1. ~IC Maint. And Updates. WAPT 2015~

2. ·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

3. 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

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

5. 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!

6. EPA 2007 MAXXFORCE DT – SENSORS
MAP MAT

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

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

9. 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

10. 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?~

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

12. 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.
MinimumViscosity
Verification that all EGR and Aftertreatment systems are in good repair: Sensors, DOC, DPF, EGR and ITV Functionality.

13. 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!

14. 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.

15. 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 #

16. MAXXFORCE 7/DT – DOC/DPF Parked Regeneration
DOC Inlet Temperature ºF
DPF Inlet Temperature ºF
DPF Outlet Temperature ºF

17. 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!

18. 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.

19. 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)

20. 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)

21. 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”

22. 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

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

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

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

26. 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

27. HD OBD
-DTC term replaced by SPN (Suspect Parameter Number)
-FMI (Failure Mode Identifier) Same SPN, Different FMI, Same system
SPN ICP Adaptation In-Range Fault
SPN ICP Above KOEO Spec
SPN 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

28. 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

29. HD OBD

30. 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>

31. 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

32. 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!

33. Thank you for your participation!
-Harlows