wearprotectivesafetyglassesandshoes.
•Wearcorrecthearingprotection.
•Wearcottonworkclothing.
•Wearsleevedheatprotectivegloves.
•Donotwearrings,watchesorotherjewelry.
•Restrainlonghair.
2
DIAGNOSTICMANUAL

Vehicle

•Makesurethevehicleisinneutral,theparkingbrakeisset,andthewheelsareblockedbeforeservicing
engineorvehicle.
•Cleartheareabeforestartingtheengine.

Engine

•Theengineandvehicleshouldbeoperatedorservicedonlybyqualiedindividuals.
•Providenecessaryventilationwhenoperatingengineinaclosedarea.
•Keepcombustiblematerialawayfromengineexhaustsystemandexhaustmanifolds.
•Installallshields,guards,andaccesscoversbeforeoperatingengineorvehicle.
•Donotrunenginewithunprotectedairinletsorexhaustopenings.Ifunavoidableforservicereasons,put
protectivescreensoverallopeningsbeforeservicingengine.
•Shutengineoffandrelieveallpressureinthesystembeforeremovingpanels,housingcovers,andcaps.
•Ifanengine,orvehicle,isnotsafetooperate,tagtheignitionkey.

FirePrevention

•Makesurechargedreextinguishersareintheworkarea.
NOTE–Checktheclassicationofeachreextinguishertoensurethatthefollowingretypescanbe extinguished.
1.TypeA-Wood,paper,textiles,andrubbish
2.TypeB-Flammableliquids
3.TypeC-Electricalequipment

Batteries

•Alwaysdisconnectthemainnegativebatterycablerst.
•Alwaysconnectthemainnegativebatterycablelast.
•Avoidleaningoverbatteries.
•Protectyoureyes.
•Donotexposebatteriestoopenamesorsparks.
•Donotsmokeinworkplace.

CompressedAir

•UseanOSHAapprovedblowgunratedat30psi(207kPa).
•Limitshopairpressureto30psi(207kPa).
•Wearsafetyglassesorgoggles.
•Wearhearingprotection.
•Useshieldingtoprotectothersintheworkarea.
•Donotdirectcompressedairatfaceorbody .
3
DIAGNOSTICMANUAL

Tools

•Makesurealltoolsareingoodcondition.
•Makesureallstandardelectricaltoolsaregrounded.
•Checkforfrayedpowercordsbeforeusingpowertools.

FluidsUnderPressure

•Useextremecautionwhenworkingonsystemsunderpressure.
•Followapprovedproceduresonly.

Fuel

•Donotoverllthefueltank.Overllcreatesarehazard.
•Donotsmokeintheworkarea.
•Donotrefuelthetankwhentheengineisrunning.

RemovalofTools,Parts,andEquipment

•Reinstallallsafetyguards,shields,andcoversafterservicingtheengineorvehicle.
•Makesurealltools,parts,andserviceequipmentareremovedfromtheengineandvehicleafterall workisdone.
4
DIAGNOSTICMANUAL
MAXXFORCE
DT,9AND10AFTERTREATMENTSYSTEMDIAGNOSTICS

3.1.STARTDIAGNOSTICSHERE:ENGINEANDAFTERTREATMENTSYSTEM OPERATIONALCHECKS

Overview

Aproperlyoperatingaftertreatmentsystemrequireslittlemanualinterventionfromtheoperator.Illuminated warninglampsmayindicateadrivingorextendedidleoperationthatmaynotallowsuccessfulregeneration oftheaftertreatmentsystem.Theseilluminatedwarninglampsmayalsoindicateanenginemechanicalor performanceconcern.

ToolsRequired

•ElectronicServiceT ool(EST)withServiceMaxx™software
•Interfacecable(RP1210BcompliantsupportingJ1939andJ1708)
NOTE–AfrequentregenconcernmaynotberepairedbyonlyperforminganOnboardFilterCleanliness Test(OBFCT).Performallstepsinthefollowingdiagnosticprocedureinordertoidentifyrootcause failure.
NOTE–Repairallactivefaultcode(s)otherthanSPN3719(DPFSootLoad)beforebeginningEngine andAftertreatmentSystemOperationalChecks.

OperationalChecks–StartAftertreatmentDiagnosticsHere

Step
1
Verifythefollowingenginesystemsareinsatisfactorycondition:
•EngineOil:Parkvehicleonlevelgroundandcheckoillevel.
•EngineCoolantLevel:Checkcoolantlevelthatisindicatedon deaerationtank.
•IntakeAir:Inspectairltergauge,locatedonairlterhousingor dashboard.
•ElectricalSystem:Inspectbatteriesandelectricalsystem(engineand vehicle)forpoororlooseconnections,corrodedterminals,orbroken anddamagedwires.
•ExhaustSystem:CheckAftertreatmentandexhaustsystemfor damage,excessivecorrosion,orleaks.
•Fuellevel:Checkinstrumentpanelfuelgauge,lookintofueltanksto verifyfuellevel,andmakesurefuellevelsareequalinbothtanks.
•FuelqualityObtainafuelsample,andcheckforwater,waxing,icing, sediment,gasoline,DieselExhaustFluid(DEF),orkerosene.
•Fuellineroutingandcondition:WithengineOFF ,visuallyinspect theconditionandroutingoffuellines.
Arealloftheaboveenginesystemsoperatingasdesigned?
ActionDecision
Yes:Gotostep2
No:Repair appropriate enginesystem andgotostep2.
5
DIAGNOSTICMANUAL
Step
2
Step
3
DetermineifengineorAftertreatmentsystemwarninglampsareilluminated. Key-OnEngine-Off(KOEO),checkInstrumentPanel(IP)forthefollowing warninglamps:
•AmberWarningLamp(AWL)
•RedStopLamp(RSL)
•MalfunctionIndicatorLamp(MIL)
•DieselParticulateFilter(DPF)Lamp
Areanyoftheabovewarninglampsilluminated?
DieselParticulateFilter(DPF)SnapAccelerationTest(QuickTest).This procedurecheckstheDPFforcracksorinternaldamagewithoutremoving theDPFfromthevehicleandisusedtotestbasicfunctionalityofthediesel particulatelter.ThisistobedonepriortoremovingtheDPF .
1.Thetransmissionmustbeinneutralandtheparkingbrake
applied.
ActionDecision
Yes:Gotostep4
No:Gotostep3
ActionDecision
Yes:Goto symptom5 (MediumDuty): Blacksmokepage
44.
Isblacksmokevisible?
2.Startandidletheengine.
3.Rapidlysnaptheacceleratorpedalfromidletofullthrottle.This
canbeperformedmultipletimes.
4.Duringtheengineaccelerations,visuallycheckforaheavy
blacksmokeexitingtheexhaustpipe.
No:Goto Symptom1 (MediumDuty): FrequentParked RegenswithNo ActiveCodes (Morethanone parkedregenper day)page8.
6
DIAGNOSTICMANUAL
Step
4
Step
5
Checkforanenginenostart.TurnignitionswitchtoONpositionandcrank engineforamaximumof20seconds.Ifenginedoesnotstart,wait2to3 minutesandcrankengineagainforamaximumof20seconds.
Doestheenginestartandrun?
UsingElectronicServiceT ool(EST)withServiceMaxx™software,check DiagnosticTroubleCode(DTC)listforSPN3719FMI0,15,and16(DPF SootLoad).
IsSPN3719orSPN3936withFMI0,15,or16theonlyfaultcode(s)active?
ActionDecision
Yes:Gotostep5
No:Goto symptom2 (MediumDuty): EngineNoStart/ StartsandStalls page17.
ActionDecision
Yes:Goto Symptom3 (MediumDuty): SPN3719or SPN3936Active OnlyorFrequent Regenspage24.
No:Goto Symptom4 (MediumDuty): SPN3719or SPN3936and OtherActiveFault Codespage34.
7
DIAGNOSTICMANUAL

3.2.SYMPTOM1(MEDIUMDUTY):FREQUENTPARKEDREGENSWITHNOACTIVE FAUL TCODES(MORETHANONEPARKEDREGENPERDAY)

NOTE–Beforebeginningthefollowingstep-baseddiagnostics,performallvehicleoperationalchecks page5.
NOTE–SPN3719FMI15maybeinactivewhenafrequentregenconcernispresent.
NOTE–SPN3936FMI8canbeactiveforthissymptom.
Step
1
CheckforafailedAirManagementSystem(AMS)actuator.
1.UsingElectronicServiceT ool(EST)withServiceMaxx™
software,gotoT ests>LoadTestSpecicSessionandverify LoadTestSpecicSessionisunchecked.
2.GotoSessions>Performanceandselecttherecordsnapshot
iconfromthetoolbar.
3.GotoTests>KOERT ests>AirManagementTest.
WhenAirManagementTestiscomplete,stoprecording.Usetheplayback featureinServiceMaxx™,andgraphthefollowingsignalvalues:
SignalValues:
•MassAirFlow(MAF)MeanValue(MMV)
•IntakeManifoldPressure(IMP)
•ExhaustGasRecirculation(EGR)valveposition
DoessnapshotmatchGraph1orGraph2page51?
ActionDecision
Graph1:Goto step2A
Graph2: Diagnoseand repairfailed actuator(See Performance Diagnostics sectioninEngine Diagnostic Manual).After repairsare complete,retest fororiginal problem.
8
DIAGNOSTICMANUAL
WARNING
Topreventpersonalinjuryordeath,donotexceedlocalspeedlimitlawsordrivetoofast forconditionswhenperforming0to60MPHTest.
NOTE–IntakeManifoldPressure(IMP)canvarybasedonECMcalibrationandvehicleweight.Using ElectronicServiceTool(EST)withServiceMaxx™software,monitorturbochargerwastegateoperation toverifylowboost.
Step
2A
Checkforengineperformanceissues.Perform0to60MPHT estprocedure below:
1.UsingEST,gotoSessions>Performance.
2.Findanopenstretchofroad,whereminimumspeedlimitis 50mphorhigher.
3.Pullovertothesideoftheroad.
4.Whendrivingconditionsaresafeandvehiclehasreached normaloperatingtemperature,selecttherecordsnapshoticon fromthetoolbar.
5.Pressacceleratorpedalfullytotheoor,andacceleratefrom0 mphtomaxallowedhighwayspeed.
After0to60MPHTestiscomplete,stoprecordingandsavesnapshot.
ActionDecision
Gotostep2B
9
DIAGNOSTICMANUAL
Step
2B
CheckforInjectionControlPressure(ICP)systemissue.UsingESTwith ServiceMaxx™software,usetheplaybackfeatureandgraphthefollowing signalvaluesfrom0to60MPHTest:
SignalValues:
•ICPdesired
•ICP
•InjectionPressureRegulator(IPR)valvecontrol%
ComparesnapshottoGraph3andassociatedGraphAnalysispage54.
IsICPsystemoperatingasperGraph3GraphAnalysis?
ActionDecision
Yes:Gotostep 2C
No:Diagnose andrepairICP systemissue(See HardStartandNo StartDiagnostics sectioninEngine Diagnostic Manual).After repairsare complete,retest fororiginal problem.
10
DIAGNOSTICMANUAL
Step
2CCheckforAirManagementSystem(AMS)issue.UsingESTwith
ServiceMaxx™software,usetheplaybackfeatureandgraphthefollowing signalvaluesfrom0to60MPHTest:
SignalValues:
•EngineSpeed
•EngineLoad
•IntakeManifoldPressure(IMP)
•ExhaustBackPressure(EBP)
•AcceleratorPedalPosition1(APP1)
ComparesnapshottoGraph4andassociatedGraphAnalysispage55.
IsAMSoperatingasperGraph4GraphAnalysis?
ActionDecision
Yes:Gotostep3
No:Diagnoseand repairAMSissue (SeePerformance Diagnostics sectioninEngine Diagnostic Manual).After repairsare complete,retest fororiginal problem.
11
DIAGNOSTICMANUAL
Step
3
Verifyexhaustgastemperaturesarewithinspecication.
1.UsingElectronicServiceTool(EST)withServiceMaxx™ software,gotoSessions>Performanceandselecttherecord snapshoticonfromthetoolbar.
2.GotoT ests>KOERAftertreatmentTests>OnboardFilter CleanlinessT est.
WhenOBFCTiscomplete,stoprecording.Usetheplaybackfeatureand graphthefollowingsignalvaluesfromOBFCT:
SignalValues:
•DieselOxidationCatalystInletT emperature(DOCIT)
•DieselParticulateFilterInletT emperature(DPFIT)
•DieselParticulateFilterOutletT emperature(DPFOT)
•DPFSootLoad
ComparesnapshottoGraph5,6,and7page57.
Whichgraphdoessnapshotmostcloselymatch?
ActionDecision
Graph5: Diagnostics complete
Graph6:Goto step4
Graph7:Goto step7
Step
4
DetermineifDPForDOCiscontaminated.RemovetheDPFandDOC (seeExhaustSystemServiceManual),andcheckforsignsoflubeoiland coolantcontamination.
NOTE–Ablackstainingintheexhausttailpipecanoccuron applicationsthatexperiencehighidletimes.Thisisnormalandthe DPFshouldNOTbereplaced.
AretheDPForDOCcontaminated?
ActionDecision
Yes:Remove PDOC,andgoto step5.
No:InstallDPF andDOC,andgo tostep7.
12
DIAGNOSTICMANUAL
Step
5
Step
6
DetermineifDPF,DOC,andPDOCarereusableseetheDPFandDOC reuseguidelinespage159.
BasedonDPFandDOCRe-UseGuidelines,aretheDPF,DOC,and PDOCreusable?
Determinerootcauseofexhaustsystemcontamination.(SeeEngine SymptomsDiagnosticssectioninEngineDiagnosticManual.)
ActionDecision
Yes:Install removed aftertreatment system components,and gotostep6.
No:Replace failed component(s). Afterrepairsare complete,goto step6.
ActionDecision
Afterrepairsare complete,goto step7.
13
DIAGNOSTICMANUAL
1.NewAftertreatmentFuelInjector (AFI)gasket
Step
7
PerformAftertreatmentFuelInjector(AFI)visualinspection.RemoveAFI (SeeEngineServiceManual)andcheckforthefollowing:
VisualChecks:
•CorrectAFIgasketisinstalled(Figure1)
•AFIandboreunrestrictedandfreeofcarbonbuildup
•AFItipfreeofcracksandotherdamage
DidAFIpassallvisualchecks?
2.EarlyproductionAFIgasket
Figure1AFIGasket
ActionDecision
Yes:InstallAFI, andgotostep8.
CAUTION
Donotremovethenozzleinjectorfromthedoser housing.Spraypatterntestisnolongeravisualcheck forAftertreatmentFuelInjector(AFI)replacement.
No:Correctfailed visualcheck(s). Afterrepairsare complete,install AFIandgotostep
8.
14
DIAGNOSTICMANUAL
Step
8
Step
9
Step
10
RunDSISystemDe-AerationProceduretwice,topurgetheDownStream Injection(DSI)systemofair.UsingEST,gotoProcedures>KOER AftertreatmentProcedures>DSISystemDe-Aeration.
UsingEST,checkDiagnosticTroubleCode(DTC)listforanyfaultcode(s) thatmayhavebecomeactiveduringOBFCT.
DoesDTClistcontainanyactivefaultcode(s)?
Verifyexhaustgastemperaturesarewithinspecication.
1.UsingElectronicServiceT ool(EST)withServiceMaxx™ software,gotoTests>KOERAftertreatmentT ests>Onboard FilterCleanlinessT est(OBFCT).
2.GotoSessions>Performanceandselecttherecordsnapshot iconfromthetoolbar.
WhenOBFCTiscomplete,stoprecording.Usetheplaybackfeatureand graphthefollowingsignalvaluesfromOBFCT:
ActionDecision
Gotostep9
ActionDecision
Yes:Repairactive faultcode(s) (SeeElectronic ControlSystems Diagnosticsin EngineDiagnostic Manual).After repairsare complete,goto step10.
No:Gotostep10
ActionDecision
Graph5:Goto step11
Graph6:Go toPerformance Diagnostics sectioninEngine Diagnostic Manual.
SignalValues:
•DieselOxidationCatalystInletT emperature(DOCIT)
•DieselParticulateFilterInletT emperature(DPFIT)
•DieselParticulateFilterOutletT emperature(DPFOT)
•DPFSootLoad
ComparesnapshottoGraph5and6page57.
Whichgraphdoessnapshotmostcloselymatch?
15
DIAGNOSTICMANUAL
Step
11
Step
12
PerformStandardT esttoverifyallenginesystemsareoperatingas designed.Verifyenginecoolanttemperatureisgreaterthan158°F(70°C). UsingESTwithServiceMaxx™software,gotoTests>KOERTests> StandardT est.
DoesStandardT estrunandpass?
PerformthefollowingMAFSensorCalibrationproceduretoaccommodate forsystemrepairs:
1.Verifyenginecoolanttemperatureisgreaterthan180°F(82°C), andlubeoiltemperatureisgreaterthan176°F(80°C).
ActionDecision
Yes:Gotostep 12
No:Diagnose andrepairactive faultcode(s) (seeElectronic ControlSystem Diagnostics sectioninEngine Diagnostic Manual).
ActionDecision
Yes:Diagnostics complete
2.UsingESTwithServiceMaxxsoftware,gotoTests>and deselectLoadT estSpecicSession.
3.GotoSessions>Performanceandselecttherecordsnapshot iconfromthetoolbar.
4.Gotoprocedures>KOERProcedures>MAFSensor Calibration.
5.AfterMAFSensorCalibrationiscomplete,stoprecording.
6.TurntheignitionswitchtotheOFFpositionforaminimumof 30seconds.
7.Repeatsteps3through5tocompletesecondMAFSensor Calibration.
DoesMAFSensorCalibrationprocedurerunandpass?
No:Goto Performance Diagnostics sectioninEngine Diagnostic Manual.
16
DIAGNOSTICMANUAL

3.3.SYMPTOM2(MEDIUMDUTY):ENGINENOSTART/STARTSANDSTALLS

NOTE–Beforebeginningthefollowingstep-baseddiagnostics,performallvehicleoperationalchecks page5.
Step
1
Checkforanexhaustsystemrestrictionbyperformingthefollowing ExhaustSystemRestrictionT est:
Topreventdamagetothestarter,ifenginefailsto startwithin20seconds,releaseignitionswitch, andwait2to3minutestoallowstartermotorto cool.
1.TurnignitionswitchtoONposition.
2.UsingESTwithServiceMaxx™software,goto Sessions>PerformanceandrecordTurbocharger1 TurbineOutletPressure(TC1TOP)Key-OnEngine-Off (KOEO)signalvalue.
3.Selecttherecordsnapshoticonfromthetoolbar.
4.Cranktheengineforamaximumof20seconds.If enginedoesnotstart,wait2to3minutesandcrank engineagainforamaximumof20seconds.
5.Stoprecording.
6.UsetheplaybackfeatureinServiceMaxx™andgraph TC1TOP ,andDieselParticulateFilterDifferential Pressure(DPFDP)signalvalues.
ActionDecision
CAUTION
BothDPFDPandTC1TOP signalsHigh:Gotostep2
TC1TOPsignalHighOnly: Gotostep3
NeitherDPFDPor TC1TOPsignalHigh: GotoHardStartandNo StartDiagnosticssection inEngineDiagnostic Manual.Afterrepairsare complete,gotostep8.
NOTE—TocalculateTC1TOP(actual),subtract TC1TOPKOEOsignalvaluerecordedinstep2from maximumTC1TOPsignalvaluereachedinstep7.
7.RecordmaximumTC1TOPsignalvaluereachedfrom snapshot,andcalculateTC1TOPactual(SeeTable21, page18).
8.VerifyDPFDPandTC1TOP(actual)arewithin specication.DPFDPsignalvalueshouldbelessthan 1psi(7kPa),andTC1TOP(actual)shouldbelessthan 5psi(34kPa).
AreDPFDPandTC1TOPsignalvalueswithinspecication?
17
DIAGNOSTICMANUAL

Table21ExampleTC1TOP(Actual)Calculations

MaximumTC1TOPSignal
ValueDuringCranking
15.7psi(108kPa)14.7psi(101kPa)15.7psi(108kPa)–14.7psi(101kPa)=
1psi(7kPa)0psi(0kPa)1psi(7kPa)–0psi(0kPa)=1psi(7kPa)
-13psi(-89kPa)-14psi(–96kPa)–13psi(80kPa)–(–14)psi(-96kPa)=1
Step
2
Step
DetermineiftheDieselParticulateFilter(DPF)iscontaminated. RemovetheDPF(seeExhaustSystemServiceManual),andcheck forsignsoflubeoilandcoolantcontamination.
NOTE–Ablackstainingintheexhausttailpipecanoccuron applicationsthatexperiencehighidletimes.Thisisnormaland theDPFshouldNOTbereplaced.
IstheDPFcontaminated?
TC1TOPKOEOSignalValueMaximumTC1TOPSignalValueDuring
Cranking—TC1TOPKOEOSignal
Value=TC1TOP(Actual)
1psi(7kPa)
psi(7kPa)
ActionDecision
Yes:RemovePre-Diesel OxidationCatalyst (PDOC)&Diesel OxidationCatalyst(DOC), andthenandthengoto step4.
No:Gotostep5
ActionDecision
3
Step
4
DetermineifPDOCorDOCiscontaminated.RemovethePDOC andDOC(seeExhaustSystemServiceManual),andcheckfor signsoflubeoilandcoolantcontamination.
NOTE–Ablackstainingintheexhausttailpipecanoccuron applicationsthatexperiencehighidletimes.Thisisnormaland theDPFshouldNOTbereplaced.
ArethePDOCandDOCcontaminated?
ActionDecision
DetermineifDPF,DOC,andPDOCarereusableseetheDPFand DOCreuseguidelinespage159.
BasedonDPFandDOCRe-UseGuidelines,aretheDPF ,DOC, andPDOCreusable?
Yes:RemoveDPF,and thengotostep4.
No:Gotostep5
Yes:Gotostep6
No:Replacefailed component(s).After repairsarecomplete,go tostep6.
18
DIAGNOSTICMANUAL
Step
5
Step
6
Step
7
Determineifremovedaftertreatmentsystemcomponentsneedto becleanedseetheDPFandDOCreuseguidelinespage159.
BasedonDPFandDOCRe-UseGuidelines,doanyofthe removedaftertreatmentsystemcomponentsneedtobecleaned?
Determinerootcauseofexhaustsystemcontamination.(See EngineSymptomsDiagnosticssectioninEngineDiagnostic Manual.)
Checkforanenginenostart.TurnignitionswitchtoONposition andcrankengineforamaximumof20seconds.Ifenginedoesnot start,wait2to3minutesandcrankengineagainforamaximum of20seconds.
ActionDecision
Yes:Cleancomponents usingappropriatecleaning equipment.Aftercleaning procedureiscomplete, Installcomponentsandgo tostep7.
No:Installremoved aftertreatmentsystem components,andthengo tostep7.
ActionDecision
Afterrepairsarecomplete, gotostep7.
ActionDecision
Yes:Gotostep8
Doestheenginestartandrun?
No:GotoHardStartand NoStartDiagnostics sectioninEngine DiagnosticManual.
19
DIAGNOSTICMANUAL
Step
8
Step
DoOnboardFilterCleanlinessTest(OBFCT)toclearactive aftertreatmentfaultcode(s).UsingElectronicServiceTool(EST) withServiceMaxx™software,gotoT ests>KOERAftertreatment Tests>OnboardFilterCleanlinessTest.WhileOBFCTisrunning, checkthefollowingcomponentsforexhaustleaks,andverifyall fasteners,brackets,andclampsaresecureandundamaged:
•LowPressure(LP)turbochargeroutletpipe
•ExhaustBackPressureValve(EBPV)
•FlexiblemeshpipetoDOCinlet
•InlettoDOC
Wereallcomponentsfreeofexhaustleaks,andallfasteners, brackets,andclampssecureandundamaged?
ActionDecision
Yes:Gotostep9
No:Repairexhaustleak orrepairfailedfastener, bracket,orclamp.After repairsarecomplete,go tostep9.
ActionDecision
9
CheckforafailedAirManagementSystem(AMS)actuator.
1.UsingESTwithServiceMaxx™software,gotoT ests >LoadT estSpecicSessionandverifyLoadT est SpecicSessionisunchecked.
2.GotoSessions>Performanceandselecttherecord snapshoticonfromthetoolbar.
3.GotoTests>KOERTests>AirManagementTest.
WhenAirManagementTestiscomplete,stoprecording.Use theplaybackfeatureinServiceMaxx™,andgraphthefollowing signalvalues:
SignalV alues:
•MassAirFlow(MAF)meanvalue
•IntakeManifoldPressure(IMP)
•ExhaustGasRecirculation(EGR)valveposition
DoessnapshotmatchGraph1orGraph2page51?
Graph1:Gotostep10A
Graph2:Diagnoseand repairfailedactuator (SeePerformance Diagnosticssection inEngineDiagnostic Manual).Afterrepairs arecomplete,retestfor originalproblem.
20
DIAGNOSTICMANUAL
WARNING
Topreventpersonalinjuryordeath,donotexceedlocalspeedlimitlawsordrivetoofast forconditionswhenperforming0to60MPHTest.
NOTE–IntakeManifoldPressure(IMP)canvarybasedonECMcalibrationandvehicleweight.Using ElectronicServiceTool(EST)withServiceMaxx™software,monitorturbochargerwastegateoperation toverifylowboost.
Step
10A
Checkforengineperformanceissues.Perform0to60MPHT est procedurebelow:
1.UsingEST,gotoSessions>Performance.
2.Findanopenstretchofroad,whereminimumspeed limitis50mphorhigher.
3.Pullovertothesideoftheroad.
4.Whendrivingconditionsaresafeandvehiclehas reachednormaloperatingtemperature,selectthe recordsnapshoticonfromthetoolbar.
5.Pressacceleratorpedalfullytotheoor,and acceleratefrom0mphtomaxallowedhighway speed.
After0to60MPHT estiscomplete,stoprecordingandsave snapshot.
ActionDecision
Gotostep10B
21
DIAGNOSTICMANUAL
Step
10B
CheckforInjectionControlPressure(ICP)systemissue.Using ESTwithServiceMaxx™software,usetheplaybackfeatureand graphthefollowingsignalvaluesfrom0to60MPHT est:

SignalV alues:

•ICPdesired
•ICP
•InjectionPressureRegulator(IPR)valvecontrol%
ComparesnapshottoGraph3andassociatedGraphAnalysis page54.
IsICPsystemoperatingasperGraph3GraphAnalysis?
ActionDecision
Yes:Gotostep10C
No:Diagnoseandrepair ICPsystemissue(See HardStartandNoStart Diagnosticssectionin EngineDiagnosticManual). Afterrepairsarecomplete, retestfororiginalproblem.
Step
10CCheckforAirManagementSystem(AMS)issue.UsingESTwith
ServiceMaxx™software,usetheplaybackfeatureandgraphthe followingsignalvaluesfrom0to60MPHTest:

SignalV alues:

•EngineSpeed
•EngineLoad
•IntakeManifoldPressure(IMP)
•ExhaustBackPressure(EBP)
•AcceleratorPedalPosition1(APP1)
ComparesnapshottoGraph4andassociatedGraphAnalysis page55.
IsAMSoperatingasperGraph4GraphAnalysis?
ActionDecision
Yes:Gotostep11
No:Diagnoseand repairAMSissue(See PerformanceDiagnostics sectioninEngine DiagnosticManual).After repairsarecomplete,retest fororiginalproblem.
22
DIAGNOSTICMANUAL
Step
11
Step
12
PerformStandardTesttoverifyallenginesystemsareoperating asdesigned.Verifyenginecoolanttemperatureisgreaterthan 158°F(70°C).UsingESTwithServiceMaxx™software,goto Tests>KOERT ests>StandardT est.
DoesStandardT estrunandpass?
PerformthefollowingMAFSensorCalibrationprocedureto accommodateforsystemrepairs:
1.Verifyenginecoolanttemperatureisgreaterthan 180°F(82°C),andlubeoiltemperatureisgreater than176°F(80°C).
2.UsingESTwithServiceMaxxsoftware,gotoT ests> anddeselectLoadTestSpecicSession.
ActionDecision
Yes:Gotostep12
No:Diagnoseandrepair activefaultcode(s).Goto ElectronicControlSystem Diagnosticssectionin EngineDiagnosticManual.
ActionDecision
Yes:Diagnosticscomplete
3.GotoSessions>Performanceandselecttherecord snapshoticonfromthetoolbar.
4.Gotoprocedures>KOERProcedures>MAFSensor Calibration.
5.AfterMAFSensorCalibrationiscomplete,stop recording.
6.TurntheignitionswitchtotheOFFpositionfora minimumof30seconds.
7.Repeatsteps3through5tocompletesecondMAF SensorCalibration.
DoesMAFSensorCalibrationprocedurerunandpass?
No:GotoPerformance Diagnosticssectionin EngineDiagnosticManual.
23
DIAGNOSTICMANUAL

3.4.SYMPTOM3(MEDIUMDUTY):SPN3719ORSPN3936ACTIVEONL YOR FREQUENTREGENS(MORETHANONEPARKEDREGENPERDAY)

NOTE–Beforebeginningthefollowingstep-baseddiagnostics,performallvehicleoperationalchecks page5.
NOTE–Thenumberofregensperformedinonedaymayvarydependingonapplication.Thefollowing criteriashouldbeusedtodetermineifaregenisconsideredfrequent:
•Line-haul:Morethan1parkedregenperdayisfrequentregeneration.
•Severeservice:Morethan2parkedregensperdayisfrequentregeneration.
Step
1
Step
2
UsingElectronicServiceT ool(EST)withServiceMaxx™software, checkDiagnosticTroubleCode(DTC)listtodeterminewhichof thefollowingfaultcodesisactive:SPN3719/3936FMI0,15,or
16.
Whichfaultcodeisactive?
DothreeOnboardFilterCleanlinessT ests(OBFCT)todecrease sootloadofDieselParticulateFilter(DPF).UsingEST ,gotoTests >KOERAftertreatmentTests>OnboardFilterCleanlinessT est. AfterOBFCTsarecomplete,checkDTClisttodetermineifSPN 3719FMI0droppedoneFMIleveltoSPN3719FMI16.
DidSPN3719FMI0droponeFMIleveltoSPN3719FMI16?
ActionDecision
SPN3719orSPN3936FMI 0:Gotostep2
SPN3719orSPN3936FMI 16:Gotostep4
SPN3719orSPN3936FMI 15:Gotostep5
ActionDecision
Yes:Gotostep3
No:Gotostep4
24
DIAGNOSTICMANUAL
Step
3
Step
4
Step
UsingElectronicServiceTool(EST)withServiceMaxx™software, ResetDPFsootload.SelectSessions>Programming>CDPF ResetRequestsetvaluetoyes,thenselectProgramEngine. Whenprogrammingcompletes,runengineatwideopenthrottle (WOT)for10minutes.Ifahighsootloadexists,youwillseeit after10minutes;Ifthehighsootloadisfalse,theDPFsootload willberecalculatedtoshowthetruesootload.
Whichfaultcodeforsootloadisactive?
DothreeOnboardFilterCleanlinessT ests(OBFCT)todecrease sootloadofDieselParticulateFilter(DPF).UsingEST ,gotoTests >KOERAftertreatmentTests>OnboardFilterCleanlinessT est. AfterOBFCTsarecomplete,checkDTClisttodetermineifSPN 3719FMI16droppedoneFMIleveltoSPN3719FMI15.
DidSPN3719FMI16droponeFMIleveltoSPN3719FMI15?
ActionDecision
SPN3719FMI16,goto Step4
SPN3719FMI15,goto Step5
SPN3719or3936FMI0, gotoStep7
Nocodes,gotoStep11
ActionDecision
Yes:Gotostep5
No:Gotostep6
ActionDecision
5
DothreeOnboardFilterCleanlinessTests(OBFCT)toclearSPN 3719FMI15.UsingEST ,gotoTests>KOERAftertreatment Tests>OnboardFilterCleanlinessTest.AfterOBFCT sare complete,checkDTClisttodetermineifSPN3719FMI15is stillactive.
IsSPN3719FMI15stillactive?
Yes:Gotostep7
No:Gotostep6
25
DIAGNOSTICMANUAL
Step
6
Step
7
DieselParticulateFilter(DPF)SnapAccelerationT est(Quick Test).ThisprocedurecheckstheDPFforcracksorinternal damagewithoutremovingtheDPFfromthevehicleandisused totestbasicfunctionalityofthedieselparticulatelter.Thisisto bedonepriortoremovingtheDPF .
1.Thetransmissionmustbeinneutralandtheparking brakeapplied.
2.Startandidletheengine.
3.Rapidlysnaptheacceleratorpedalfromidletofull throttle.Thiscanbeperformedmultipletimes.
4.Duringtheengineaccelerations,visuallycheckfora heavyblacksmokeexitingtheexhaustpipe.
Isblacksmokevisible?
DetermineifDieselParticulateFilter(DPF),Pre-DieselOxidation Catalyst(PDOC),andDieselOxidationCatalyst(DOC)are contaminated.RemovetheDPF,PDOC,andDOC(seeExhaust SystemServiceManual),andcheckforsignsoflubeoiland coolantcontamination.
ActionDecision
Yes:GotoSymptom5 (MediumDuty):Blacksmoke page44.
No:Gotostep11
ActionDecision
Yes:Gotostep8
NOTE–Ablackstainingintheexhausttailpipecanoccuron applicationsthatexperiencehighidletimes.Thisisnormal andtheDPFshouldNOTbereplaced.
AretheDPF,PDOC,orDOCcontaminated?
No:Gotostep9
Step
8
DetermineifDPF ,DOC,andPDOCarereusableseeDPFand DOCreuseguidelinespage159.
BasedonDPFandDOCRe-UseGuidelines,aretheDPF ,DOC, andPDOCreusable?
ActionDecision
Yes:Gotostep10
No:Replacefailed component(s).Afterrepairs arecomplete,gotostep10.
26
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