IK1200894 - 2010 MaxxForce DT/9/10 Aftertreatment Service

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Title: 2010 MaxxForce DT/9/10 Aftertreatment Service
Applies To: 2010 MaxxForce DT/9/10
DESCRIPTION
A properly operating aftertreatment system requires little manual intervention from the operator. DPF Lamps that are illuminated may indicate a
problematic drive cycle or an extended idle condition that may not be conducive to transparent DPF regenerations. These illuminated lamps may also be
the result of a previous or current upstream engine system concern.
NOTE:
Removal of the DOC or DPF for inspection purposes should not be performed until diagnostics require it.

TRIAGE
• Check the vehicle service history (Warranty and Case Files).
• Record all active and inactive diagnostic trouble codes(DTCs); Record SPN and FMI of active and inactive DTCs.
• Record the current calibration and check the vehicle calibration scorecard to determine if an updated calibration is available.
• Check for any open campaigns applicable to this repair and update per campaign.
CUSTOMER QUESTIONNAIRE
1. Can you explain when the vehicle experiences the problem?
- For instance: Is it at idle, under load or is there anything unique about the circumstances?
2. Check the status of the INHIBIT switch (when equipped). Position should be OFF.
3. Ask the driver if a parked REGENERATION was attempted and what was the result?
4. Did any lights such as the 'Check Engine Light' or 'DPF Lamp' show up on the dash? If so, what lamps were ON?
5. Did the problem just start or has it been getting worse over time?
6. Has any work been done recently to the engine or chassis?
7. Has the vehicle been in for the same problem before? If we rode with you, how would you duplicate the problem?
8. Record the percentage of time the vehicle is spending at idle.
9. Record the percentage of time the vehicle is in PTO operation.
10. Does the vehicle exhibit any of the following symptoms?
• Visible black smoke
• Gray smoke / faint black smoke
• Aftertreatment lamps illuminated
GENERAL INFORMATION
Dash Identification (Only Lamps 5, 6 and 7 will be discussed in this article):

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IK1200894 - 2010 MaxxForce DT/9/10 Aftertreatment Service

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Lamp ID Lamp Name

Description
Illuminates Red Used in conjunction with other Warning Lights or General Text and Warning
Messages to indicate a red STOP alert. This alert may be an indication of a serious problem
Stop Engine
has occurred. The Engine may derate or Shutdown soon. Pull the vehicle safely off the
roadway, turn on flashers, set park brake, place warning and Shut Off the engine. Seek service
immediately.
Illuminates Yellow when exhaust system components are operating under normal conditions
High Exhaust Temperature (HEST) and exhaust gases are at high temperatures. This is normal operation when the
aftertreatment system is in active or passive regeneration.

5

6

7

Diesel Particulate Filter (DPF)

DPF Lamp

Level

Yellow (Solid or Flashing) to indicate the need to regenerate the Diesel Particulate Filter.
Operators should follow the instructions on the Sun Visor Decal.

Condition

Codes

Warranty Coverage

Level 1

Exhaust Filter regeneration is required.

SPN 3719 FMI 15

No – customer responsibility unless related to upstream engine
system concern.

Level 2

Exhaust Filter is full; Parked Regen is
required.

SPN 3719 FMI 16

No – customer responsibility unless related to upstream engine
system concern.

Level 3

Exhaust Filter is full; Engine Performance is
SPN 3719 FMI 0
lmited.

Solid

Flashing

No – customer responsibility unless related to upstream engine
system concern.

and
Flashing
Alarm
ShutdownA serious problem has occurred.

Exhaust System is HOT

SPN 3936

Yes – Normal Warranty coverage

None

No - Normal Operation

VISOR STICKER

DIAGNOSTIC PROCEDURE

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IK1200894 - 2010 MaxxForce DT/9/10 Aftertreatment Service

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1. Diagnose and repair any active or inactive fault codes before troubleshooting SPN 3719 FMI 16, SPN 3719 FMI 0, 3719 FMI 15, and 3936 FMI 0.
- Codes other than the above mentioned; can be the root cause for the aftertreatment concerns and need to be repaired before proceeding to Step
2.
2. Perform a snap acceleration of the engine from idle to high idle (100% APS). Repeat this step several times while watching for black smoke coming
out of the exhaust outlet pipe.
a. If black smoke is seen repeatedly:
- Drop the DOC/DPF and inspect. Upload pictures of the inlet and outlets of both parts into the Case file. A case file is required for Aftertreatment
component
replacement under warranty.
b. If black smoke is not seen during Step 2, proceed to Step 3.

Please take a picture of the outlet of the DPF as shown above. Open an iApprove
case file to replace DPF if this is discovered.
3. Perform Onboard Filter Cleanliness Test (OBFCT) using Service Maxx.
- Record a Performance Session while OBFCT is running.
- Performance of the OBFCT can be observed live while the test is running and can be replayed later for review.
4. Please CLICK HERE to play an example of an OBFCT signal playback in ServiceMaxx.
a. Observe exhaust gas temperatures from DOC Inlet Temperature, DPF Inlet Temperature and DPF Outlet Temperature.
- Refer to Table 1 (below) with ranges.
b. If DPF Soot Load is at an elevated level (7+), perform 1 additional OBFCT.
- Watch for temperatures to raise (please note that during high soot load levels the DOC and DPF temperatures will be lower than normally
expected to prevent cracking of
the filter).
- Additional OBFCT’s may be required to reduce soot load and turn off the DPF lamp.
c. Do not continue OBFCT’s if:
- Other DTCs trigger during testing.
- Exhaust temperatures do not increase enough to enter into a dosing (Active) regeneration.
- Soot Load level is low enough to remove all DPF overload lamp levels.
5. Replay OBFCT using Service Maxx and observe Aftertreatment temperatures and diagnostic trouble codes.
- The replay of the snapshot can be used to observe temperatures and other parameters that could abort the OBFCT.
- Refer to DTC diagnostic information.
- If the values below are met the OBFCT was good and no further diagnosis is necessary.
After Treatment Guidelines for Actuators and Sensors during OBFCT:
TABLE 1
DOC Inlet minimum operating temperature 500F (260C)

DPF Inlet operating range 900 - 1250F (482 - 676C)

DPF Outlet operating range 900 - 1250F (482 - 676C)
Representative Aftertreatment Replay of a Properly Performing OBFCT:

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This image is showing DOC and DPF temperatures only.
- If the OBFCT aborted and temp values were not met, perform an AMT (air management test) and collect a snapshot using the performance session.
I-6 Air Management Test (AMT)
During an AMT, MAF average values are compared with the EGR Valve open and closed. As you can see in the graph below, EGR position is
commanded and based on this you may see the Intake Manifold and Exhaust back pressures change. The test will only look for proper operation of the
EGR Valve.

- If there is an issue with the EGR valve, the fault that will appear from the AMT test will be SPN2659 FMI20 (KOER AMT – EGR test failure). Also,
attach the snapshot to the case file for Tech Services to review.
6. After the repairs are completed, return to Step 3 and run the OBFCT.
a. After successfully performing an OBFCT, proceed to Step 7.
7. Perform the following:
a. Complete all open AFC’s.
b. Clear DTCs.
RELATED INFORMATION
1. Maintenance:
a. Steps to take after DPF cleaning or replacement (enables ECM to recognize new or cleaned part).
- Change ServiceMaxx ID 95171 (CDPF Reset Request) = YES
- NOTE: Should reset value to 0 and this is for new or cleaned DPF’s ONLY.

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IK1200894 - 2010 MaxxForce DT/9/10 Aftertreatment Service

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b.DPF ash cleaning interval chart.
- Service Operation interval – Whichever comes first: Kilometers/miles, months, years, hours
EPA 2010 Emissions CI-4 Oil EPA 2010 Emissions CJ-4 Oil
240,000 km (150,000 mi)
22 months, or 4,500 hours

322,000 km (200,000 mi)
30 months, or 6,000 hours

2. DPF:
• Service guidelines:
a. If DPF Soot Load is at an elevated level (7+), perform 1 additional OBFCT.
b.Watch for temperatures to raise (please note that during high soot load levels the DOC and DPF temperatures will be lower than normally
expected to prevent cracking of
the filter).
c. Additional OBFCT’s may be required to reduce soot load and turn off the DPF lamp.
• Do not continue OBFCT’s if:
a.Other DTC’s trigger during testing.
b.Exhaust temperatures do not increase enough to enter into a dosing (Active) regeneration.
c.Soot Load level is low enough to remove all DPF overload lamp levels.
• DPF face plugging can be traced to the following concerns:
- Air Management System
- Fuel System
- Drive cycle / load factor
- Vehicle application
* Please Refer to: FSX DPF_Reuse_Guidelines.pdf

DPF Outlet Normal Operation

DPF Outlet Coolant Stained - Reusable

3. Oil Ingestion:
-Oil contaminated DPFs can be cleaned with OBFCT if not saturated (DPF outlet completely covered with oil) Follow manufacturer’s cleaning
instructions IK700031 and
before cleaning or replaclement a case file must be opened and an IApprove completed.
- If the DPF is saturated with oil, see FSX oil contamination safety letter.

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IK1200894 - 2010 MaxxForce DT/9/10 Aftertreatment Service

DPF Outlet - Oil Contaminated - Reusable

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DPF Outlet Coolant - Oil Contaminated Reusable

4. Damaged DPF - Open an iApprove Case File if:
- External canister damaged (canister or sealing damage).
- Media damage due to over fueling.

Media Damage from Over Fueling
5. DPF Face Plugging:
- Normal operation.
- A face plugged DPF can be cleaned with OBFCT. Only use a cleaning machine if the engine does not start.

Normal Operation

DPF face plugged – A face plugged DPF can be
cleaned with OBFCT. Only use a cleaning
machine if the engine does not start.

6. Pre DOC / DOC Service Guidelines:
• Pre DOC and DOC face plugging (indicated by poor OBFCT results) can only be cleaned by baking.
• Do not use the DPF Pneumatic Cleaner on these components as damage may result. See DOC Damage as a Result of Improper Cleaning.
• Pre DOC and DOC face plugging can be traced to the following concerns:
- Air Management System
- Fuel System
- Drive cycle / load factor
- Vehicle application

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• If no white smoke and no coolant loss is observed, the pre DOC and DOC are operating normally.
* See photos below of acceptable and not acceptable pre DOC / DOC components:

Pre DOC media damaged - open iApprove Case File

Acceptable Pre DOC

DOC face plugging - Compressed air
cleaning is not permissible - bake only

Pre DOC media face plugged - bake in cleaning
machine

Acceptable DOC

DOC damaged from compressed air cleaning Compressed air cleaning is not permissable - bake
only

7. Cleaning Machine Locator:
- DPF Cleaning Tool Locator
- Navistar Dealer Cleaning Tool Locator – Select 'DPF Cleaning' under 'Show Advanced Options'.
8. AFI Service Guidelines:
- Refer to IK1200753
- Perform DSI de-aeration fuel bleeding procedure with Service Maxx to eliminate air from the AFI fuel supply line. This procedure should be performed
anytime fuel system
service is required including fuel filter service.

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IK1200894 - 2010 MaxxForce DT/9/10 Aftertreatment Service

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Repair Aftertreatment SRT Operations:
NOTE:
Use ONLY SRT operations that are required.

Procedure

SRT Code

Model

DOC Replace (Horizontal Mount)

Hours
1.2

A12-4902

All Models

DOC Replace (Vertical Mount)
DPF Replacement (Horizontal Mount, Under
Cab)
DPF Replacement (Horizontal Mount, Under
Cab)
DPF Replacement (Vertical Mount)

1.3

A12-4904

All Models

0.8

A12-4930

7000

0.6

A12-4932

All Models non 7000

0.9

A12-4934

All Models non 7000

AFI Replacement

1.5

E12-7559T

HC Bus

AFI Replacement

1.5

GY12-7559T

CE/ BE

AFI Replacement

1.6

KL12-7559T

4300, 4400

AFI Replacement

1.6

M12-7559T

7300, 7400, 7500

AFI Replacement

1.5

NH12-7559T

RE/ Motorhome

OBFCT

0.5

GY12-2235A

CE/ BE

OBFCT

0.5

I12-2235A

RE

OBFCT

0.5

KL12-2235A

4300, 4400

OBFCT

0.5

M12-2235A

7300, 7400, 7500

WARRANTY
Locating DPF serial number IK1200272
• Warranty Information:
- WPL2800073 - WPL 12-018G Warranty iApproval Requirements
- WPL2800021 - Diesel Particulate Filter (DPF) Cleaning Reimbursement WPL 11- WPL2800020 - Engine Emission Component Coverage WPL 11-003G
- IK0700031 - DPF cleaning or replacement warranty

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