~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 PLUGGINGWarranty: 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 SYSTEMCLEAN 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.

‘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!

New Socket#12-800-01

MAXXFORCE 7/DT – DOC/DPF Parked Regeneration

DOC Inlet Temperature 600-800ºFDPF Inlet Temperature 1000-1150ºFDPF 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 FaultSPN164.0 - ICP Above KOEO SpecSPN164.10 - 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 LevelFMI=1 - Data Valid but Below Normal Operational Range, Most Severe LevelFMI=2 - Data Erratic, Intermittent or Incorrect (rationality)FMI=3 - Voltage Above Normal, or Shorted to High SourceFMI=4 - Voltage Below Normal, or Shorted to High SourceFMI=5 - Current Below Normal, or Open CircuitFMI=6 - Current Above Normal, or Grounded CircuitFMI=7 - Mechanical System not Responding or Out of AdjustmentFMI=8 - Abnormal Frequency or Pulse Width or PeriodFMI=9 - Abnormal Update RateFMI=10 - Abnormal Rate of ChangeFMI=11 - Failure Code not IdentifiableFMI=12 - Bad Intelligent Device or ComponentFMI=13 - Out of CalibrationFMI=14 - Special InstructionsFMI=15 - Data Valid but Above Normal Range : Least Severe Level FMI=16 - Data Valid but Above Normal Range: Moderately Severe LevelFMI=17 - Data Valid but Below Normal Range: Least Severe LevelFMI=18 - Data Valid but Below Normal Range: Moderately Severe LevelFMI=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 AssignmentFMI=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>

DPFDOC

Aftertreatment Diesel Oxidation Catalyst Intake Temperature

Aftertreatment Diesel Particulate

Filter Intake Temperature

Aftertreatment Diesel

Particulate Filter Outlet

Temperature

Aftertreatment Diesel Oxidation Catalyst

Aftertreatment Diesel Particulate Filter

SCRCatalyst

Aftertreatment Outlet NOx Sensor

Aftertreatment SCR Catalyst

Aftertreatment SCR Intermediate Temperature

Aftertreatment SCR Outlet Temperature

DieselExhaust

Fluid (DEF)

Aftertreatment DEF Tank Temperature

SCR ComponentDOC/DPF ComponentAftertreatment Fuel Doser Component

XX

Aftertreatment Fuel DoserHD - ONLY

Aftertreatment Fuel Shutoff

Valve

Aftertreatment Fuel

Pressure Sensor

Aftertreatment Diesel Particulate Filter Outlet Pressure Sensor

Aftertreatment DEF Tank

Aftertreatment DEF Dosing Unit

Aftertreatment DEF Tank Level

Aftertreatment DEF Line Heater 1

Aftertreatment Particulate Filter Differential Pressure Sensor

Aftertreatment DEF Line Heater 3

Aftertreatment DEF Tank Heater Control Valve

(Engine Out)

Aftertreatment DEF Dosing Valve

Aftertreatment DEF Line Heater 2

Aftertreatment DEF Line Heater 4

Aftertreatment DEF Pressure

Aftertreatment DEF Return Valve

(Coolant Flow)

Aftertreatment DEF Line Heater Relay

Aftertreatment Intake NOx Sensor

Aftertreatment Purge Air Actuator

Aftertreatment Intermediate NH3 Sensor

Aftertreatment DEF Quallity Sensor

Aftertreatment DEF Dosing Unit Heater Relay

DEF/SCR

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