Authorized Field Change
AFC 12947
Date: February 2013
Subject File: ENGINE
Subject: Removal and Replacement of the MaxxForce® 15 Doser Tube Coolant Return Hose, leak checking
cooler hose assemblies, and replacing if necessary.
Model: PayStar®, ProStar®, 9900 Premium Conventional®
Start Date: 21 December 2010 End Date: 1 April 2012
Engine Family: MaxxForce® 15

DESCRIPTION
Doser Tube Coolant Return Hose assemblies and coolant hoses for certain MaxxForce® 15 engines have
been found to leak. This AFC describes a repair procedure to replace Doser Tube Coolant Return hoses and,
if leaking, coolant hoses with improved hose clamps for all affected MaxxForce® 15 engines.

PARTS INFORMATION
Table 1.

Kit Contents: 7092256C91 — Low Temperature Radiator (LTR) Lower Bypass Kit
Part Number
3014154C1

Table 2.

Description
Hose, Elbow

Quantity
1

3016974C1

Clamp

1

2022867C1

Clamp

1

Kit Contents: 7092257C91 — LTR Supply Hose Kit
Part Number

Description

Quantity

3014155C1

Hose, Elbow

1

3016945C1

Clamp, SAE 15

1

3008685C2

Clamp, SAE 16

1

© 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

1

PARTS INFORMATION (CONT.)
Table 3.

Kit Contents: 7092259C91 — Low Pressure (LP) Cooling Circuit Hose Kit
Part Number

Table 4.

Description

3014225C1

Coolant Adapter

1

3008822C2

Coolant Hose, 24.6 X 55

1

2022867C1

Clamp, 27 mm

1

3016974C1

Clamp

3

7092258C91

Kit, ISC Hoses (Included)

1

3002242C1

Low Pressure Charge Air Cooler (LPCAC)
Coolant Return Hose

1

3008779C2

Clamp, SAE 24

1

3004250C1

Clamp, 30 mm

2

3004369C1

High Pressure Charge Air Cooler
(HPCAC) Coolant Supply and Return
Hose

1

3016974C1

Clamp, 35 mm

1

Kit Contents: 3015974C92 — Coolant Control Valve (CCV) Supply Hose
Part Number

Table 5.

Description
Hose

1

3013733C1

Clamp, SAE LH Clip

2

Kit Contents: 3015976C91 — Fitting Assembly, Water Outlet
Description

Quantity

3015975C1

Water Outlet Fitting

1

3007808C1

O-ring Seal 3–910

2

Doser Components
Part Number
3013830C93
138241
3007325C1

Table 7.

Quantity

3015973C1

Part Number

Table 6.

Quantity

Description

Quantity

Doser Tube

1

Bolt

2

Washer

2

Interstage Cooler Seals
Part Number

AFC–12947

Description

Quantity

1883141C1

O-ring size 2–230 3.5 X 63.09 ID

1

3013030C1

O-ring, size 333

2

2

PARTS INFORMATION (CONT.)
Table 7.

Interstage Cooler Seals (cont.)
Part Number

Table 8.

Description

Quantity

3013029C1

Seal, Inlet Low Pressure Compressor

1

3014369C1

Tube, Extension Diameter 72.2 X 60

1

Equipment Required

Coolant Management Tool KL5007NAV
Table 9.

Tools Required

Regular hand tools

3

AFC–12947

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING
CIRCUIT HOSE LEAK CHECK AND REPLACEMENT FOR MAXXFORCE®
15
WARNING: Park vehicle on hard flat surface, turn the engine off, set the parking brake, and
block the wheels to prevent the vehicle from moving in both directions. Failure to do so may result
in property damage, personal injury, and / or death.

WARNING: If the vehicle must be raised, do not work under the vehicle supported only by
jacks. Jacks can slip or fall over, potentially resulting in property damage, personal injury, and / or
death.

WARNING: Always wear safe eye protection when performing vehicle maintenance. Failure
to do so may result in serious eye injury.

WARNING: Keep flames or sparks away from vehicle and do not smoke while servicing
the vehicle’s batteries. Batteries expel explosive gases. Failure to do so may result in property
damage, personal injury, and / or death.

WARNING: Remove the ground cable from the negative terminal of the battery box before
disconnecting any electrical components. Always connect the ground cable last. Failure to do so
may result in property damage, personal injury, and / or death.

WARNING: To prevent personal injury or death from hot coolant or steam, use only the
following procedure to remove the pressure cap from the surge tank. Allow the engine to cool
first. Wrap a thick, heavy cloth around the cap. Loosen cap slowly and then pause a moment
to allow pressure to release. After the pressure has been released, the pressure cap may be
removed. Failure to follow this warning could result in personal injury and / or death.

NOTE: All of the hoses pertaining to this AFC are one-time use only.

AFC–12947

4

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING CIRCUIT HOSE
LEAK CHECK AND REPLACEMENT FOR MAXXFORCE® 15 (CONT.)

Figure 1.

Cooler Hoses and Clamps Replacement.
1. ISC Hoses Kit 7092258C91. (Contains HPCAC coolant supply / return hose and LPCAC
coolant return hose. This kit number is included in Kit number 7092259C91)
2. ISC Coolant Supply Hose and CCV LTR bypass hose connections at coolant manifold
7092259C91
3. LTR Lower Bypass Kit 7092256C91
4. LTR Supply Hose Kit 7092257C91
5. CCV Supply Hose Assembly Kit 3015974C92

NOTE: Before performing any work on the cooling package system components, be sure to perform
these basic tasks first:

5

AFC–12947

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING CIRCUIT HOSE
LEAK CHECK AND REPLACEMENT FOR MAXXFORCE® 15 (CONT.)
1. Park vehicle on a flat, level surface.
2. Place transmission in neutral (or PARK, if automatic transmission).
3. Set parking brake.
4. Turn off ignition.
5. Install wheel chocks.
NOTE: Replace only the hoses that have leaking connections.
Initial Pressure Leak Test
1. Run engine to get coolant up to operating temperature.
2. Carefully visually inspect for any signs of external coolant leaks.
3. Shut off engine and allow it to cool.
A. If leakage is observed, determine source of coolant leak.
If leakage is from a hose joint covered in this AFC, proceed to Doser Tube Coolant Return
Hose Replacement. If leakage is from another source, repair as necessary.
B. If no leakage was observed, after completing Doser Tube Coolant Return Hose Replacement,
proceed to Inspection of LTR Supply Hose connection to CCV for Over-Insertion section of
AFC.

WARNING: To prevent personal injury or death: Allow engine to cool before removing any
hose connections. Drain coolant before removing any hose connections.
Doser Tube Coolant Return Hose Replacement
1. Disconnect negative battery terminal from battery.
2. Replace doser components listed in Table 6 above. (See Table 6. page 2 )
3. Refer to Aftertreatment System section of the MaxxForce® 15 Service Manual (EGES 510) for instructions
on how to replace tube.
4. If no leakage is found in Initial Pressure Leak Test, proceed to Inspection of LTR Supply Hose connection
to CCV for Over-Insertion section of AFC.
Hose and Clamp Replacements
1. If leak is found on Coolant Control Valve (CCV) Low Temperature Radiator (LTR) Bypass Hose, ISC
coolant supply hose on connection with coolant manifold (Figure 1, Item 2), HPCAC coolant supply and
return hoses, or LPCAC coolant return hose (Figure 1, Item 1), proceed to next step.

AFC–12947

6

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING CIRCUIT HOSE
LEAK CHECK AND REPLACEMENT FOR MAXXFORCE® 15 (CONT.)
2. Remove interstage cooler. Refer to Turbocharger Interstage Cooler (ISC) Assembly in Turbocharger
section of MaxxForce® 15 Engine Service Manual (EGES 510) for instructions on how to remove and
install interstage cooler. Replace Interstage Cooler Seals with parts from Table 7. (See Table 7. page 2 )
3. Remove leaking hose assemblies and replace with new parts.

Figure 2. Proper Placement of Spring Loaded Clamp Release Prongs at ISC Coolant Supply and CCV
LTR Bypass Hose Connections to Coolant Manifold.
1. Correct position of release prongs on ISC coolant supply tube
2. Correct position of release prongs on CCV LTR bypass tube
4. Position clamp release prongs properly (Figure 2, Item 1) when installing ISC coolant supply tube.
Position clamp release prongs properly (Figure 2, Item 2) when installing CCV LTR bypass tube.
5. If leak is found on any connection with LTR Lower Bypass Hose (Figure 1, Item 3), or LTR Supply Hose
(Figure 1, Item 4), proceed to next step.
6. Remove and replace hose assemblies. Refer to Coolant Manifold, ISC Coolant Supply Tube Assembly,
and CCV LTR Bypass Tube Assembly in Exhaust Gas Recirculation (EGR) System section of MaxxForce®
15 Engine Service Manual (EGES 510) for instructions on how to replace these hose assemblies.
NOTE: Parts Kit Number. 7092256C91, Table 1, includes updated spring loaded clamps, as well as worm
gear style clamps. Proper placement of release prongs of spring loaded clamps is critical to allow for
removal and installation.

7

AFC–12947

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING CIRCUIT HOSE
LEAK CHECK AND REPLACEMENT FOR MAXXFORCE® 15 (CONT.)

Figure 3.

Proper Placement of Spring Loaded Clamp Release Prongs.
1. Correct position of release prongs on LTR lower bypass hose.

7. Position spring loaded clamp release prongs properly (Figure 3, Item 1) when installing LTR lower bypass
hose.

AFC–12947

8

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING CIRCUIT HOSE
LEAK CHECK AND REPLACEMENT FOR MAXXFORCE® 15 (CONT.)
Inspection of LTR Supply Hose Connection to CCV for Over-Insertion

Figure 4.

LTR Supply Hose Over-insertion.
1. Hose over-inserted all the way up to Coolant Control Valve body.

1. Inspect LTR Supply Hose for over-insertion (Figure 4, Item 1).

9

AFC–12947

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING CIRCUIT HOSE
LEAK CHECK AND REPLACEMENT FOR MAXXFORCE® 15 (CONT.)

Figure 5.

LTR Supply Hose Properly Installed.
1. Proper hose insertion shown. (hose is not pushed all the way to Coolant Control Valve body)

2. If over-inserted, replace hose and clamp with Kit Part Number 7092257C91. For correct installation,
see Figure 5, Item 1. If no leaks were found from Initial Pressure Leak Test, proceed to Final Pressure
Leak Test section of AFC.
3. If leak is found on either connection of Coolant Control Valve (CCV) Assembly Supply Hose (Figure 1, Item
5), remove and replace hose assembly. Refer to Coolant Control Valve (CCV) Assembly and Coolant
Adapter in Exhaust Gas Recirculation (EGR) System Section of MaxxForce® 15 Engine Service Manual
(EGES 510), for instructions on how to replace hose assembly. New fitting assembly 3015976C91 is
to be used.

AFC–12947

10

DOSER TUBE COOLANT RETURN REPLACEMENT AND COOLING CIRCUIT HOSE
LEAK CHECK AND REPLACEMENT FOR MAXXFORCE® 15 (CONT.)

Figure 6.

Proper Positioning of Water Outlet Fitting at End of CCV Supply Hose.
1. Correct positioning of water outlet fitting at end of CCV supply hose shown.

4. Install water outlet fitting to CCV supply hose properly (Figure 6, Item 1).
5. Reinstall interstage cooler.
Final Pressure Leak Test
1. Using Coolant Management Tool KL5007NAV, refill cooling system.
2. Carefully remove coolant surge tank cap and install surge tank cap adapter, part of Coolant Management
Tool KL5007NAV.
3. Connect clean, dry compressed air (15 psi) to pressure module and open air valve.
4. Carefully inspect for any signs of external coolant leakage.
A. If leakage is observed, determine source of leak.
If leakage is from a hose joint covered in this AFC, return to Hoses and Clamps Replacement
section of AFC. If leakage is from another source, repair as necessary.
B. If no leakage was observed, leak testing is complete.
5. Reconnect negative terminal to battery.
6. Close and secure hood.
7. Remove wheel chocks.

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AFC–12947

LABOR INFORMATION
Operation number must appear on all claims.
Table 10.

Labor Information
Description

Operation No.

Time

A40–12947–1

R&R Doser Coolant Return Line and inspect for leaks

1.8

A40–12947–2

R&R Interstage Cooler

1.3

A40–12947–3

R&R Interstage Cooler Mounting

.1

A40–12947–4

R&R hoses and clamps (per hose)

.1

ADMINISTRATIVE PROCEDURE
Expense is to be charged to Warranty. Claims are to be submitted in the normal manner, making reference to
Authorized Field Change 12947.
It is important that the coding be completed properly to assist in processing the warranty claim. Complete
instructions will be found in the Warranty Policy Manual, Section 7.1.8.
As with all claim submissions, items acquired locally must be submitted in the “Other Charges” tab. The cost
of any bulk items (such as a bag of cable tie straps, roll of wire, barrel of oil, or tube of silicone) should be
prorated for the cost of the individual pieces / amount used during each repair.
To make sure this important improvement is made in a timely manner, all claims for AFC 12947 activity must be
submitted by 28 February 2014 or within the normal warranty period for the vehicle, if after 28 February 2014.

AFC–12947

12