~IC Maint. And Updates. WAPT 2015~
·EPA 2007 Maxxforce DT/Maxxforce 7
-EGR
-Sensors
-Injector Faults
-Fuel System
-Fuel Dilution
-Coolant Fill
-Coolant Pressure
-IPR (Injection Pressure Regulator)
-DOC: Regen Temperatures
-Bed Plates
·EPA 2010 Maxxforce DT
-Air Filters
- AHI (Aftertreatment Hydrocarbon Injector)
-DPF
-EGR Cooler
·HD OBD EPA 2010/2013
·DEF and SCR
·2014 Cummin’s ISB6.7 CM2350 B101
EPA 2007 MAXXFORCE DT – EGR COOLER/VALVE
VISUAL INSPECTION OF OPERATION:
-REMOVE CROSS OVER PIPE
-SERVICE MAXX: KOEO STANDARD TEST
(Note: valve should be closed KOEO)
VISUAL INSPECTION OF LEAK:
-REMOVE CROSS OVER PIPE
-INSPECT FOR COOLANT COLOR/SMELL
(Note: cooler and cross over will be damp until engine is warm)
EGR VALVE
EPA 2007 MAXXFORCE DT – EGR COOLER/VALVE
COLD SIDE COOLER PLUGGING
Warranty: DTC 2389 - EGR flow insufficient - possible plugged system
DO NOT ERASE!
<<<INLET
OUTLET >>>
EPA 2007 MAXXFORCE DT – SENSORS
Clean sensors, ports and tubes. No deformations.
-MAT (Manifold Air Temperature
-MAP (Manifold Absolute Pressure: AKA Boost)
-EBP (Exhaust Back Pressure)
Same style sensors on MF7.
DO NOT INTERCHANGE!
EPA 2007 MAXXFORCE DT – SENSORS
MAP
MAT
EPA 2007 MAXXFORCE DT – SENSORS
-Service Maxx, Default Screen, KOEO
EPA 2007 MAXXFORCE DT – INJECTORS AND CAMSHAFT
-Camshaft Follower(lifter) guides
-Forced Lubrication: Rockers and Pushrods
EPA 2007 MAXXFORCE DT – INJECTORS AND CAMSHAFT
-Any Injector Fault Code – Run a Relative Compression Test
EPA ’07 Maxxforce
EPA ’10 Maxxforce
EPA 2007 MAXXFORCE DT – FUEL SYSTEM
-Fuel pressure range 40-80psi (Navistar)
Should not ‘bounce’ more than 10-15psi
-Best Practice: Change Fuel Filter with Oil Change
And clean out the bowl
-Keep fuel supply tanks in good repair.
~When was the filter
on your tank
changed last?~
EPA 2007 MAXXFORCE DT – FUEL SYSTEM
CLEAN FUEL = CLEAN FUEL SYSTEM
EPA 2007 MAXXFORCE DT – FUEL DILUTION
-RARE FOR UNITS WITH ‘SKRJ’ CALIBRATION
-SKSE CALIBRATION available through Dealer
Fill out dilution form: documentation in miles/hours of oil growth, oil change
intervals, provide samples if possible.
10cst @100ºC MinimumViscosity
Verification that all EGR and Aftertreatment systems are in good repair: Sensors,
DOC, DPF, EGR and ITV Functionality.
MAXXFORCE – COOLANT FILL
-BOTTOM FILL ONLY!
-Harlow’s Parts Dept: Radiator Fittings, Quick Hose Fitting, Air Lift Kit
-RE BUS: Fill to lower sight glass cold!
-Radiator Caps: On 3rd revision. Pressure test every oil change!
INTERNATIONAL DT466 AND MAXXFORCE– COOLANT PRESSURES
-Chassis Heater Hoses are rated to 30psi
-Testing shows spiking near 50psi, blowing hoses,causing EGR Cooler Failures.
-3/8” pressure relief line:
Plumb at Heater Valve, out from engine, to top of expansion tank.
MAXXFORCE DT – IPR (Injection Pressure Regulator)
EPA 2007: Replacement Pigtail.
Remove engine harness plug and
wire in new connector
EPA 2010: Redesigned IPR Valve Kit.
Glued pigtail, and new style connector.
New Socket
#12-800-01
‘07 DT HP Oil System, IPR has the filter screen
‘10 DT HP Oil System, HP Oil Pump has the filter screen
DO NOT INTERCHANGE!
MAXXFORCE 7/DT – DOC/DPF Parked Regeneration
DOC Inlet Temperature 600-800ºF
DPF Inlet Temperature 1000-1150ºF
DPF Outlet Temperature 1000-1150ºF
EPA 2007 MAXXFORCE 7 – BEDPLATE
-Bed Plate/Lower Crankcase Leaks:
-New Sealing and Torque Procedures
-Engine Must Be Removed
-Rear Main Seal: Two thicknesses of wear sleeve. Measure!
EPA 2010 MAXXFORCE DT – AIR FILTERS
-Air Filter Restriction Gauges: Not 100% accurate
-Once the gauge moves, it may be too late
-RE BUS – Filter size appears to be too small, plugs quickly.
-Check at oil change visually. Replace as necessary
10,000miles on filter.
EPA 2010 MAXXFORCE DT – AHI (Aftertreatment Hydrocarbon Injector
-Injects Fuel for ‘Active’ regen into exhaust
-No more fuel dilution
-Plugs with dirty air filter
-Must be cleaned after EGR Cooler failure.
-Updated Gasket
-ACM (Aftertreatment Control Module)
EPA 2010 MAXXFORCE DT – AHI (Aftertreatment Hydrocarbon Injector
-Injects Fuel for ‘Active’ regen into exhaust stream
-No more fuel dilution
-Plugs with dirty air filter
-Must be cleaned after EGR Cooler failure.
-Updated Gasket
-ACM (Aftertreatment Control Module)
EPA 2010 MAXXFORCE DT – DOC/DPF
-ALL MODELS: Clean DPF at yearly or hourly specifications found in Maintenance Manual
-Leading causes of DPF Failure on 2010 DT:
Defective CAC Pipe, Plugged AHI, Dirty Air Filters, Failed EGR Cooler
“If it’s Smokin’ it’s Broken”
EPA 2010 MAXXFORCE DT – DOC/DPF
-DOC Face Plugging =
-Low Regen Temperatures: Incomplete and More Frequent Regens
-White Smoke
-Fuel Dilution
-Coolant/Excess Fuel/Oil Contamination = Poisoning
EPA 2010 MAXXFORCE DT – EGR COOLER
-2010 DT Has one large EGR Cooler
-TOW to Dealer when confirmed failed
-Hydro-lock very possible
EPA 2010 MAXXFORCE DT – EGR COOLER
-2010 DT Has one large EGR Cooler
-TOW to Dealer when confirmed failed
-Hydro-lock very possible
EPA 2010 MAXXFORCE DT – EGR COOLER
-2010 DT Has one large EGR Cooler
-TOW to Dealer when confirmed failed
-Hydro-lock very possible
HD OBD
-Heavy Duty On-Board Diagnostics
-EPA/CARB Standardization
-Class 4 and above, 14,000lb gross or higher.
-MIL (Malfunction Indicator Lamp) – Emissions related faults
HD OBD
-DTC term replaced by SPN (Suspect Parameter Number)
-FMI (Failure Mode Identifier) Same SPN, Different FMI, Same system
SPN164.13 - ICP Adaptation In-Range Fault
SPN164.0 - ICP Above KOEO Spec
SPN164.10 - ICP Abnormal Rate of Change
-Fault Status
·Pending (Monitor run an failed 1 drive cycle.) MIL OFF. Freeze Frame Stored
·Active (Monitor run and failed 2 drive cycle.) MIL ON. Freeze Frame Stored
·Healing (Monitor run and pass. Healing for 3 drive cycles.) 4th cycle, inactive.
·Previously Active/Inactive (Monitor has run and passed for 3 drive cycles.)
·Permanent Fault (Cannot be cleared by dealer or user, only by drive cycles.)
-Failure Description
·What the code is indicating: IE: Cylinder (#) Balance maximum limit exceeded
-Freeze Frame Data
·Stored information for when the fault is set. RPM, Temp, Speed, ETC
-Count
·How many drive cycles have occurred with the fault
HD OBD
FMI (Failure Mode Identifier)
FMI=0 - Data Valid but Above Normal Operational Range, Most Severe Level
FMI=1 - Data Valid but Below Normal Operational Range, Most Severe Level
FMI=2 - Data Erratic, Intermittent or Incorrect (rationality)
FMI=3 - Voltage Above Normal, or Shorted to High Source
FMI=4 - Voltage Below Normal, or Shorted to High Source
FMI=5 - Current Below Normal, or Open Circuit
FMI=6 - Current Above Normal, or Grounded Circuit
FMI=7 - Mechanical System not Responding or Out of Adjustment
FMI=8 - Abnormal Frequency or Pulse Width or Period
FMI=9 - Abnormal Update Rate
FMI=10 - Abnormal Rate of Change
FMI=11 - Failure Code not Identifiable
FMI=12 - Bad Intelligent Device or Component
FMI=13 - Out of Calibration
FMI=14 - Special Instructions
FMI=15 - Data Valid but Above Normal Range : Least Severe Level
FMI=16 - Data Valid but Above Normal Range: Moderately Severe Level
FMI=17 - Data Valid but Below Normal Range: Least Severe Level
FMI=18 - Data Valid but Below Normal Range: Moderately Severe Level
FMI=19 - Received Network Data in Error: (Multiplexed Data)
FMI=20 - Data Drifted High (rationality high)
FMI=21 - Data Drifted Low (rationality low)
FMI=22 to 30 - Reserved for SAE Assignment
FMI=31 - Condition Exists
HD OBD
DEF/SCR
-DEF (Diesel Exhaust Fluid):
-32.5% Urea/67.5% Water
-18 Month Shelf life at 30ºF
-SCR (Selective Catalyst Reduction)
-Cleans up the NOx Emission
-NOx Inlet and Outlet sensors, NH3 Ammonia sensor.
SCR Unit
DEF Tank
DOC/DPF
Engine>
DEF/SCR
Aftertreatment Fuel
Doser Component
Aftertreatment
Fuel Pressure
Sensor
Aftertreatment
Fuel Shutoff Valve
DOC/DPF Component
Aftertreatment
Diesel Oxidation
Catalyst Intake
Temperature
SCR Component
Aftertreatment
Diesel Particulate
Filter Intake
Temperature
Aftertreatment
Diesel Particulate
Filter Outlet
Temperature
X
Aftertreatment DEF
Dosing Valve
X
D
O
C
(Engine Out)
Aftertreatment
Intake NOx
Sensor
Aftertreatment SCR
Intermediate
Temperature
Aftertreatment
Intermediate
NH3 Sensor
Aftertreatment
Aftertreatment SCR
SCR Catalyst
Outlet Temperature
Aftertreatment
Fuel Doser
HD - ONLY
Aftertreatment
Purge Air
Actuator
Aftertreatment
Diesel
Oxidation
Catalyst
Aftertreatment
Particulate Filter
Differential
Pressure Sensor
Aftertreatment
Outlet NOx
Sensor
SCR
Catalyst
DPF
Aftertreatment DEF
Line Heater 1
Aftertreatment
DEF Dosing
Unit Heater
Relay
Aftertreatment DEF Dosing Unit
Aftertreatment DEF Line Heater 4
Aftertreatment DEF Pressure
Aftertreatment DEF Return Valve
Aftertreatment
Diesel
Particulate
Filter Outlet
Pressure
Sensor
Aftertreatment
Diesel
Particulate
Filter
Aftertreatment DEF Line Heater 3
Aftertreatment DEF Line Heater 2
Aftertreatment DEF Line Heater Relay
(Coolant Flow)
Aftertreatment DEF Tank
Heater Control Valve
Aftertreatment DEF
Tank Temperature
Diesel
Exhaust
Fluid (DEF)
Aftertreatment DEF
Tank Level
Aftertreatment DEF
Quallity Sensor
Aftertreatment DEF Tank
CUMMINS ISB6.7 CM2350 B101
-CE (Conventional) bus only at this time
-Do Not Pre-Fill secondary fuel filter(Fuel water sep.) Use hand primer
-Rear Gear Train Only
-ISB uses BOSCH Fuel Injection Pumps
-High Pressure Common Rail
-Fuel Pressure bleeds off almost immediately after engine shutdown
Do not loosen High Pressure Fuel lines while engine is running!
Thank you for your participation!
-Harlows