~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: -INSPECT FOR COOLANT COLOR/SMELL (Note: cooler and cross over will be damp until engine is warm) EGR VALVE

EPA 2007 MAXXFORCE DT – EGR COOLER/VALVE COLD SIDE COOLER PLUGGING Warranty: DTC 2389 - EGR flow insufficient - possible plugged system DO NOT ERASE! <<<INLET OUTLET >>>

EPA 2007 MAXXFORCE DT – SENSORS Clean sensors, ports and tubes. No deformations. -MAT (Manifold Air Temperature -MAP (Manifold Absolute Pressure: AKA Boost) -EBP (Exhaust Back Pressure) Same style sensors on MF7. DO NOT INTERCHANGE!

EPA 2007 MAXXFORCE DT – SENSORS MAP MAT

EPA 2007 MAXXFORCE DT – SENSORS -Service Maxx, Default Screen, KOEO

EPA 2007 MAXXFORCE DT – INJECTORS AND CAMSHAFT -Camshaft Follower(lifter) guides -Forced Lubrication: Rockers and Pushrods

EPA ’07 Maxxforce EPA ’10 Maxxforce EPA 2007 MAXXFORCE DT – INJECTORS AND CAMSHAFT -Any Injector Fault Code – Run a Relative Compression Test EPA ’07 Maxxforce EPA ’10 Maxxforce

EPA 2007 MAXXFORCE DT – FUEL SYSTEM -Fuel pressure range 40-80psi (Navistar) Should not ‘bounce’ more than 10-15psi -Best Practice: Change Fuel Filter with Oil Change And clean out the bowl -Keep fuel supply tanks in good repair. ~When was the filter on your tank changed last?~

EPA 2007 MAXXFORCE DT – FUEL SYSTEM CLEAN FUEL = CLEAN FUEL SYSTEM

EPA 2007 MAXXFORCE DT – FUEL DILUTION -RARE FOR UNITS WITH ‘SKRJ’ CALIBRATION -SKSE CALIBRATION available through Dealer Fill out dilution form: documentation in miles/hours of oil growth, oil change intervals, provide samples if possible. 10cst @100ºC MinimumViscosity Verification that all EGR and Aftertreatment systems are in good repair: Sensors, DOC, DPF, EGR and ITV Functionality.

MAXXFORCE – COOLANT FILL -BOTTOM FILL ONLY! -Harlow’s Parts Dept: Radiator Fittings, Quick Hose Fitting, Air Lift Kit -RE BUS: Fill to lower sight glass cold! -Radiator Caps: On 3rd revision. Pressure test every oil change!

INTERNATIONAL DT466 AND MAXXFORCE– COOLANT PRESSURES -Chassis Heater Hoses are rated to 30psi -Testing shows spiking near 50psi, blowing hoses,causing EGR Cooler Failures. -3/8” pressure relief line: Plumb at Heater Valve, out from engine, to top of expansion tank.

MAXXFORCE DT – IPR (Injection Pressure Regulator) EPA 2007: Replacement Pigtail. Remove engine harness plug and wire in new connector EPA 2010: Redesigned IPR Valve Kit. Glued pigtail, and new style connector. ‘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 600-800ºF DPF Inlet Temperature 1000-1150ºF DPF Outlet Temperature 1000-1150ºF

EPA 2007 MAXXFORCE 7 – BEDPLATE -Bed Plate/Lower Crankcase Leaks: -New Sealing and Torque Procedures -Engine Must Be Removed -Rear Main Seal: Two thicknesses of wear sleeve. Measure!

EPA 2010 MAXXFORCE DT – AIR FILTERS -Air Filter Restriction Gauges: Not 100% accurate -Once the gauge moves, it may be too late -RE BUS – Filter size appears to be too small, plugs quickly. -Check at oil change visually. Replace as necessary 10,000miles on filter.

EPA 2010 MAXXFORCE DT – AHI (Aftertreatment Hydrocarbon Injector -Injects Fuel for ‘Active’ regen into exhaust -No more fuel dilution -Plugs with dirty air filter -Must be cleaned after EGR Cooler failure. -Updated Gasket -ACM (Aftertreatment Control Module)

EPA 2010 MAXXFORCE DT – AHI (Aftertreatment Hydrocarbon Injector -Injects Fuel for ‘Active’ regen into exhaust stream -No more fuel dilution -Plugs with dirty air filter -Must be cleaned after EGR Cooler failure. -Updated Gasket -ACM (Aftertreatment Control Module)

EPA 2010 MAXXFORCE DT – DOC/DPF -ALL MODELS: Clean DPF at yearly or hourly specifications found in Maintenance Manual -Leading causes of DPF Failure on 2010 DT: Defective CAC Pipe, Plugged AHI, Dirty Air Filters, Failed EGR Cooler “If it’s Smokin’ it’s Broken”

EPA 2010 MAXXFORCE DT – DOC/DPF -DOC Face Plugging = -Low Regen Temperatures: Incomplete and More Frequent Regens -White Smoke -Fuel Dilution -Coolant/Excess Fuel/Oil Contamination = Poisoning

EPA 2010 MAXXFORCE DT – EGR COOLER -2010 DT Has one large EGR Cooler -TOW to Dealer when confirmed failed -Hydro-lock very possible

EPA 2010 MAXXFORCE DT – EGR COOLER -2010 DT Has one large EGR Cooler -TOW to Dealer when confirmed failed -Hydro-lock very possible

EPA 2010 MAXXFORCE DT – EGR COOLER -2010 DT Has one large EGR Cooler -TOW to Dealer when confirmed failed -Hydro-lock very possible

HD OBD -Heavy Duty On-Board Diagnostics -EPA/CARB Standardization -Class 4 and above, 14,000lb gross or higher. -MIL (Malfunction Indicator Lamp) – Emissions related faults

HD OBD -DTC term replaced by SPN (Suspect Parameter Number) -FMI (Failure Mode Identifier) Same SPN, Different FMI, Same system SPN164.13 - ICP Adaptation In-Range Fault SPN164.0 - ICP Above KOEO Spec SPN164.10 - ICP Abnormal Rate of Change -Fault Status ·Pending (Monitor run an failed 1 drive cycle.) MIL OFF. Freeze Frame Stored ·Active (Monitor run and failed 2 drive cycle.) MIL ON. Freeze Frame Stored ·Healing (Monitor run and pass. Healing for 3 drive cycles.) 4th cycle, inactive. ·Previously Active/Inactive (Monitor has run and passed for 3 drive cycles.) ·Permanent Fault (Cannot be cleared by dealer or user, only by drive cycles.) -Failure Description ·What the code is indicating: IE: Cylinder (#) Balance maximum limit exceeded -Freeze Frame Data ·Stored information for when the fault is set. RPM, Temp, Speed, ETC -Count ·How many drive cycles have occurred with the fault

FMI (Failure Mode Identifier) HD OBD FMI (Failure Mode Identifier) FMI=0 - Data Valid but Above Normal Operational Range, Most Severe Level FMI=1 - Data Valid but Below Normal Operational Range, Most Severe Level FMI=2 - Data Erratic, Intermittent or Incorrect (rationality) FMI=3 - Voltage Above Normal, or Shorted to High Source FMI=4 - Voltage Below Normal, or Shorted to High Source FMI=5 - Current Below Normal, or Open Circuit FMI=6 - Current Above Normal, or Grounded Circuit FMI=7 - Mechanical System not Responding or Out of Adjustment FMI=8 - Abnormal Frequency or Pulse Width or Period FMI=9 - Abnormal Update Rate FMI=10 - Abnormal Rate of Change FMI=11 - Failure Code not Identifiable FMI=12 - Bad Intelligent Device or Component FMI=13 - Out of Calibration FMI=14 - Special Instructions FMI=15 - Data Valid but Above Normal Range : Least Severe Level FMI=16 - Data Valid but Above Normal Range: Moderately Severe Level FMI=17 - Data Valid but Below Normal Range: Least Severe Level FMI=18 - Data Valid but Below Normal Range: Moderately Severe Level FMI=19 - Received Network Data in Error: (Multiplexed Data) FMI=20 - Data Drifted High (rationality high) FMI=21 - Data Drifted Low (rationality low) FMI=22 to 30 - Reserved for SAE Assignment FMI=31 - Condition Exists

HD OBD

DEF/SCR -DEF (Diesel Exhaust Fluid): -32.5% Urea/67.5% Water -18 Month Shelf life at 30ºF -SCR (Selective Catalyst Reduction) -Cleans up the NOx Emission -NOx Inlet and Outlet sensors, NH3 Ammonia sensor. SCR Unit DEF Tank DOC/DPF Engine>

DEF/SCR X X DPF Aftertreatment Fuel Doser Component DOC/DPF Component SCR Component Aftertreatment Diesel Oxidation Catalyst Intake Temperature Aftertreatment Diesel Particulate Filter Intake Temperature Aftertreatment SCR Intermediate Temperature Aftertreatment Fuel Pressure Sensor Aftertreatment Intermediate NH3 Sensor Aftertreatment Fuel Shutoff Valve Aftertreatment Diesel Particulate Filter Outlet Temperature Aftertreatment SCR Catalyst Aftertreatment SCR Outlet Temperature X Aftertreatment DEF Dosing Valve X Aftertreatment Outlet NOx Sensor (Engine Out) DOC DPF SCR Catalyst Aftertreatment DEF Dosing Unit Aftertreatment Fuel Doser HD - ONLY Aftertreatment DEF Dosing Unit Heater Relay Aftertreatment Intake NOx Sensor Aftertreatment DEF Line Heater 1 Aftertreatment DEF Line Heater 4 Aftertreatment Diesel Oxidation Catalyst Aftertreatment DEF Pressure Aftertreatment DEF Return Valve Aftertreatment Diesel Particulate Filter Outlet Pressure Sensor Aftertreatment Purge Air Actuator Aftertreatment Diesel Particulate Filter Aftertreatment DEF Line Heater 3 Aftertreatment Particulate Filter Differential Pressure Sensor Aftertreatment DEF Line Heater 2 Aftertreatment DEF Line Heater Relay (Coolant Flow) Aftertreatment DEF Tank Temperature Aftertreatment DEF Tank Heater Control Valve Diesel Exhaust Fluid (DEF) Aftertreatment DEF Tank Level Aftertreatment DEF Quallity Sensor Aftertreatment DEF Tank

CUMMINS ISB6.7 CM2350 B101 -CE (Conventional) bus only at this time -Do Not Pre-Fill secondary fuel filter(Fuel water sep.) Use hand primer -Rear Gear Train Only -ISB uses BOSCH Fuel Injection Pumps -High Pressure Common Rail -Fuel Pressure bleeds off almost immediately after engine shutdown Do not loosen High Pressure Fuel lines while engine is running!

Thank you for your participation! -Harlows