2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
0000003081
Revision 5
October 2014
Navistar, Inc.
DIAGNOSTIC MANUAL
Aftertreatment Symptom-Based Diagnostic and Inspection Manual - MaxxForce DT, 9 and 10 (EPA 10) , MaxxForce 11, 13 and 15 (EPA 10)
EPA 10 - US, Canada
DIAGNOSTIC MANUAL
TABLE OF CONTENTS
TABLE OF CONTENTS
1. FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
8
17
24
34
44
51
51
53
54
55
63
63
66
66
75
75
78
78
57
59
60
62
TABLE OF CONTENTS
120
120
122
124
126
127
135
135
138
138
147
147
151
151
152
152
156
159
159
160
161
162
163
164
165
166
167
168
169
170
172
18. TERMINOLOGY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181
ii
129
131
133
171
DIAGNOSTIC MANUAL
FOREWORD
Navistar, Inc. is committed to continuous research and development to improve products and introduce
technological advances. Procedures, specifications, and parts defined in published technical service literature
may be altered.
Technical service literature is revised periodically. If a technical publication is ordered, the latest revision
will be supplied.
NOTE To order technical service literature, contact your International dealer.
DIAGNOSTIC MANUAL
SAFETY INFORMATION
This manual provides general and specific maintenance procedures essential for reliable engine operation
and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all
possible safety conditions and hazards cannot be stated.
Read safety instructions before doing any service and test procedures for the engine or vehicle. See related
application manuals for more information.
Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or
damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note.
Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to
the engine or vehicle.
Note: A note describes actions necessary for correct, efficient engine or vehicle operation.
Safety Instructions
Work Area
Safety Equipment
Protective Measures
DIAGNOSTIC MANUAL
Vehicle
Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before servicing
engine or vehicle.
Engine
The engine and vehicle should be operated or serviced only by qualified individuals.
Keep combustible material away from engine exhaust system and exhaust manifolds.
Install all shields, guards, and access covers before operating engine or vehicle.
Do not run engine with unprotected air inlets or exhaust openings. If unavoidable for service reasons, put
protective screens over all openings before servicing engine.
Shut engine off and relieve all pressure in the system before removing panels, housing covers, and caps.
Fire Prevention
NOTE Check the classification of each fire extinguisher to ensure that the following fire types can be
extinguished.
1. Type A - Wood, paper, textiles, and rubbish
2. Type B - Flammable liquids
3. Type C - Electrical equipment
Batteries
Compressed Air
DIAGNOSTIC MANUAL
Tools
Fuel
Do not over fill the fuel tank. Overfill creates a fire hazard.
Reinstall all safety guards, shields, and covers after servicing the engine or vehicle.
Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all
work is done.
DIAGNOSTIC MANUAL
NOTE A frequent regen concern may not be repaired by only performing an Onboard Filter Cleanliness
Test (OBFCT). Perform all steps in the following diagnostic procedure in order to identify root cause
failure.
NOTE Repair all active fault code(s) other than SPN 3719 (DPF Soot Load) before beginning Engine
and Aftertreatment System Operational Checks.
Operational Checks Start Aftertreatment Diagnostics Here
Action
Step
1
Engine Oil: Park vehicle on level ground and check oil level.
Intake Air: Inspect air filter gauge, located on air filter housing or
dashboard.
Fuel level: Check instrument panel fuel gauge, look into fuel tanks to
verify fuel level, and make sure fuel levels are equal in both tanks.
Fuel quality Obtain a fuel sample, and check for water, waxing, icing,
sediment, gasoline, Diesel Exhaust Fluid (DEF), or kerosene.
Fuel line routing and condition: With engine OFF, visually inspect
the condition and routing of fuel lines.
Decision
Yes: Go to step 2
DIAGNOSTIC MANUAL
Action
Step
2
Decision
Determine if engine or Aftertreatment system warning lamps are illuminated. Yes: Go to step 4
Key-On Engine-Off (KOEO), check Instrument Panel (IP) for the following
warning lamps:
Action
Decision
Diesel Particulate Filter ( DPF) Snap Acceleration Test (Quick Test). This
procedure checks the DPF for cracks or internal damage without removing
the DPF from the vehicle and is used to test basic functionality of the diesel
particulate filter. This is to be done prior to removing the DPF.
Yes: Go to
symptom 5
(Medium Duty):
Black smoke page
44.
DIAGNOSTIC MANUAL
Step
Action
Decision
Check for an engine no start. Turn ignition switch to ON position and crank
engine for a maximum of 20 seconds. If engine does not start, wait 2 to 3
minutes and crank engine again for a maximum of 20 seconds.
Yes: Go to step 5
Action
Decision
Yes: Go to
Symptom 3
(Medium Duty):
SPN 3719 or
Is SPN 3719 or SPN 3936 with FMI 0, 15, or 16 the only fault code(s) active? SPN 3936 Active
Only or Frequent
Regens page 24.
Using Electronic Service Tool (EST) with ServiceMaxx software, check
Diagnostic Trouble Code (DTC) list for SPN 3719 FMI 0, 15, and 16 (DPF
Soot Load).
No: Go to
Symptom 4
(Medium Duty):
SPN 3719 or
SPN 3936 and
Other Active Fault
Codes page 34.
DIAGNOSTIC MANUAL
Step
1
Decision
Graph 1: Go to
step 2A
Graph 2:
Diagnose and
repair failed
actuator (See
Performance
Diagnostics
section in Engine
Diagnostic
Manual). After
repairs are
complete, retest
for original
problem.
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing 0 to 60 MPH Test.
NOTE Intake Manifold Pressure (IMP) can vary based on ECM calibration and vehicle weight. Using
Electronic Service Tool (EST) with ServiceMaxx software, monitor turbocharger wastegate operation
to verify low boost.
Step
2A
Action
Decision
Check for engine performance issues. Perform 0 to 60 MPH Test procedure Go to step 2B
below:
1. Using EST, go to Sessions > Performance.
2. Find an open stretch of road, where minimum speed limit is
50 mph or higher.
3. Pull over to the side of the road.
4. When driving conditions are safe and vehicle has reached
normal operating temperature, select the record snapshot icon
from the toolbar.
5. Press accelerator pedal fully to the floor, and accelerate from 0
mph to max allowed highway speed.
After 0 to 60 MPH Test is complete, stop recording and save snapshot.
DIAGNOSTIC MANUAL
Step
Action
2B
Check for Injection Control Pressure (ICP) system issue. Using EST with
ServiceMaxx software, use the playback feature and graph the following
signal values from 0 to 60 MPH Test:
Decision
Yes: Go to step
2C
Signal Values:
ICP desired
ICP
10
DIAGNOSTIC MANUAL
Step
Action
Decision
2C
Check for Air Management System (AMS) issue. Using EST with
ServiceMaxx software, use the playback feature and graph the following
signal values from 0 to 60 MPH Test:
Yes: Go to step 3
Signal Values:
Engine Speed
Engine Load
11
DIAGNOSTIC MANUAL
Action
Step
3
Decision
Graph 5:
Diagnostics
complete
Graph 6: Go to
step 4
Graph 7: Go to
step 7
Signal Values:
Action
Decision
Yes: Remove
PDOC, and go to
step 5.
12
DIAGNOSTIC MANUAL
Step
5
Action
Determine if DPF, DOC, and PDOC are reusable see the DPF and DOC
reuse guidelines page 159.
Based on DPF and DOC Re-Use Guidelines, are the DPF, DOC, and
PDOC reusable?
Decision
Yes: Install
removed
aftertreatment
system
components, and
go to step 6.
No: Replace
failed
component(s).
After repairs are
complete, go to
step 6.
Step
6
Action
Determine root cause of exhaust system contamination. (See Engine
Symptoms Diagnostics section in Engine Diagnostic Manual.)
Decision
After repairs are
complete, go to
step 7.
13
DIAGNOSTIC MANUAL
Figure 1
AFI Gasket
Action
Step
7
Decision
Yes: Install AFI,
and go to step 8.
CAUTION
Do not remove the nozzle injector from the doser
housing. Spray pattern test is no longer a visual check
for Aftertreatment Fuel Injector (AFI) replacement.
Perform Aftertreatment Fuel Injector (AFI) visual inspection. Remove AFI
(See Engine Service Manual) and check for the following:
Visual Checks:
14
DIAGNOSTIC MANUAL
Step
Action
Run DSI System De-Aeration Procedure twice, to purge the Down Stream
Injection (DSI) system of air. Using EST, go to Procedures > KOER
Aftertreatment Procedures > DSI System De-Aeration.
Step
Action
Decision
Using EST, check Diagnostic Trouble Code (DTC) list for any fault code(s)
that may have become active during OBFCT.
Decision
Go to step 9
No: Go to step 10
Action
Step
10
Decision
Graph 5: Go to
step 11
Graph 6: Go
to Performance
Diagnostics
section in Engine
Diagnostic
Manual.
Signal Values:
15
DIAGNOSTIC MANUAL
Step
Action
11
Decision
Yes: Go to step
12
Action
Decision
12
Yes: Diagnostics
complete
16
DIAGNOSTIC MANUAL
Action
Decision
CAUTION
Neither DPFDP or
TC1TOP signal High:
Go to Hard Start and No
Start Diagnostics section
in Engine Diagnostic
Manual. After repairs are
complete, go to step 8.
17
DIAGNOSTIC MANUAL
Table 21
Maximum TC1TOP Signal
Value During Cranking
1 psi (7 kPa)
0 psi (0 kPa)
Action
Step
2
Decision
Step
3
Action
Determine if PDOC or DOC is contaminated. Remove the PDOC
and DOC (see Exhaust System Service Manual), and check for
signs of lube oil and coolant contamination.
Decision
Yes: Remove DPF, and
then go to step 4.
Action
Determine if DPF, DOC, and PDOC are reusable see the DPF and
DOC reuse guidelines page 159.
Decision
Yes: Go to step 6
Based on DPF and DOC Re-Use Guidelines, are the DPF, DOC,
and PDOC reusable?
No: Replace failed
component(s). After
repairs are complete, go
to step 6.
18
DIAGNOSTIC MANUAL
Step
Action
Decision
Step
7
Action
Determine root cause of exhaust system contamination. (See
Engine Symptoms Diagnostics section in Engine Diagnostic
Manual.)
Action
Decision
After repairs are complete,
go to step 7.
Decision
Yes: Go to step 8
Check for an engine no start. Turn ignition switch to ON position
and crank engine for a maximum of 20 seconds. If engine does not
start, wait 2 to 3 minutes and crank engine again for a maximum
of 20 seconds.
Does the engine start and run?
No: Go to Hard Start and
No Start Diagnostics
section in Engine
Diagnostic Manual.
19
DIAGNOSTIC MANUAL
Step
Action
Inlet to DOC
Decision
Yes: Go to step 9
Step
9
20
Decision
Graph 1: Go to step 10A
Graph 2: Diagnose and
repair failed actuator
(See Performance
Diagnostics section
in Engine Diagnostic
Manual). After repairs
are complete, retest for
original problem.
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing 0 to 60 MPH Test.
NOTE Intake Manifold Pressure (IMP) can vary based on ECM calibration and vehicle weight. Using
Electronic Service Tool (EST) with ServiceMaxx software, monitor turbocharger wastegate operation
to verify low boost.
Step
Action
10A
Decision
Go to step 10B
21
DIAGNOSTIC MANUAL
Step
Action
10B
Decision
Yes: Go to step 10C
Signal Values:
ICP desired
ICP
Action
10C
Check for Air Management System (AMS) issue. Using EST with
ServiceMaxx software, use the playback feature and graph the
following signal values from 0 to 60 MPH Test:
Decision
Yes: Go to step 11
Signal Values:
Engine Speed
Engine Load
22
DIAGNOSTIC MANUAL
Step
Action
11
Decision
Yes: Go to step 12
Action
Perform the following MAF Sensor Calibration procedure to
accommodate for system repairs:
Decision
Yes: Diagnostics complete
23
DIAGNOSTIC MANUAL
3.4. SYMPTOM 3 (MEDIUM DUTY): SPN 3719 OR SPN 3936 ACTIVE ONLY OR
FREQUENT REGENS (MORE THAN ONE PARKED REGEN PER DAY)
NOTE Before beginning the following step-based diagnostics, perform all vehicle operational checks
page 5.
NOTE The number of regens performed in one day may vary depending on application. The following
criteria should be used to determine if a regen is considered frequent:
Severe service: More than 2 parked regens per day is frequent regeneration.
Step
1
Step
2
Action
Decision
Using Electronic Service Tool (EST) with ServiceMaxx software, SPN 3719 or SPN 3936 FMI
0: Go to step 2
check Diagnostic Trouble Code (DTC) list to determine which of
the following fault codes is active: SPN 3719/3936 FMI 0, 15, or
SPN 3719 or SPN 3936 FMI
16.
16: Go to step 4
Which fault code is active?
SPN 3719 or SPN 3936 FMI
15: Go to step 5
Action
Decision
Yes: Go to step 3
Do three Onboard Filter Cleanliness Tests (OBFCT) to decrease
soot load of Diesel Particulate Filter (DPF). Using EST, go to Tests
> KOER Aftertreatment Tests > Onboard Filter Cleanliness Test.
After OBFCTs are complete, check DTC list to determine if SPN
3719 FMI 0 dropped one FMI level to SPN 3719 FMI 16.
Did SPN 3719 FMI 0 drop one FMI level to SPN 3719 FMI 16?
No: Go to step 4
24
DIAGNOSTIC MANUAL
Step
Action
Decision
SPN 3719 FMI 16, go to
Step 4
SPN 3719 FMI 15, go to
Step 5
SPN 3719 or 3936 FMI 0,
go to Step 7
Action
Decision
Yes: Go to step 5
Do three Onboard Filter Cleanliness Tests (OBFCT) to decrease
soot load of Diesel Particulate Filter (DPF). Using EST, go to Tests
> KOER Aftertreatment Tests > Onboard Filter Cleanliness Test.
After OBFCTs are complete, check DTC list to determine if SPN
3719 FMI 16 dropped one FMI level to SPN 3719 FMI 15.
Did SPN 3719 FMI 16 drop one FMI level to SPN 3719 FMI 15?
No: Go to step 6
Step
Action
Decision
Yes: Go to step 7
25
DIAGNOSTIC MANUAL
Step
Action
Decision
Yes: Go to Symptom 5
(Medium Duty): Black smoke
page 44.
Action
Decision
Yes: Go to step 8
Action
Determine if DPF, DOC, and PDOC are reusable see DPF and
DOC reuse guidelines page 159.
Decision
Yes: Go to step 10
Based on DPF and DOC Re-Use Guidelines, are the DPF, DOC,
and PDOC reusable?
No: Replace failed
component(s). After repairs
are complete, go to step 10.
26
DIAGNOSTIC MANUAL
Step
Action
Decision
Step
10
Step
11
Decision
After repairs are complete, go
to step 11.
Decision
Graph 1: Go to step 11A
Graph 2: Diagnose and
repair failed actuator (See
Performance Diagnostics
section in Engine Diagnostic
Manual). After repairs are
complete, retest for original
problem.
27
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing 0 to 60 MPH Test.
NOTE Intake Manifold Pressure (IMP) can vary based on ECM calibration and vehicle weight. Using
Electronic Service Tool (EST) with ServiceMaxx software, monitor turbocharger wastegate operation
to verify low boost.
Step
Action
11A
28
Decision
Go to step 11B
DIAGNOSTIC MANUAL
Step
Action
11B
Decision
Yes: Go to step 11C
Signal Values:
ICP desired
ICP
Action
11C
Check for Air Management System (AMS) issue. Using EST with
ServiceMaxx software, use the playback feature and graph the
following signal values from 0 to 60 mph test:
Decision
Yes: Go to step 12
Signal Values:
Engine Speed
Engine Load
29
DIAGNOSTIC MANUAL
Action
Step
12
30
Decision
Graph 5: Diagnostics
complete
Graph 6: Go to step 13
Graph 7: Go to step 15
DIAGNOSTIC MANUAL
Figure 2
AFI Gasket
Action
Step
Decision
Yes: Install AFI, and go to
step 14.
13
CAUTION
Do not remove the nozzle injector from the
doser housing. Spray pattern test is no longer a
visual check for Aftertreatment Fuel Injector (AFI)
replacement.
Perform Aftertreatment Fuel Injector (AFI) visual inspection. Remove
AFI (see Engine Service Manual) and check for the following:
Visual Checks:
31
DIAGNOSTIC MANUAL
Step
Action
14
Step
Action
15
Decision
Go to step 15
Decision
Using EST, check Diagnostic Trouble Code (DTC) list for fault code(s) Yes: Repair active fault
that may have become active during OBFCT.
code(s) (See Electronic
Control Systems Diagnostics
Does DTC list contain active fault code(s)?
in Engine Diagnostic Manual).
After repairs are complete, go
to step 16.
No: Go to step 16
Action
Step
16
Decision
Graph 5: Go to step 17
Graph 6: Replace DOC. After
repairs are complete, retest
for original problem.
Action
Verify root cause of frequent regens symptom.
Decision
Yes: Go to step 18
Has root cause for frequent regens been diagnosed and repaired?
No: Go back to step 1 of
Engine and Aftertreatment
System Operational Checks
page 5 to verify engine
systems are in satisfactory
condition.
32
DIAGNOSTIC MANUAL
Step
18
Action
Perform Standard Test to verify all engine systems are operating as
designed. Verify engine coolant temperature is greater than 158F
(70C). Using Electronic Service Tool (EST) with ServiceMaxx
software, go to Tests > KOER Tests > Standard Test.
Decision
Yes: Go to step 19
Action
Perform the following MAF Sensor Calibration procedure to
accommodate for system repairs:
Decision
Yes: Diagnostics complete
33
DIAGNOSTIC MANUAL
3.5. SYMPTOM 4 (MEDIUM DUTY): SPN 3719 OR SPN 3936 AND OTHER ACTIVE
FAULT CODES
NOTE Before beginning the following step-based diagnostics, perform all vehicle operational checks
page 5.
Action
Step
1
Decision
Step
2
Decision
SPN 3719 or SPN 3936 FMI
0: Go to step 3
SPN 3719 or SPN 3936 FMI
16: Go to step 5
Action
Decision
Yes: Go to step 5
Did SPN 3719 FMI 0 drop one FMI level to SPN 3719 FMI 16?
No: Go to step 4
34
DIAGNOSTIC MANUAL
Step
Action
Decision
Action
Decision
Yes: Go to step 6
Did SPN 3719 FMI 16 drop one FMI level to SPN 3719 FMI 15?
No: Go to step 7
Step
6
Action
Decision
Yes: Go to step 8
Do three Onboard Filter Cleanliness Tests (OBFCT) to clear SPN
3719 FMI 15. Using EST, go to Tests > KOER Aftertreatment Tests >
Onboard Filter Cleanliness Test. After OBFCTs are complete, check
DTC list to determine if SPN 3719 FMI 15 is still active.
Is SPN 3719 FMI 15 still active?
No: Go to step 7
35
DIAGNOSTIC MANUAL
Step
Action
Decision
Yes: Go to Symptom 5
(Medium Duty): Black smoke
page 44.
Action
Decision
Yes: Go to step 9
Action
Determine if DPF, DOC, and PDOC are reusable see DPF and DOC
reuse guidelines page 159.
Decision
Yes: Go to step 11
Based on DPF and DOC Re-Use Guidelines, are the DPF, DOC,
and PDOC reusable?
No: Replace failed
component(s). After repairs
are complete, go to step 11.
36
DIAGNOSTIC MANUAL
Action
Step
10
Decision
Step
11
Step
12
Decision
After repairs are complete, go
to step 12.
Decision
Graph 1: Go to step 12A
Graph 2: Diagnose and
repair failed actuator (See
Performance Diagnostics
section in Engine Diagnostic
Manual). After repairs are
complete, retest for original
problem.
37
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing 0 to 60 MPH Test.
NOTE Intake Manifold Pressure (IMP) can vary based on ECM calibration and vehicle weight. Using
Electronic Service Tool (EST) with ServiceMaxx software, monitor turbocharger wastegate operation
to verify low boost.
Step
12A
Action
Check for engine performance issues. Perform 0 to 60 MPH Test
procedure below:
1. Using EST, go to Sessions > Performance.
2. Find an open stretch of road, where minimum speed
limit is 50 mph or higher.
3. Pull over to the side of the road.
4. When driving conditions are safe and vehicle has
reached normal operating temperature, select the
record snapshot icon from the toolbar.
5. Press accelerator pedal fully to the floor, and accelerate
from 0 mph to max allowed highway speed.
After 0 to 60 MPH Test is complete, stop recording and save
snapshot.
38
Decision
Go to step 12B
DIAGNOSTIC MANUAL
Action
Step
12B
Decision
Yes: Go to step 12C
Signal Values:
ICP desired
ICP
Step
12C
Check for Air Management System (AMS) issue. Using EST with
ServiceMaxx software, use the playback feature and graph the
following signal values from 0 to 60 mph test:
Decision
Yes: Go to step 10
Signal Values:
Engine Speed
Engine Load
39
DIAGNOSTIC MANUAL
Action
Step
13
Graph 6: Go to step 14
Using Electronic Service Tool (EST) with
ServiceMaxx software, go to Sessions > Performance
Graph 7: Go to step 16
and select the record snapshot icon from the toolbar.
40
Decision
DIAGNOSTIC MANUAL
Action
Step
Decision
Yes: Install AFI, and go to step
15
14
CAUTION
Do not remove the nozzle injector from the
doser housing. Spray pattern test is no longer
a visual check for Aftertreatment Fuel Injector
(AFI) replacement.
Perform Aftertreatment Fuel Injector (AFI) visual inspection.
Remove AFI (see Engine Service Manual) and check for the
following:
Visual Checks:
41
DIAGNOSTIC MANUAL
Step
Action
15
Step
16
Using EST, check Diagnostic Trouble Code (DTC) list for fault
code(s) that may have become active during OBFCT.
Does DTC list contain active fault code(s)?
Decision
Go to step 16
Decision
Yes: Repair active fault
code(s) (See Electronic Control
Systems Diagnostics in Engine
Diagnostic Manual). After
repairs are complete, go to step
17.
No: Go to step 17
Action
Step
17
Decision
Graph 5: Go to step 18
Graph 6: Replace DOC. After
repairs are complete, retest for
original problem.
Action
Verify root cause of frequent regens symptom.
Decision
Yes: Go to step 19
Has root cause for frequent regens been diagnosed and repaired?
No: Go back to step 1 of Engine
and Aftertreatment System
Operational Checks on page 5
to verify engine systems are in
satisfactory condition.
42
DIAGNOSTIC MANUAL
Step
Action
19
Decision
Yes: Go to step 20
Action
Perform the following MAF Sensor Calibration procedure to
accommodate for system repairs:
Decision
Yes: Diagnostics complete
43
DIAGNOSTIC MANUAL
Step
1
Decision
Yes: Go to step 2
Step
2
Decision
Yes: Install the DPF and go to
step 3
Compare the DPF to the DPF and DOC Reuse Guidelines page
159.
Can the DPF be reused?
No: Replace the DPF and go to
step 4
44
DIAGNOSTIC MANUAL
Step
Action
Decision
Yes: Repair complete
Step
4
Decision
Graph 1: Go to step 5A
Graph 2: Diagnose and repair
failed actuator (See Performance
Diagnostics section in Engine
Diagnostic Manual). After repairs
are complete, retest for original
problem.
45
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing 0 to 60 MPH Test.
NOTE Intake Manifold Pressure (IMP) can vary based on ECM calibration and vehicle weight. Using
Electronic Service Tool (EST) with ServiceMaxx software, monitor turbocharger wastegate operation
to verify low boost.
Step
Action
5A
46
Decision
Go to step 5B
DIAGNOSTIC MANUAL
Step
Action
5B
ICP Desired
ICP Actual
Decision
Yes: Go to step 5C
Action
5C
Engine Speed
Engine Load
Decision
Yes: GO to step 6
47
DIAGNOSTIC MANUAL
Action
Step
6
48
Decision
Graph 5: Diagnostics complete
Graph 7: Go to step 7
DIAGNOSTIC MANUAL
Action
Step
7
Decision
Yes: Install AFI and go to step 8
CAUTION
Do not remove the nozzle injector from the
doser housing. Spray pattern test is no
longer a visual check for Aftertreatment Fuel
Injector (AFI) replacement.
Perform Aftertreatment Fuel Injector (AFI) visual inspection.
Remove the AFI doser housing from the turbo outlet pipe (see
Engine Service Manual) and perform the following visual checks:
49
DIAGNOSTIC MANUAL
Step
Action
Step
Action
Decision
Go to step 9
Decision
Step
10
50
Decision
Graph 5: End of diagnostics
Graph 6: Go to Performance
Diagnostics section in the Engine
Diagnostics Manual.
DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows normal operation of the Air Management System (AMS) during the Air Management Test
(AMT). The AMT gives pass or fail results based on the difference of flow in MAF Mean Value (MMV). It allows
the user to validate the AMS by monitoring the effects each actuator has on Intake Manifold Pressure (IMP).
IMP is normally between 2 psi (14 kPa) to 6 psi (41 kPa)
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DIAGNOSTIC MANUAL
Actions:
1. When EGR valve is commanded ON, verify Intake Manifold Pressure (IMP) signal value drops.
2. When EGR valve is commanded ON, verify Mass Air Flow (MAF) Mean Value (MMV) drops.
Calculate the difference between MMV at a stabilized high point and a stabilized low point, then
compare to the table below.
Engine
Tolerance
690 1000
740 1000
850 1130
MaxxForce DT
215 - 230 HP
MaxxForce DT
245 - 300 HP
MaxxForce 9 and 10
300 - 350 HP
NOTE EGR valve position will never read less than 35% and is considered closed.
52
DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows an Air Management System (AMS) not operating as designed during the Air Management
Test (AMT). The AMT gives pass or fail results. It allows the user to validate the AMS by monitoring the effects
each actuator has on Intake Manifold Pressure (IMP). IMP is normally between 2 psi (14 kPa) to 6 psi (41 kPa)
on engine ramp up during AMT. If the Exhaust Gas Recirculation (EGR) valve is not operating as designed,
IMP will not respond to changes in EGR valve position. Excess soot will then be generated by the engine
causing frequent regeneration of the aftertreatment system.
Actions:
1. When EGR valve is commanded ON, verify Intake Manifold Pressure (IMP) signal value drops. In
this graph, IMP does not drop when EGR valve is commanded ON.
NOTE EGR valve position will never read less than 35% and is considered closed.
53
DIAGNOSTIC MANUAL
Graph Analysis
This graph shows an Injection Control Pressure (ICP) system operating as designed. This test does not give
pass or fail results. It only allows the user to validate ICP and Injection Control Pressure Desired (ICPD) signal
values under load. As engine rpm increases, ICP should steadily increase. Low ICP will cause low Intake
Manifold Pressure (IMP). Diagnose low ICP concerns before diagnosing low IMP concerns.
Actions
1. Verify ICP is within 150 psi (1,034 kPa) of ICPD signal value during acceleration.
2. Verify Injection Pressure Regulator (IPR) valve control is less than 75%.
NOTE Analyze 0 to 60 MPH Test signal values only during acceleration, and not deceleration or shifting.
54
DIAGNOSTIC MANUAL
4.4. GRAPH 4: 0 TO 60 MPH TEST (ENGINE SPEED, ENGINE LOAD, IMP, EBP, AND
APP1)
Graph 4: 0 to 60 MPH Test (Engine Speed, Engine Load, IMP, EBP, and APP1)
Graph Analysis
This graph shows the Intake Manifold Pressure (IMP) signal value operating as designed. This test does not
give pass or fail results. It only allows the user to validate the IMP signal value under load. Accelerator Pedal
Position 1 (APP1) signal value must be 99.6% to successfully reach peak boost during this test. Low IMP
can be the result of low Injection Control Pressure (ICP). Diagnose low ICP concerns before diagnosing
low IMP concerns.
55
DIAGNOSTIC MANUAL
Actions
1. Verify IMP signal value is between 36 psi (248 kPa) to 42 psi* (289 kPa), with APP1 signal value
at 99.6%, and engine speed between 1800 rpm to 2200 rpm.
2. Verify Exhaust Back Pressure (EBP) is less than 70 psi (414 kPa), with APP1 signal value at
99.6%, and engine speed between 1800 rpm to 2200 rpm.
NOTE * IMP signal value may be as low as 29 psi (221 kPa) on lower horsepower configurations.
NOTE Analyze 0 to 60 mph test signal values only during acceleration, and not deceleration or shifting.
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DIAGNOSTIC MANUAL
Graph 5: Normal Exhaust Gas Temperatures (Efficient DOC AND Unrestricted AFI)
Graph Analysis:
This graph shows an aftertreatment system operating as designed. This test does not give pass or fail results. It
only allows the user to validate operation of the aftertreatment system by monitoring exhaust gas temperatures.
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DIAGNOSTIC MANUAL
Actions:
1. After Diesel Oxidation Catalyst (DOC) reaches operating temperature and stabilizes, verify Diesel
Particulate Filter Inlet Temperature (DPFIT) signal value is at approximate target temperature for
current soot load level (See Soot Load Level vs. Exhaust Gas Target Temperature Chart, page 62).
2. Verify Diesel Oxidation Catalyst Inlet Temperature (DOCIT) signal value is between 550F (287C)
to 800F (427C).
NOTE It is normal to see DOCIT, DPFIT, and DPFOT signal values to fluctuate at the beginning and end
of the OBFCT.
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DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows erratic exhaust gas temperatures. Erratic temperatures in the exhaust stream occur when
the Diesel Oxidation Catalyst becomes contaminated, or an issue with the Aftertreatment Fuel Injector (AFI)
is present. This test does not give pass or fail results. It only allows the user to validate operation of the
aftertreatment system by monitoring exhaust gas temperatures.
Actions:
1. After Diesel Oxidation Catalyst (DOC) reaches operating temperature, verify Diesel Particulate
Filter Inlet Temperature (DPFIT) and Diesel Particulate Filter Outlet Temperature (DPFOT) signal
values do not fluctuate more than 50F (28C) within 2 minutes. In this graph, DPFIT and DPFOT
fluctuate more than 50F (28C) within 2 minutes.
59
DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows low exhaust gas temperatures indicating a restricted Aftertreatment Fuel Injector (AFI). Low
temperatures in the exhaust stream occur when fuel flow from the AFI is restricted, resulting in less fuel burning
in the exhaust stream. This test does not give pass or fail results. It only allows the user to validate operation
of the aftertreatment system by monitoring exhaust gas temperatures.
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DIAGNOSTIC MANUAL
Actions:
1. After Diesel Oxidation Catalyst (DOC) reaches operating temperature and stabilizes, verify Diesel
Particulate Filter Inlet Temperature (DPFIT) signal value is at approximate target temperature for
current soot load level (See Soot Load Level vs. Exhaust Gas Target Temperature Chart, page 62).
2. Verify Diesel Oxidation Catalyst Inlet Temperature (DOCIT) signal value is between 550F (287C)
to 800F (427C).
NOTE It is normal to see DOCIT, DPFIT, and DPFOT signal values fluctuate at the beginning and end
of the OBFCT.
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DIAGNOSTIC MANUAL
4.8. SOOT LOAD LEVEL VS. EXHAUST GAS TARGET TEMPERATURE CHART
Soot Load (%)
0 -16
1125F (607C)
17 -33
1110F (599C)
34 - 49
1090F (588C)
50 - 66
1075F (579C)
67 - 83
1050F (566C)
84 - 99
1025F (552C)
100 - 116
1000F (538C)
117 - 132
975F (524C)
133 - 149
900F (482C)
150 - 169
860F (460C)
170 - 184
10
850F (454C)
185 - 199
11
840F (449C)
200 - 216
12
835F (446C)
217 - 234
13
830F (443C)
235 - 249
14
825F (441C)
250 - 269
15
820F (438C)
16 and above
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DIAGNOSTIC MANUAL
Monitors exhaust gas temperatures Diesel Oxidation Catalyst Inlet Temperature (DOCIT), Diesel Oxidation
Catalyst Outlet Temperature (DOCOT), and Diesel Particulate Filter Outlet Temperature (DPFOT).
Controls engine operating parameters for emission control and failure recognition.
Cancels regeneration of the AFT system in the event of catalyst or sensor failure.
Calculates the level of ash accumulation in the Diesel Particulate Filter (DPF).
Initiates regeneration of the AFT system when DPF soot load is too high by increasing exhaust gas
temperatures.
63
DIAGNOSTIC MANUAL
Engine Control Module (ECM) with Barometric Absolute Pressure (BARO) internal sensor
Park brake
64
DIAGNOSTIC MANUAL
Warning Indicators
65
DIAGNOSTIC MANUAL
Allows for oxidation (regeneration) of stored particulates once loading gets to a particular level (restriction)
Provides the required exhaust back pressure drop for engine performance
66
DIAGNOSTIC MANUAL
67
DIAGNOSTIC MANUAL
Control actuators
68
DIAGNOSTIC MANUAL
69
DIAGNOSTIC MANUAL
EBPV (Typical)
70
DIAGNOSTIC MANUAL
71
DIAGNOSTIC MANUAL
72
4.
5.
6.
7.
11 x 20 x 24 mm spacer (3)
M10 x 50 bolt (3)
PDOC
M10 x 25 bolt (2)
DIAGNOSTIC MANUAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
Figure 20
High and Low Pressure Turbocharger Components MaxxForce DT, 9 and 10 Engines
(Below 245 HP Shown)
MaxxForce DT, 9, and 10 (EPA 10) engines are equipped with an electronically controlled two stage
turbocharging system. The high and low-pressure turbochargers are installed as an assembly on the exhaust
manifold, on right side of engine.
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DIAGNOSTIC MANUAL
Intake air flow: Filtered air enters the LP compressor, where it is compressed and directed to the LPCAC
(if equipped). Cooled LP air enters the HP compressor where it is further compressed and directed into the
HPCAC. Compressed air then travels through the ETV and the intake throttle duct. This system provides high
charge air pressure to improve engine performance and to help reduce emissions.
Exhaust gas flow: The HP turbocharger is connected directly to the exhaust manifold through the HP turbine
inlet. Exhaust gases exit the HP turbine outlet and are directed to the LP turbine inlet. The HP turbocharger is
equipped with a single wastegate, which is controlled by pneumatic actuator. When boost demand is low, the
wastegate is opened, allowing part of the exhaust gas flow to bypass the turbine.
74
DIAGNOSTIC MANUAL
FMI
Condition
Possible Causes
3242
3242
3242
3246
3246
3246
3246
3246
20
Restricted DPF
DOC Failure
3251
3251
3251
3251
10
75
DIAGNOSTIC MANUAL
3471
3471
3471
10
3479
Failed AFTFD
Failed AFTFD
Failed AFTFIS
Failed AFTFIS
Failed AFTFSV
Failed AFTFSV
3479
3480
3480
3482
3482
3512
3556
3556
14
3719
3719
15
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DIAGNOSTIC MANUAL
3719
16
3936
3936
14
DOC failure
DPF failure
Failed AFTFIS
4077
4765
4765
4765
4765
5456
Failed AFTFIS
Failed AFTFIS
5456
5541
5541
5541
77
DIAGNOSTIC MANUAL
78
DIAGNOSTIC MANUAL
Tools Required
NOTE A frequent regen concern may not be repaired by only performing an Onboard Filter Cleanliness
Test (OBFCT). Perform all steps in the following diagnostic procedure in order to identify root cause
failure.
NOTE Repair all active fault code(s) other than SPN 3719 (DPF Soot Load) before beginning Engine
and Aftertreatment System Operational Checks.
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DIAGNOSTIC MANUAL
Step
1
Decision
Verify the following engine systems are in satisfactory condition: Yes: Go to step 2
Action
Decision
Yes: Go to step 4
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DIAGNOSTIC MANUAL
Action
Step
3
Decision
Step
Action
Decision
No: Go to step 5
Step
5
Action
Decision
Check for an engine no start. Turn ignition switch to ON position Yes: Go to step 6
and crank engine for a maximum of 20 seconds. If engine
does not start, wait 2 to 3 minutes and crank engine again for a
maximum of 20 seconds.
Does the engine start and run?
No: Go to Symptom 2 (Heavy Duty):
Engine No Start / Starts and Stalls
page 91.
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DIAGNOSTIC MANUAL
Step
6
Action
Using Electronic Service Tool (EST) with ServiceMaxx
software, check Diagnostic Trouble Code (DTC) list for SPN
3719 FMI 0 or 16 (DPF Soot Load).
Decision
Yes: Go to Symptom 3 (Heavy Duty):
SPN 3719 Active Only or Frequent
Regens page 96.
Is SPN 3719 FMI 0 or SPN 3719 FMI 16 the only fault code(s)
active?
No: Go to Symptom 4 (Heavy Duty):
SPN 3719 and Other Active Fault
Codes page 104.
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DIAGNOSTIC MANUAL
Severe service: More than 2 parked regens per day is frequent regeneration.
Action
Step
1
Decision
Graph 1: Go to step 2A
Graph 2: Diagnose and repair
failed actuator (See Performance
Diagnostics section in Engine
Diagnostic Manual). After repairs
are complete, retest for original
problem.
Engine Speed
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DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing Lug Down Test.
Action
Step
2A
Decision
Go to step 2B
Step
2B
Decision
Check for low fuel rail pressure. Using EST with ServiceMaxx Yes: Go to step 2C
software, use the playback feature and graph the following
signal values from Lug Down Test:
Signal Values:
Engine Speed
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DIAGNOSTIC MANUAL
Step
Action
2C
Decision
Yes: Go to step 2D
Signal Values:
Engine Speed
Step
2D
Decision
Yes: Go to step 3
Signal Values:
Engine Speed
Vehicle Speed
85
DIAGNOSTIC MANUAL
Action
Step
3
Decision
Graph 6: Diagnostics complete
Graph 7: Go to step 4
Graph 8: Go to step 7
Action
Decision
Action
Decision
Determine if DPF, DOC, and PDOC are reusable see DPF and
DOC reuse guidelines page 159.
Based on DPF and DOC Re-Use Guidelines, are the DPF, DOC,
and PDOC reusable?
No: Replace failed component(s).
After repairs are complete, go to
step 6.
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DIAGNOSTIC MANUAL
Step
6
Step
7
Action
Determine root cause of exhaust system contamination. (See
Engine Symptoms Diagnostics section in Engine Diagnostic
Manual.)
Action
Decision
After repairs are complete, go to
step 7
Decision
Yes: Go to step 8
Check Oxygen Sensor (O2S) operation. Start the engine and
allow to reach normal operating temperature. Using EST with
ServiceMaxx software, go to Sessions > Performance. Let
the engine idle for 5 minutes while monitoring O2S Temperature
signal value.
Is O2S Temperature signal value greater than 1400F (760C)?
No: Repair O2S or circuit (See
Electronic Control Systems
Diagnostics in Engine Diagnostic
Manual). After repairs are complete,
retest for original problem.
Step
8
Action
Visually inspect Aftertreatment Fuel Injector (AFI) supply line
for leaks, kinks, bends, or other damage?
Decision
Yes: Replace AFI supply line. After
repairs are complete, go to step 10.
87
DIAGNOSTIC MANUAL
Action
Step
Decision
Yes: Install AFI, and go to step 10
9
CAUTION
Do not remove the nozzle injector from the
doser housing. Spray pattern test is no
longer a visual check for Aftertreatment
Fuel Injector (AFI) replacement.
Perform Aftertreatment Fuel Injector (AFI) visual inspection.
Remove AFI (see Engine Service Manual) and check for the
following:
Visual Checks:
88
DIAGNOSTIC MANUAL
Action
Step
10
Decision
Step
Action
11
Using EST, check Diagnostic Trouble Code (DTC) list for fault
code(s) that may have become active during OBFCT.
Does DTC list contain active fault code(s)?
Decision
Yes: Repair active fault code(s)
(See Electronic Control Systems
Diagnostics in Engine Diagnostic
Manual). After repairs are complete,
go to step 12.
No: Go to step 12
Action
Step
12
Decision
Graph 7: Go to step 13
Graph 8: After repairs are complete,
retest for original problem.
89
DIAGNOSTIC MANUAL
Step
Action
13
Decision
Yes: Diagnostics complete
90
DIAGNOSTIC MANUAL
Step
1
Decision
Both DPFDP and TC1TOP signals
High: Go to step 2
TC1TOP signal High Only: Go to step
3
Neither DPFDP or TC1TOP signal
High: Go to Hard Start and No
Start Diagnostics section in Engine
Diagnostic Manual. After repairs are
complete, go to step 7.
Action
Decision
91
DIAGNOSTIC MANUAL
Step
Action
Decision
Yes: Remove DPF, and then go to
step 4.
Action
Determine if DPF, DOC, and PDOC are reusable see DPF
and DOC reuse guidelines page 159.
Decision
Yes: Go to step 6
Action
Decision
92
Step
Action
Decision
DIAGNOSTIC MANUAL
Action
Step
7
Decision
Yes: Go to step 8
Inlet to DOC
Step
8
Decision
Graph 1: Go to step 9A
Graph 2: Diagnose and repair
failed actuator (See Performance
Diagnostics section in Engine
Diagnostic Manual). After repairs are
complete, retest for original problem.
Engine Speed
93
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing Lug Down Test.
Action
Step
9A
Decision
Go to step 9B
Action
9B
Decision
Yes: Go to step 9C
Signal Values:
Engine Speed
94
DIAGNOSTIC MANUAL
Step
Action
9C
Decision
Yes: Go to step 9D
Signal Values:
Engine Speed
Action
9D
Decision
Yes: Diagnostics complete
Signal Values:
Engine Speed
Vehicle Speed
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DIAGNOSTIC MANUAL
9.4. SYMPTOM 3 (HEAVY DUTY): SPN 3719 ACTIVE ONLY OR FREQUENT REGENS
(MORE THAN ONE PARKED REGEN PER DAY)
NOTE Before beginning the following step-based diagnostics, perform all vehicle operational checks
page 80.
NOTE The number of regens performed in one day may vary depending on application. The following
criteria should be used to determine if a regen is considered frequent:
Action
Do Onboard Filter Cleanliness Test (OBFCT) to clear SPN
3719 active fault code(s). Using Electronic Service Tool
(EST) with ServiceMaxx software, go to Sessions >
Performance and select the record snapshot icon from the
toolbar. Then go to Tests > KOER Aftertreatment Tests >
Onboard Filter Cleanliness Test.
Decision
Yes: Go to step 2
Action
Determine if Diesel Particulate Filter (DPF), Pre-Diesel
Oxidation Catalyst (PDOC), and Diesel Oxidation Catalyst
(DOC) are contaminated. Remove the DPF, PDOC, and
DOC (see Exhaust System Service Manual), and check for
signs of lube oil and coolant contamination.
Decision
Yes: Go to step 3
Action
Determine if DPF, DOC, and PDOC are reusable see DPF
and DOC reuse guidelines page 159. .
Decision
Yes: Go to step 5
96
DIAGNOSTIC MANUAL
Action
Step
4
Decision
Yes: Clean components using
appropriate cleaning equipment. After
cleaning procedure is complete, install
components and go to step 6.
Step
5
Step
6
Decision
After repairs are complete, go to step 7
Decision
Diesel Particulate Filter (DPF) Snap Acceleration Test (Quick Yes: Go to symptom 5 (Heavy Duty):
Test). This procedure checks the DPF for cracks or internal Black smoke page 113.
damage without removing the DPF from the vehicle and is
used to test basic functionality of the DPF. This is to be done
prior to removing the DPF.
1. The transmission must be in neutral and the
parking brake applied.
2. Start and idle the engine.
3. Rapidly snap the accelerator pedal from idle
to full throttle. This can be performed multiple
times.
4. During the engine accelerations, visually check
for a heavy black smoke exiting the exhaust
pipe.
Is black smoke visible?
No: Go to step 7
97
DIAGNOSTIC MANUAL
Step
Action
Engine Speed
98
Decision
Graph 1: Go to step 8A
Graph 2: Diagnose and repair failed
actuator (See Performance Diagnostics
section in Engine Diagnostic Manual).
After repairs are complete, retest for
original problem.
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing Lug Down Test.
Step
Action
8A
Decision
Go to step 8B
Step
8B
Decision
Yes: Go to step 8C
Signal Values:
Engine Speed
99
DIAGNOSTIC MANUAL
Action
Step
8C
Decision
Yes: Go to step 8D
Signal Values:
Engine Speed
Step
8D
Decision
Check for an Intake Manifold Pressure (IMP) issue. Use the Yes: Go to step 9
playback feature in ServiceMaxx, and graph the following
signal values from Lug Down Test:
Signal Values:
Engine Speed
Vehicle Speed
100
DIAGNOSTIC MANUAL
Step
Action
Decision
Graph 6: Diagnostics complete
Signal Values:
Graph 8: Go to step 10
Action
Check Oxygen Sensor (O2S) operation. Start the engine
and allow to reach normal operating temperature. Using
EST with ServiceMaxx software, go to Sessions >
Performance. Let the engine idle for 5 minutes while
monitoring O2S Temperature signal value.
Decision
Yes: Go to step 11
Action
Visually inspect Aftertreatment Fuel Injector (AFI) supply
line for leaks, kinks, bends, or other damage?
Decision
Yes: Replace AFI supply line. After
repairs are complete, go to step 13.
101
DIAGNOSTIC MANUAL
Action
Step
Decision
Yes: Install AFI, and then go to step 13.
12
CAUTION
Do not remove the nozzle injector
from the doser housing. Spray pattern
test is no longer a visual check for
Aftertreatment Fuel Injector (AFI)
replacement.
Perform Aftertreatment Fuel Injector (AFI) visual inspection.
Remove AFI (see Engine Service Manual) and check for
the following:
Visual Checks:
102
DIAGNOSTIC MANUAL
Step
Action
13
Step
Action
Decision
14
Decision
Go to step 14
No: Go to step 15
Action
Step
15
Decision
Graph 7: Go to step 16
Graph 8: Replace DOC. After repairs
are complete, retest for original problem.
Action
Verify root cause of frequent regens symptom.
Decision
Yes: Diagnostics complete
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DIAGNOSTIC MANUAL
9.5. SYMPTOM 4 (HEAVY DUTY): SPN 3719 AND OTHER ACTIVE FAULT CODES
NOTE Before beginning the following step-based diagnostics, perform all vehicle operational checks
page 80.
Step
Action
Decision
No: Go to step 2
Step
Action
Decision
Yes: Go to step 3
Action
Decision
Yes: Go to step 4
Determine if Diesel Particulate Filter (DPF), Pre-Diesel
Oxidation Catalyst (PDOC), and Diesel Oxidation Catalyst
(DOC) are contaminated. Remove the DPF, PDOC, and
DOC (see Exhaust System Service Manual), and check for
signs of lube oil and coolant contamination.
NOTE A black staining in the exhaust tailpipe can
occur on applications that experience high idle times.
This is normal and the DPF should NOT be replaced.
Are the DPF, PDOC, or DOC contaminated?
No: Go to step 5
Step
Action
Decision
Yes: Go to step 6
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DIAGNOSTIC MANUAL
Step
Action
Decision
Yes: Clean components using
appropriate cleaning equipment. After
cleaning procedure is complete, install
components and go to step 7.
Step
6
Step
7
Decision
After repairs are complete, go to step 8.
Decision
Yes: Go to symptom 5 (Heavy Duty):
Black smoke page 113.
105
DIAGNOSTIC MANUAL
Action
Step
8
Check for a failed Air Management System (AMS) actuator. Graph 1: Go to step 9A
1. Using Electronic Service Tool (EST) with
ServiceMaxx software, go to Tests > Load
Test Specific Session and verify Load Test
Specific Session is unchecked.
2. Go to Sessions > Performance and select the
record snapshot icon from the toolbar.
3. Go to Tests > KOER Tests > Air Management
Test.
When Air Management Test is complete, stop recording.
Use the playback feature in ServiceMaxx, and graph
the following signal values:
Signal Values:
Engine Speed
106
Decision
DIAGNOSTIC MANUAL
WARNING
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing Lug Down Test.
Action
Step
9A
Decision
Go to step 9B
Using EST, go to Sessions > Performance. Find an open
stretch of road in order to perform Lug Down Test. When
driving conditions are safe, select the record snapshot icon
from the toolbar, and perform Lug Down procedure below:
1. Select a suitable high range gear (Example:
In a 10 speed gearbox, select the 8th speed).
2. Allow engine speed to drop to 1000 rpm.
3. Press accelerator pedal fully to the floor, and
accelerate to rated engine speed.
After Lug Down Test is complete, stop recording and save
snapshot.
Action
Step
9B
Decision
Yes: Go to step 9C
Signal Values:
Engine Speed
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DIAGNOSTIC MANUAL
Step
Action
9C
Decision
Yes: Go to step 9D
Signal Values:
Engine Speed
Action
9D
Decision
Yes: Go to step 10
Signal Values:
Engine Speed
Vehicle Speed
108
DIAGNOSTIC MANUAL
Step
Action
10
Decision
Graph 6: Diagnostics complete
Signal Values:
Graph 8: Go to step 11
Action
11
Decision
Yes: Go to step 12
Action
12
Decision
Yes: Replace AFI supply line. After
repairs are complete, go to step 14.
109
DIAGNOSTIC MANUAL
Action
Step
Decision
Yes: Install AFI, and go to step 14.
13
CAUTION
Do not remove the nozzle injector
from the doser housing. Spray pattern
test is no longer a visual check for
Aftertreatment Fuel Injector (AFI)
replacement.
Perform Aftertreatment Fuel Injector (AFI) visual
inspection. Remove AFI (see Engine Service Manual)
and check for the following:
Visual Checks:
110
DIAGNOSTIC MANUAL
Action
Step
14
Step
15
Decision
After procedure is complete, go to step
15.
Decision
Using EST, check Diagnostic Trouble Code (DTC) list for Yes: Repair active fault code(s) (See
fault code(s) that may have become active during OBFCT. Electronic Control Systems Diagnostics
in Engine Diagnostic Manual). After
Does DTC list contain active fault code(s)?
repairs are complete, go to step 16.
No: Go to step 16
Step
Action
16
Decision
Graph 7: Go to step 17
Graph 8: Replace DOC. After repairs are
complete, retest for original problem.
111
DIAGNOSTIC MANUAL
Step
17
Action
Verify root cause of frequent regens symptom.
Decision
Yes: Diagnostics complete
112
DIAGNOSTIC MANUAL
NOTE The Diesel Particulate Filter (DPF) is not 100 percent efficient. Some evidence of exhaust soot
is normal, and does not indicate a malfunctioning DPF.
WARNING
To prevent unexpected movement of the vehicle and possible injury or death, park the
vehicle on a flat, level surface, apply the parking brake, turn the engine off and chock the
wheels to prevent vehicle from moving in either direction.
NOTE Before beginning the following step-based diagnostics, perform all vehicle operational checks
page 80.
Step
Action
Decision
Yes: Go to step 2
113
DIAGNOSTIC MANUAL
Step
Action
Decision
Yes: Install the DPF and go to step 3
Step
3
Decision
Inlet to DOC
114
DIAGNOSTIC MANUAL
Action
Step
4
Decision
Graph 1: Go to step 5A
Graph 2: Diagnose and repair failed
actuator (See Performance Diagnostics
section in Engine Diagnostic Manual).
After repairs are complete, retest for
original problem.
Engine Speed
Action
Decision
Go to step 5B
Check for engine performance issues. Using EST, go
to Sessions > Performance. Find an open stretch of
road in order to perform Lug Down Test. When driving
conditions are safe, select the record snapshot icon from
the toolbar, and perform Lug Down procedure below:
1. Select a suitable high range gear (Example:
In a 10 speed gearbox, select the 8th
speed).
2. Allow engine speed to drop to 1000 RPM
3. Press accelerator pedal fully to the floor,
and accelerate to rated engine speed.
After Lug Down Test is complete, stop recording and
save snapshot.
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DIAGNOSTIC MANUAL
Action
Step
5B
Decision
Yes: Go to step 5C
Signal Values:
Engine Speed
Step
5C
Decision
Engine Speed
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DIAGNOSTIC MANUAL
Action
Step
5D
Decision
Yes: Go to step 6
Signal Values:
Engine Speed
Vehicle Speed
Step
6
Decision
Verify exhaust gas temperatures are within specification. Graph 6: Diagnostics Complete
1.
Graph 8: Go to step 7
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DIAGNOSTIC MANUAL
Action
Step
7
Decision
Yes: Install AFI, then go to step 8.
CAUTION
Do not remove the nozzle injector
from the doser housing.
Spray
pattern test is no longer a visual
check for Aftertreatment Fuel
Injector (AFI) replacement.
Perform Aftertreatment Fuel Injector (AFI) visual
inspection. Remove AFI (See Engine Service Manual)
and check for the following:
Visual Checks:
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DIAGNOSTIC MANUAL
Step
Action
Decision
Step
Action
Decision
Go to step 9
Step
10
Decision
Verify exhaust gas temperatures are within specification. Graph 6: Repair complete
1. Using Electronic Service Tool (EST) with
ServiceMaxx software, go to Tests >
KOER Aftertreatment Tests > Onboard
Filter Cleanliness Test (OBFCT).
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DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows normal operation of the Air Management System (AMS) during the Air Management Test
(AMT). The AMT does not give pass or fail results. It only allows the user to validate the AMS by monitoring
the effects each actuator has on Intake Manifold Pressure (IMP). IMP is normally between 8 psi (55 kPa) to 13
psi (90 kPa) on engine ramp up during AMT. If Turbocharger 2 Wastegate Control (TC2WC) is not operating as
designed, boost pressure will not respond to changes in engine load. Excess soot will then be generated by
the engine causing frequent regeneration of the aftertreatment system.
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Actions:
1. When TC2WC is commanded ON, verify Intake Manifold Pressure (IMP) signal value drops.
NOTE MaxxForce 11 ONLY: AFT regen status stays Not Active.
NOTE Turbocharger 1 Wastegate Control (TC1WC) does not affect engine performance and is removed
from post-production engines. If engine is equipped with one, it is not used by the Engine Control
Module (ECM).
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DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows an Air Management System (AMS) not operating as designed during the Air management
Test (AMT). The AMT does not give pass or fail results. It only allows the user to validate the AMS by
monitoring the effects each actuator has on Intake Manifold Pressure (IMP) sensor. IMP is normally between 8
psi (55 kPa) to 13 psi (90 kPa) on engine ramp up during AMT. If Turbocharger 2 Wastegate Control (TC2WC)
is not operating as designed, boost pressure will not respond to changes in engine load. Excess soot will then
be generated by the engine causing frequent regeneration of the aftertreatment system.
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DIAGNOSTIC MANUAL
Actions:
1. When Turbocharger 2 Wastegate Control (TC2WC) is commanded ON, verify Intake Manifold
Pressure (IMP) drops. In this graph, IMP does not drop when TC2WC is commanded ON.
NOTE MaxxForce 11 ONLY: AFT regen status stays Not Active.
NOTE Turbocharger 1 Wastegate Control (TC1WC) does not affect engine performance and is removed
from post-production engines. If engine is equipped with one, it is not used by the Engine Control
Module (ECM).
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DIAGNOSTIC MANUAL
10.3. GRAPH 3: LUG DOWN TEST (ENGINE SPEED, FRP, AND FRPD)
Graph Analysis:
This graph shows a fuel management system operating as designed. This test does not give pass or fail results.
It only allows the user to validate Fuel Rail Pressure (FRP) and Fuel Rail Pressure Desired (FRPD) signal
values under load. As engine rpm increases, Fuel Rail Pressure (FRP) should steadily increase. Low FRP will
cause low Intake Manifold Pressure (IMP). Diagnose low FRP concerns before diagnosing low IMP concerns.
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DIAGNOSTIC MANUAL
Actions:
1. Verify FRP signal value reaches 31,900 psi (219,943 kPa) at full load.
2. Verify FRP signal value is within a 1000 psi (6,895 kPa) range of FRPD signal value during
acceleration.
NOTE Analyze Lug Down Test signal values only during engine acceleration, and not deceleration or
shifting.
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DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows an exhaust aftertreatment system operating as designed (unrestricted). This test does not
give pass or fail results. It only allows the user to validate Turbocharger 1 Turbine Outlet Pressure (TC1TOP)
signal value under load. High TC1TOP will cause low Intake Manifold Pressure (IMP). Diagnose high TC1TOP
concerns before diagnosing low IMP concerns.
Actions:
1. Verify TC1TOP signal value is less than 5 psi (34 kPa) during Lug Down Test.
NOTE Analyze Lug Down Test signal values only during engine acceleration, and not deceleration or
shifting.
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DIAGNOSTIC MANUAL
10.5. GRAPH 5: LUG DOWN TEST (ENGINE SPEED, APP1, VEHICLE SPEED, AND IMP)
Graph 5: Lug Down Test (Engine Speed, APP1, Vehicle Speed, and IMP)
Graph Analysis:
This graph shows the Intake Manifold Pressure (IMP) signal value responding as designed. This test does not
give pass or fail results. It only allows the user to validate IMP signal value under load. Engine power band is
typically between 1300 to 1700 rpm with peak power occurring around 1600 rpm. Anything outside of this
power band drops boost and power significantly. Accelerator Pedal Position 1 (APP1) signal value must be
99.6% to successfully reach peak boost during this test. Low IMP can be the result of low Fuel Rail Pressure
(FRP), or high Turbocharger 1 Turbine Outlet Pressure (TC1TOP). Diagnose low FRP concerns first, high
TC1TOP concerns second, and low IMP concerns third.
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DIAGNOSTIC MANUAL
1. Verify IMP signal value is between 40 psi (276 kPa) to 43 psi (296 kPa), with Accelerator Pedal
Position 1 (APP1) signal value at 99.6%, and engine speed between 1300 rpm to 1700 rpm.
NOTE Analyze Lug Down Test signal values only during engine acceleration, and not deceleration or
shifting.
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DIAGNOSTIC MANUAL
Graph 6: Normal Exhaust Gas Temperatures (Efficient DOC AND Unrestricted AFI)
Graph Analysis:
This graph shows an aftertreatment system operating as designed. This test does not give pass or fail results. It
only allows the user to validate operation of the aftertreatment system by monitoring exhaust gas temperatures.
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DIAGNOSTIC MANUAL
Actions:
1. After Diesel Oxidation Catalyst (DOC) reaches operating temperature and stabilizes (see callout 4,
graph 6), verify Diesel Oxidation Catalyst Outlet Temperature (DOCOT) and Diesel Particulate
Filter Outlet Temperature (DPFOT) signal values are greater than 900F (482C).
2. Verify Diesel Oxidation Catalyst Inlet Temperature (DOCIT) signal value is between 550F (287C)
to 800F (427C).
NOTE It is normal to see Diesel Oxidation Catalyst Inlet Temperature (DOCIT), DOCOT, and DPFOT
signal values to fluctuate at the beginning and end of the OBFCT.
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DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows inverted exhaust gas temperatures indicating an inefficient Diesel Oxidation Catalyst (DOC).
Inverted temperatures in the exhaust stream occur when the Diesel Particulate Filter Outlet Temperature
(DPFOT) is higher than Diesel Oxidation Catalyst Outlet Temperature (DOCOT) after the DOC has reached
operating temperature and stabilized (see callout 3, graph 7). This is caused by unburned fuel reacting with
the DPF, instead of the DOC, causing an increase in DPFOT. This test does not give pass or fail results. It only
allows the user to validate operation of the aftertreatment system by monitoring exhaust gas temperatures.
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DIAGNOSTIC MANUAL
Actions:
1. After DOC reaches operating temperature and stabilizes (see callout 3, graph 7), verify DPFOT
signal value is not 122F (50C) higher than DOCOT signal value. In this graph, DPFOT signal
value is 122F (50C) higher than DOCOT indicating inverted exhaust gas temperatures.
2. Verify Diesel Oxidation Catalyst Inlet Temperature (DOCIT) signal value is between 550F (287C)
to 800F (427C).
NOTE It is normal to see Diesel Oxidation Catalyst Inlet Temperature DOCIT, DOCOT, and DPFOT signal
values to fluctuate at the beginning and end of the OBFCT.
NOTE SPN 4766 FMI 10 (DOC Efficiency) may be active when exhaust gas temperatures are inverted.
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DIAGNOSTIC MANUAL
Graph Analysis:
This graph shows low exhaust gas temperatures indicating a restricted Aftertreatment Fuel Injector (AFI). Low
temperatures in the exhaust stream occur when Diesel Oxidation Catalyst Outlet Temperature (DOCOT) and
Diesel Particulate Filter Outlet Temperature (DPFOT) are less than 900F (482C) after the DOC has reached
operating temperature and stabilized (see callout 2, graph 8). This is caused by restricted fuel flow from the
AFI, resulting in less fuel burning in the exhaust stream. This test does not give pass or fail results. It only
allows the user to validate operation of the aftertreatment system by monitoring exhaust gas temperatures.
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DIAGNOSTIC MANUAL
Actions:
1. After DOC reaches operating temperature and stabilizes (see callout 2, graph 8), verify DOCOT
and DPFOT signal values are greater than 900F (482C). In this graph, DOCOT and DPFOT
are less than 900F (482C).
2. Verify Diesel Oxidation Catalyst Inlet Temperature (DOCIT) signal value is between 550F (287C)
to 800F (427C).
NOTE It is normal to see Diesel Oxidation Catalyst Inlet Temperature DOCIT, DOCOT, and DPFOT signal
values to fluctuate at the beginning and end of the OBFCT.
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DIAGNOSTIC MANUAL
Monitors exhaust gas temperatures Diesel Oxidation Catalyst Inlet Temperature (DOCIT), Diesel Oxidation
Catalyst Outlet Temperature (DOCOT), and Diesel Particulate Filter Outlet Temperature (DPFOT).
Controls engine operating parameters for emission control and failure recognition.
Cancels regeneration of the AFT system in the event of catalyst or sensor failure.
Calculates the level of ash accumulation in the Diesel Particulate Filter (DPF).
Initiates regeneration of the AFT system when DPF soot load is too high by increasing exhaust gas
temperatures.
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DIAGNOSTIC MANUAL
The functional diagram for the Aftertreatment (AFT) system includes the following:
Engine Control Module (ECM) with Barometric Absolute Pressure (BARO) internal sensor
Park brake
136
DIAGNOSTIC MANUAL
Warning Indicators
137
DIAGNOSTIC MANUAL
1. Electrical connector
2. Turbocharger 1 Wastegate Control
(TC1WC) port
3. Vehicle air supply port
4. Exhaust Back Pressure Valve
(EBPV) port
Figure 35
138
DIAGNOSTIC MANUAL
Allows for oxidation (regeneration) of stored particulates once loading gets to a particular level (restriction)
Provides the required exhaust back pressure drop for engine performance
139
DIAGNOSTIC MANUAL
140
DIAGNOSTIC MANUAL
Control actuators
141
DIAGNOSTIC MANUAL
142
DIAGNOSTIC MANUAL
EBPV (Typical)
143
DIAGNOSTIC MANUAL
144
DIAGNOSTIC MANUAL
4.
5.
6.
7.
11 x 20 x 24 mm spacer (3)
M10 x 50 bolt (3)
PDOC
M10 x 25 bolt (2)
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DIAGNOSTIC MANUAL
High and Low Pressure Turbocharger Components Inner and Outer Views (MaxxForce
11 and 13 Engines)
Turbochargers
MaxxForce 11 and 13 engines are equipped with a pneumatically regulated two-stage turbo charging system.
The HP and LP turbochargers are installed on the right side of the engine.
Intake air flow: Filtered air enters the LP compressor, where it is compressed and directed to the LPCAC
(if equipped). Cooled LP air enters the HP compressor where it is further compressed and directed into the
HPCAC. Compressed air then travels through the ETV and the intake throttle duct. This system provides high
charge air pressure to improve engine performance and to help reduce emissions.
Exhaust gas flow: The HP turbocharger is connected directly to the exhaust manifold through the HP turbine
inlet. Exhaust gases exit the HP turbine outlet and are directed to the LP turbine inlet. The HP and LP
turbochargers are equipped with wastegates, which are controlled by pneumatic actuators. When boost
demand is low, the wastegate is opened, allowing part of the exhaust gas flow to bypass the turbine.
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DIAGNOSTIC MANUAL
FMI
Condition
Possible Causes
3251
Exhaust leak(s)
Cracked DPF
3251
3251
3471
3471
3480
14
21
147
DIAGNOSTIC MANUAL
3480
3481
3556
3556
Exhaust leak(s)
3556
3719
3719
15
3719
16
148
DIAGNOSTIC MANUAL
3720
4077
4077
4766
4766
4766
5298
10
20
21
Exhaust leak(s)
AFI plugged
Engine over-fueling
DOC failure
DSI failure
DOC failure
Exhaust leaks
149
DIAGNOSTIC MANUAL
5319
150
31
DIAGNOSTIC MANUAL
151
DIAGNOSTIC MANUAL
Figure 45
Overview
A Regen may not occur due to any of the following conditions:
To view the status of Regen inhibitors, use an Electronic Service Tool (EST) with ServiceMaxx software, go
to Tests > KOER Aftertreatment Tests > Onboard Filter Cleanliness Test. Select the Inhibitors tab.
152
DIAGNOSTIC MANUAL
NOTE Any active aftertreatment system fault code(s) may inhibit a Regen. Diagnose active fault
code(s), other than SPN 3719 (DPF Soot Load), before continuing (see Electronic Control Systems
Diagnostics in Engine Diagnostic Manual).
Table 182
Expected Results
Comment
Not Inhibited
Off
Off
If On, turn switch Off. If switch does not turn Off, then
diagnose circuit fault.
Off
If On, turn switch Off. If switch does not turn Off, then
diagnose circuit fault.
PTO Switch
Off
If On, turn switch Off. If switch does not turn Off, then
diagnose circuit fault.
If no inhibitors are active and Regen is needed, go to Parked Regen Checks (page 155).
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DIAGNOSTIC MANUAL
Table 183
Expected Results
Comment
Not Inhibited
Off
Off
If On, turn switch Off. If switch does not turn Off, then
diagnose circuit fault.
Off
If On, turn switch Off. If switch does not turn Off, then
diagnose circuit fault.
PTO switch
Off
If On, turn switch Off. If switch does not turn Off, then
diagnose circuit fault.
On
If Off, set parking brake, if switch does not turn On, then
diagnose circuit fault.
Off
Accelerator Pedal
Position
0%
Off
Transmission Position
Park or Neutral
DPFDP: Decreasing steadily once DPFIT and DPFOT are steady and above 1022F (550C).
Using EST with ServiceMaxx software, open the Aftertreatment session. Start a Parked Regen and
monitor signals.
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DIAGNOSTIC MANUAL
Table 184
Using EST with ServiceMaxx software, open the Aftertreatment session. Open the inhibitors tab and check
for Inhibitors.
Checks
Expected Results
Comment
Engine condition
DPF Status
Regen Needed
Engine Coolant
Temperature
Active
EGR Position
Closed
ETV Position
80% 5%
DOCIT
482F (250C) to
572F (300C)
DOCOT
DPFOT
DPFDP
If the DPF is face plugged, measure the distance between the filter and outlet. If not within specification,
the filter cannot be cleaned and must be replaced.
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DIAGNOSTIC MANUAL
To view the status of Regen inhibitors, use an Electronic Service Tool (EST) with ServiceMaxx software, go
to Tests > KOER Aftertreatment Tests > Onboard Filter Cleanliness Test. Select the Inhibitors tab.
NOTE Any active aftertreatment system fault code(s) may inhibit a Regen. Diagnose active fault code(s)
before continuing (see Electronic Control Systems Diagnostics in Engine Diagnostic Manual)
Table 185
When the ECM determines the soot level threshold is reached, the system triggers DPF Regen.
NOTE Short trips or stop and go driving could prevent a successful Regen.
The following conditions are required for an Active Regen:
If DPF Status displays Regen needed and vehicle is unable to perform an Active Regen, go to appropriate
aftertreatment system diagnostics section in this manual.
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DIAGNOSTIC MANUAL
Engine Running
Vehicle stationary
Driveline disengaged
If the Soot level is within normal range, the test completes and displays Test Completed Successful. This
test does not give pass or fail results. The test only allows the operation of the aftertreatment system to be
validated by monitoring the effects of DOCIT, DOCOT, DPFOT, and DPFDP sensor.
If the test is aborted, go to Regen Inhibitors page 152. If no regen inhibitors are identified, go to appropriate
aftertreatment system diagnostics section in this manual.
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DIAGNOSTIC MANUAL
Table 187
A Parked Regen can only be performed when the DPF soot level threshold is reached. The DPF lamp will
flash or stay on solid, signaling the need for Regen.
The following conditions are required for a Parked Regen:
Engine Running
DPF lamp is on
Onboard Filter Cleanliness Test. DPF Status displays Regen needed and vehicle is unable to perform an Active
Regen, go to appropriate aftertreatment system diagnostics section in this manual.
158
DIAGNOSTIC MANUAL
159
DIAGNOSTIC MANUAL
Figure 46
Appearance
Black soot or gray ash can be seen on the face of the DPF and within the channels.
Cause
Action
160
DIAGNOSTIC MANUAL
Figure 47
Appearance
Black soot or gray ash on the face of the DPF and within the channels.
Cause
Action
161
DIAGNOSTIC MANUAL
Figure 48
Appearance
Cause
Action
Determine and repair the root cause of excessive soot generation. Once the root cause
is repaired, properly service and reuse the DPF.
162
DIAGNOSTIC MANUAL
Figure 49
Appearance
Cause
Action
Determine the cause of excessive exhaust gas temperatures. Refer to the appropriate
Engine Diagnostic Manual for diagnostic procedures. Once the cause of the excessive
exhaust gas temperature has been repaired, replace the DPF.
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DIAGNOSTIC MANUAL
Figure 50
Appearance
Action
NOTE Surface cracking on either face of the Diesel Particulate Filter (DPF) substrate is normal and
acceptable. If no black smoke is present during Snap Acceleration Test do NOT replace the DPF for
surface cracks.
164
DIAGNOSTIC MANUAL
Figure 51
Appearance
Cause
Action
165
DIAGNOSTIC MANUAL
Appearance
The DPF brick has shifted past the DPFOT sensor causing damage to the DPF
substrate.
Cause
Excessive soot accumulation caused by a base engine concern resulting in higher than
normal exhaust back pressure.
Action
Determine and repair the root cause of the excessive exhaust back pressure. Once the
root cause is repaired, replace the DPF.
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DIAGNOSTIC MANUAL
Appearance
The DPF brick has shifted and made contact with the DPFOT sensor port bung, but has
not damaged the DPF substrate.
Cause
Excessive soot accumulation caused by a base engine concern, resulting in higher than
normal exhaust back pressure.
Action
Determine and repair the root cause of the excessive exhaust back pressure. Once the
root cause is repaired, perform the DPF snap acceleration test. If no black smoke is
seen during the snap acceleration test, the DPF can be reused.
167
DIAGNOSTIC MANUAL
Figure 54
Appearance
Cause
Action
168
DIAGNOSTIC MANUAL
A. DOC separation
Figure 55
Appearance
Cause
Action
169
DIAGNOSTIC MANUAL
Figure 56
Appearance
Cause
Action
Determine the cause of excessive exhaust gas temperatures. Refer to the appropriate
Engine Diagnostic Manual for diagnostic procedures. Once the cause of the excessive
exhaust gas temperature has been repaired, replace the DOC.
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DIAGNOSTIC MANUAL
16.1.12. Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter (DPF) - Damaged
Sensor Port Threads
Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter (DPF) Damaged Sensor Port
Threads.
Appearance
The DOC or DPF differential pressure or temperature sensor port threats are damaged.
Cause
Seized threads.
Action
Repair the damaged threads with DPF Repair Kit 1223502 (12 mm thread) and DPF
Repair Kit 1223503 (14 mm thread).
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DIAGNOSTIC MANUAL
172
DIAGNOSTIC MANUAL
APS
Accelerator Position Sensor
APS/IVS
Accelerator Position Sensor / Idle Validation Switch
ATA
American Trucking Association
ATDC
After Top Dead Center
AWL
Amber Warning Lamp
B+ or VBAT
Battery Voltage
BAP or BARO
Barometric Absolute Pressure
BBDC
Before Bottom Dead Center
BC
Body Controller
BCS
Boost Control Solenoid
BDC
Bottom Dead Center
bhp
Brake Horsepower
BOO
Brake On / Off
BTDC
Before Top Dead Center
C
Celsius
CAC
Charge Air Cooler
CACOT
Charge Air Cooler Outlet Temperature
CAN
Controller Area Network
CAP
Cold Ambient Protection
CARB
California Air Resources Board
cc
Cubic centimeter
CCA
Cold Cranking Ampere
CCV
Coolant Control Valve
CCOS
Crankcase Oil Separator (breather)
CCPS
Crankcase Pressure Sensor
CCS
Cruise Control Switches
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DIAGNOSTIC MANUAL
cfm
Cubic feet per minute
cfs
Cubic feet per second
CFV
Coolant Flow Valve
CKP
Crankshaft Position
cm
Centimeter
CMP
Camshaft Position
CMV
Coolant Mixer Valve
CO
Carbon Monoxide
Cyl
Cylinder
DC
Direct Current
DLC
Data Link Connector
DMM
Digital Multimeter
DOC
Diesel Oxidation Catalyst
DOCIT
Diesel Oxidation Catalyst Inlet Temperature
DOCOT
Diesel Oxidation Catalyst Outlet Temperature
DPF
Diesel Particulate Filter
DPFDP
Diesel Particulate Filter Differential Pressure
DPFIT
Diesel Particulate Filter Inlet Temperature
DPFOT
Diesel Particulate Filter Outlet Temperature
DSI
Down Stream Injection
DTC
Diagnostic Trouble Code
DTCs
Diagnostic Trouble Codes
EBP
Exhaust Back Pressure
EBPV
Exhaust Back Pressure Valve
ECB
Engine Compression Brake
ECL
Engine Coolant Level
174
DIAGNOSTIC MANUAL
ECM
Engine Control Module
ECT
Engine Coolant Temperature
ECT1
Engine Coolant Temperature 1
ECT2
Engine Coolant Temperature 2
EGR
Exhaust Gas Recirculation
EGT
Exhaust Gas Temperature
EGT1
Exhaust Gas Temperature 1
EGT2
Exhaust Gas Temperature 2
EGT3
Exhaust Gas Temperature 3
EMI
Electromagnetic Interference
EOP
Engine Oil Pressure
EOT
Engine Oil Temperature
EPA
Environmental Protection Agency
ESN
Engine Serial Number
EST
Electronic Service Tool
ETC
Engine Throttle Control
ETP
Engine Throttle Position
ETV
Engine Throttle Valve
EVB
Exhaust Valve Brake
EWPS
Engine Warning Protection System
F
Fahrenheit
FCV
Fuel Coolant Valve
FDP
Fuel Delivery Pressure
fhp
Friction horsepower
FMI
Failure Mode Indicator
FPC
Fuel Pump Control
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DIAGNOSTIC MANUAL
FPCV
Fuel Pressure Control Valve
fpm
Feet per minute
fps
Feet per second
FRP
Fuel Rail Pressure
FRPD
Fuel Rail Pressure Desired
ft
Feet
GND
Ground (electrical)
gal
Gallon
gal/h
U.S. Gallons per hour
gal/min
U.S. Gallons per minute
GCW
Gross Combined Weight
GCWR
Gross Combined Weight Rating
GVW
Gross Vehicle Weight
H2O
Water
HC
Hydrocarbons
HCI
Hydrocarbon Injection
HEST
High Exhaust System Temperature
Hg
Mercury
hp
Horsepower
HPCAC
High-Pressure Charge Air Cooler
HPCR
High-Pressure Common Rail
HPFP
High-Pressure Fuel Pump
hr
Hour
HS
Humidity Sensor
Hyd
Hydraulic
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DIAGNOSTIC MANUAL
IAH
Inlet Air Heater
IAHR
Inlet Air Heater Relay
IAT
Inlet Air Temperature
IC
Integrated Circuit
ICP
Injection Control Pressure
ICPR
Injection Control Pressure Regulator
IGN
Ignition
IMP
Intake Manifold Pressure
IMT
Intake Manifold Temperature
in
Inch
inHg
Inch of mercury
INJs
Injectors
IPR
Injection Pressure Regulator
ISC
Interstage Cooler
ITV
Intake Throttle Valve
J1939H
J1939 Data Link High
J1939L
J1939 Data Link Low
kg
Kilogram
km
Kilometer
km/h
Kilometers per hour
KOEO
Key-On Engine-Off
KOER
Key-On Engine-Running
kPa
Kilopascal
L
Liter
lb
Pound
lbf
Pounds of force
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DIAGNOSTIC MANUAL
lb/s
Pounds per second
lbf ft
Pounds of force per foot
lb in
Pounds of force per inch
lbm
Pounds of mass
LPCAC
Low-pressure Charge Air Cooler
LSD
Low Sulfur Diesel
m
Meter
m/s
Meters per second
MAF
Mass Air Flow
MAP
Manifold Absolute Pressure
MAP/IAT
Manifold Absolute Pressure / Inlet Air Temperature
mi
Mile
MIL
Malfunction Indicator Lamp
mm
Millimeter
mpg
Miles per gallon
mph
Miles per hour
MSDS
Material Safety Data Sheet
MSM
Multiplex System Module
MY
Model Year
NC
Normally Closed (electrical)
Nm
Newton meter
NO
Normally Open (electrical)
NOX
Nitrogen Oxides
O2S
Oxygen Sensor
O2SH
Oxygen Sensor Heater
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DIAGNOSTIC MANUAL
OSHA
Occupational Safety and Health Administration
OWL
Oil/Water Lamp
PID
Parameter Identifier
P/N
Part Number
PDOC
Pre-Diesel Oxidation Catalyst
ppm
Parts per million
PROM
Programmable Read Only Memory
psi
Pounds per square inch
psia
Pounds per square inch absolute
psig
Pounds per square inch gauge
pt
Pint
PTO
Power Takeoff
PWM
Pulse Width Modulate
PWR
Power (voltage)
qt
Quart
RAM
Random Access Memory
rpm
Revolutions per minute
SIG GND
Signal Ground
S/N
Serial Number
SPEEDO
Speedometer
SPN
Suspect Parameter Number
SWBAT
Switch Battery
TC2CIS
Turbocharger 2 Compressor Inlet Sensor
TC1TOP
Turbocharger 1 Turbine Outlet Pressure
TC2TOP
Turbocharger 2 Turbine Outlet Pressure
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DIAGNOSTIC MANUAL
TC1WC
Turbocharger 1 Wastegate Control
TC2WC
Turbocharger 2 Wastegate Control
TCM
Transmission Control Module
TDC
Top Dead Center
V
Volt
VBAT or B+
Battery Voltage
VGT
Variable Geometry Turbo
VIN
Vehicle Identification Number
VREF
Reference Voltage
VSS
Vehicle Speed Sensor
WTSL
Wait to Start Lamp
WIF
Water In Fuel
WIFL
Water In Fuel Lamp
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DIAGNOSTIC MANUAL
TERMINOLOGY
Accelerator Pedal Position
(APP) sensor
A potentiometer sensor that indicates the position of the throttle pedal.
Actuator
A device that performs work in response to an input signal.
Actuator Control
The ECM controls the actuators by applying a low-level signal (low-side driver) or a high-level signal (high
side driver). When switched on, both drivers complete a ground or power circuit to an actuator.
Aeration
The entrainment of air or combustion gas in coolant, lubricant, or fuel.
Aftercooler (Charge Air Cooler)
A heat exchanger mounted in the charge air path between the turbocharger and engine intake manifold.
The aftercooler reduces the charge air temperature by transferring heat from the charge air to a cooling
medium (usually air).
Aftertreatment Fuel Doser
(AFTFD)
A part of the Down Stream Injection (DSI) unit that sends pressurized fuel to the Aftertreatment Fuel
Injector (AFI) to inject fuel into the exhaust pipe.
Aftertreatment Fuel Injector
(AFI)
Injects fuel into the exhaust system to increase temperature of the exhaust gases.
Aftertreatment (AFT) system
A part of the exhaust system that processes engine exhaust to meet emission requirements and traps
particulate matter (soot) to prevent it from leaving the tailpipe.
Air Control Valve (ACV)
Contains the LP turbocharger wastegate control port, HP turbocharger wastegate control port, the EBPV
control port, and the TC1TOP port. Although these components are integral to the ACV, each circuit is
controlled by the ECM. The ACV controls compressed air for each control valve.
Ambient temperature
The environmental air temperature in which a unit is operating. In general, the temperature is measured in
the shade (no solar radiation) and represents the air temperature for other engine cooling performance
measurement purposes. Air entering the radiator may or may not be the same ambient due to possible
heating from other sources or recirculation. (SAE J1004 SEP81)
Ampere (amp)
The standard unit for measuring the strength of an electrical current. The flow rate of a charge in a
conductor or conducting medium of one coulomb per second. (SAE J1213 NOV82)
Analog
A continuously variable voltage.
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Horsepower (hp)
Horsepower is the unit of work done in a given period of time, equal to 33,000 pounds multiplied by one
foot per minute. 1 hp = 33,000 lb x 1 ft. /1 min.
Humidity Sensor (HS)
A sensor that measures the moisture content of filtered air entering the intake system.
Hydrocarbons
Organic compounds consisting of hydrogen and carbon (fuel and oil).
Hydrocarbon slip
A normal condition that occurs in the exhaust stream in high idle time applications, where diesel fuel does
not fully combust in the aftertreatment system during regeneration. The diesel fuel slips through the Diesel
Particulate Filter (DPF), and into the clean side of the exhaust.
Injection Pressure Regulator
(IPR) valve
A valve that is used to maintain desired injection control pressure.
Injection Control Pressure (ICP)
sensor
Provides a feedback signal to the ECM indicating injection control pressure.
Inlet Air Heater (IAH)
The IAH is primarily used to assist in starting the engine during cold weather. In addition, it helps to reduce
white smoke emissions by heating the incoming air.
Inlet Air Heater Fuel Igniter
(IAHFI)
The IAHFI heats the intake air by vaporizing and igniting fuel in the air inlet duct.
Inlet Air Heater Fuel Solenoid
(IAHFS)
As the engine is cranked, the ECM energizes the IAHFS valve, introducing fuel into the IAHFI, which ignites
and warms the air being drawn into the engine.
Inlet Air Heater Relay (IAHR)
The IAHR provides voltage to the IAHFI, and is controlled by the ECM.
Inlet Air Temperature (IAT)
sensor
A thermistor sensor that monitors intake air temperature.
Intake manifold
Engine component that evenly supplies air to each intake port in the cylinder head(s).
Intake Manifold Pressure (IMP)
sensor
A variable capacitance sensor used to indicate air pressure in the intake manifold.
Intake Manifold Temperature
(IMT) sensor
A thermistor sensor used to indicate air temperature in the intake manifold.
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Ohm ()
The unit of electrical resistance. One ohm is the value of resistance through which a potential of one volt will
maintain a current of one ampere. (SAE J1213 NOV82)
Oxides of Nitrogen (NOx)
Nitrogen oxides formed by a reaction between nitrogen and oxygen at high temperatures.
Oxygen Sensor (O2S)
A sensor that monitors oxygen levels in the exhaust.
Particulate matter
Particulate matter includes mostly burned particles of fuel and engine oil.
Piezometer
An instrument for measuring fluid pressure.
Power
Power is a measure of the rate at which work (force x distance) is done during a specific time. Compare
with Torque.
Power TakeOff (PTO)
Accessory output, usually from the transmission, used to power a hydraulic pump for a special auxiliary
feature (garbage packing, lift equipment, etc).
Pulse Width Modulation (PWM)
Succession of digital electrical pulses, rather than an analog signal. Efficient method of providing power
between fully on and fully off.
Random Access Memory
(RAM)
Computer memory that stores information. Information can be written to and read from RAM. Input
information (current engine speed or temperature) can be stored in RAM to be compared to values stored in
Read Only Memory (ROM). All memory in RAM is lost when the ignition switch is turned off.
Rated gross horsepower
Engine gross horsepower at rated speed as declared by the manufacturer. (SAE J1995 JUN90)
Rated horsepower
Maximum brake horsepower output of an engine as certified by the engine manufacturer. The power of
an engine when configured as a basic engine. (SAE J1995 JUN90)
Rated net horsepower
Engine net horsepower at rated speed as declared by the manufacturer. (SAE J1349 JUN90)
Rated speed
The speed, as determined by the manufacturer, at which the engine is rated. (SAE J1995 JUN90)
Rated torque
Maximum torque produced by an engine as certified by the manufacturer.
Reference voltage (VREF)
A 5 volt reference supplied by the ECM to operate the engine sensors.
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Regeneration
Oxidation of accumulated soot (carbon-based particulates) in the Diesel Particulate Filter (DPF). The soot is
reduced to ash and stored in the PDF.
ServiceMaxx software
Diagnostics software for engine components and systems.
Signal ground
The common ground wire to the ECM for the sensors.
Strategy
A plan or set of operating instructions that the microprocessor follows for a desired goal. Strategy is the
computer program itself, including all equations and decision making logic. Strategy is always stored in
ROM and cannot be changed during calibration.
Stroke
The movement of the piston from Top Dead Center (TDC) to Bottom Dead Center (BDC).
Suspect Parameter Number
(SPN)
A 19-bit number used to identify the item for which diagnostics are being reported. The SPN is used for
multiple purposes, some that are specific to diagnostics are as follows;
Identify subsystems or assemblies that may not have hard failures but may be exhibiting abnormal
operating performance.
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Turbocharger
A turbine driven compressor mounted on the exhaust manifold. The turbocharger increases the pressure,
temperature and density of intake air to charge air.
Turbocharger 1 Turbine Outlet
Pressure (TC1TOP) sensor
A variable capacitance sensor that monitors exhaust back-pressure.
Turbocharger 2 Compressor
Inlet (TC2CIS) sensor
The TC2CIS sensor includes a thermistor sensor that monitors the temperature of charge air entering the
HP turbocharger. This sensor also monitors boost pressure for the LP turbocharger.
Turbocharger Wastegate
Control (TCWC) solenoid
Controls the TCWC actuator by regulating the amount of charge air pressure supplied to the TCWC
actuator. The TCWC solenoid is controlled by signals from the ECM in response to engine speed, required
fuel quantity, boost, exhaust back-pressure, and altitude.
Turbocharger 1 Wastegate
Control (TC1WC) solenoid
Controls the TC1WC actuator by regulating the amount of charge air pressure supplied to the TC1WC
actuator. The TC1WC solenoid is controlled by signals from the ECM in response to engine speed, required
fuel quantity, boost, exhaust back-pressure, and altitude. The TC1WC actuator is part of the turbocharger
assembly.
NOTE TC1WC does not affect engine performance and is removed from postproduction engines.
Turbocharger 2 Wastegate
Control (TC2WC) solenoid
Controls the TC2WC actuator by regulating the amount of charge air pressure supplied to the wastegate
actuator. The TC2WC solenoid is controlled by signals from the ECM in response to engine speed, required
fuel quantity, boost, exhaust back-pressure, and altitude. The TC2WC actuator is part of the turbocharger
assembly.
Variable capacitance sensor
A variable capacitance sensor measures pressure. The pressure forces a ceramic material closer to a thin
metal disc in the sensor, changing the capacitance of the sensor.
Vehicle Speed Sensor (VSS)
Normally a magnetic pickup sensor mounted in the tailshaft housing of the transmission, used to indicate
ground speed.
Viscosity
The internal resistance to the flow of fluid.
Volt (v)
A unit of electromotive force that will move a current of one ampere through a resistance of one Ohm.
Voltage
Electrical potential expressed in volts.
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Voltage drop
Reduction in applied voltage from the current flowing through a circuit or portion of the circuit current
multiplied by resistance.
Voltage ignition
Voltage supplied by the ignition switch when the key is ON.
Water In Fuel (WIF) sensor
A switch sensor that measures the amount of water in the fuel.
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