Navistar 9900 DuraStar LoneStar PayStar ProStar+ TerraStar TranStar WorkStar Service Manual

Navistar 9900 DuraStar LoneStar PayStar ProStar+ TerraStar TranStar WorkStar Exhaust Aftertreatment System with DPF and SCR Service Manual – PDF DOWNLOAD

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Navistar 9900 DuraStar LoneStar PayStar ProStar+ TerraStar TranStar WorkStar Exhaust Aftertreatment System with DPF and SCR Service Manual – PDF DOWNLOAD

Language : English
Pages : 165
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Navistar 9900 DuraStar LoneStar PayStar ProStar+ TerraStar TranStar WorkStar Exhaust Aftertreatment System with DPF and SCR Service Manual – PDF DOWNLOAD

1 DESCRIPTION 1
1 1 THEORY OF OPERATION 7
1 1 1 MaxxForce® DT, 9, 10, 11, 13, and 15 7
1 1 2 MaxxForce® 7 7
1 1 3 Cummins ISX15, ISB and Navistar® N9, N10, and N13 7
1 2 SINGLE HORIZONTAL / HORIZONTAL 8
1 3 SINGLE VERTICAL / VERTICAL 9
1 4 SINGLE HORIZONTAL / VERTICAL 10
1 5 SINGLE UNDER-CAB HORIZONTAL / VERTICAL 11
1 6 SINGLE HORIZONTAL / DUAL VERTICAL 12
1 7 SWITCHBACK / HORIZONTAL 13
1 8 VERTICAL / VERTICAL 14
1 9 IN-LINE 15
2 GENERAL SERVICE INFORMATION 16
2 1 EXHAUST AFTERTREATMENT SYSTEM MODIFICATIONS 17
2 2 GASKETS AND FASTENERS 18
2 3 DIESEL PARTICULATE FILTER (DPF) INDEXING 18
2 4 DPF AND DOC CLEANING 18
2 5 DPF GENERAL INSPECTION 19
2 5 1 DPF Inspection Points 20
2 6 DOC GENERAL INSPECTION 23
2 6 1 DOC Inspection Points 23
2 7 DPF / DOC THREAD REPAIR 27
2 7 1 12 MM Thread Replacement 27
2 7 2 14 MM Thread Replacement 31
2 8 DOC AND DPF REUSE GUIDELINES 35
2 8 1 General Information 35
2 8 2 Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted 36
2 8 3 Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged 37
2 8 4 Diesel Particulate Filter (DPF) Inlet / Outlet – New 38
2 8 5 Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1) 39
2 8 6 Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2) 40
2 8 7 Diesel Particulate Filter (DPF) Inlet – Clean 41
2 8 8 Diesel Particulate Filter (DPF) Inlet – Gouged 42
2 8 9 Diesel Particulate Filter (DPF) Inlet – Ash 43
2 8 10 Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings 44
2 8 11 Diesel Particulate Filter (DPF) Outlet – Soot Stains 45
2 8 12 Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process 46
2 8 13 Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains 47
2 8 14 Diesel Particulate Filter (DPF) Outlet – Face Cracked 48
2 8 15 Diesel Particulate Filter (DPF) Outlet – Coolant Staining 49
2 8 16 Diesel Particulate Filter (DPF) Outlet – Melted 50
2 9 DECOMPOSITION REACTOR TUBE CLEANING 50
2 10 DIESEL EXHAUST FLUID (DEF) DOSING VALVE CLEANING 51
2 11 DEF SUPPLY MODULE FILTER INSPECTION 52
2 12 DIESEL EXHAUST FLUID (DEF) SYSTEM CONTAMINATION 53
2 13 DEF SYSTEM DECONTAMINATION PROCEDURE 56
2 14 DIESEL EXHAUST FLUID (DEF) REFRACTOMETER TOOL 56
2 15 DIESEL EXHAUST FLUID (DEF) DOSING SYSTEM REUSE GUIDELINES 58
2 16 DIESEL EXHAUST FLUID (DEF) TANK DRAINING 61
3 COMPONENT REPLACEMENT 62
3 1 MAXXFORCE® 7, DT, 9, OR 10 SYSTEMS 63
3 1 1 Tubes and Diesel Particulate Filter Differential Pressure (DPFDP) Sensor –
Removal 63
3 1 2 Tubes and DPFDP Sensor – Installation 64
3 1 3 Temperature Sensor – Removal 65
3 1 4 Temperature Sensor – Installation 65
3 1 5 Aftertreatment Control Module (ACM) – Removal 66
3 1 6 Aftertreatment Control Module (ACM) – Installation 67
3 2 MAXXFORCE® 11, 13, OR 15 SYSTEM 68
3 2 1 Tubes and DPFDP Sensor – Removal 68
3 2 2 Tubes and DPFDP Sensor – Installation 69
3 2 3 Temperature Sensor – Removal 69
3 2 4 Temperature Sensor – Installation 70
3 2 5 Sensor Junction Box – Removal 70
3 2 6 Sensor Junction Box – Installation 71
4 SINGLE HORIZONTAL / HORIZONTAL 72
4 1 MAXXFORCE® 7, DT, 9, OR 10 ENGINE 72
4 1 1 Diesel Particulate Filter (DPF) (One-Can System) (Except TerraStar®) – Removal 72
4 1 2 Diesel Particulate Filter (DPF) (One-Can System) (Except TerraStar®) – Installation 73
4 1 3 Diesel Particulate Filter (DPF) (One-Can System) (TerraStar®) – Removal 74
4 1 4 Diesel Particulate Filter (DPF) (One-Can System) (TerraStar®) – Installation 75
4 1 5 Diesel Particulate Filter (DPF) (Two-Can System) – Removal 76
4 1 6 Diesel Particulate Filter (DPF) (Two-Can System) – Installation 77
4 2 MAXXFORCE® 11, 13, OR 15 ENGINE 78
4 2 1 Diesel Particulate Filter (DPF) – Removal 78
4 2 2 Diesel Particulate Filter (DPF) – Installation 79
5 SINGLE VERTICAL / VERTICAL 80
5 1 MAXXFORCE® 7, DT, 9, OR 10 ENGINE 80
5 1 1 Diesel Particulate Filter (DPF) – Removal 80
5 1 2 Diesel Particulate Filter (DPF) – Installation 83
5 2 MAXXFORCE® 11, 13, OR 15 ENGINE 84
5 2 1 Diesel Particulate Filter (DPF) – Removal 84
5 2 2 Diesel Particulate Filter (DPF) – Installation 86
6 SINGLE HORIZONTAL / VERTICAL 87
6 1 MAXXFORCE® 7, DT, 9, OR 10 ENGINE 87
6 1 1 Diesel Particulate Filter (DPF) – Removal 87
6 1 2 Diesel Particulate Filter (DPF) – Installation 89
6 2 MAXXFORCE® 11, 13, OR 15 ENGINE 90
6 2 1 Diesel Particulate Filter (DPF) – Removal 90
6 2 2 Diesel Particulate Filter (DPF) – Installation 91
7 UNDER – CAB HORIZONTAL / VERTICAL 92
7 1 MAXXFORCE® 7, DT, 9, OR 10 ENGINE 92
7 1 1 Diesel Particulate Filter (DPF) – Removal 92
7 1 2 Diesel Particulate Filter (DPF) – Installation 94
7 2 MAXXFORCE® 11, 13, OR 15 ENGINE 95
7 2 1 Diesel Particulate Filter (DPF) – Removal 95
7 2 2 Diesel Particulate Filter (DPF) – Installation 97
8 SINGLE HORIZONTAL / DUAL VERTICAL 98
8 1 MAXXFORCE® 11, 13, OR 15 ENGINE 98
8 1 1 Diesel Particulate Filter (DPF) – Removal 98
8 1 2 Diesel Particulate Filter (DPF) – Installation 99
9 SWITCHBACK / HORIZONTAL 100
9 1 CUMMINS ISX15 OR NAVISTAR® N13 ENGINE 100
9 1 1 Switchback / Horizontal – Removal 100
9 1 2 Switchback / Horizontal – Installation 102
9 1 3 Diesel Exhaust Fluid (DEF) Dosing Valve – Removal 103
9 1 4 Diesel Exhaust Fluid (DEF) Dosing Valve – Installation 104
9 1 5 Decomposition Reactor Tube – Removal 105
9 1 6 Decomposition Reactor Tube – Installation 106
9 1 7 Aftertreatment Assembly Mounting Bracket – Removal 107
9 1 8 Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR)
Assembly Mounting Bracket – Installation 108
9 1 9 Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal 109
9 1 10 Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation 109
9 1 11 Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal 111
9 1 12 Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation 111
9 1 13 Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal 112
9 1 14 Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation 112
9 1 15 Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal 114
9 1 16 Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation 114
9 1 17 Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal 115
9 1 18 Selective Catalyst Reduction (SCR) Temperature Sensors and Module –
Installation 115
9 1 19 Diesel Particulate Filter (DPF) Temperature Sensors and Module – Removal 117
9 1 20 Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation 117
9 1 21 Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal 119
9 1 22 Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation 120
9 1 23 Diesel Particulate Filter (DPF) High Pressure Tube – Removal 121
9 1 24 Diesel Particulate Filter (DPF) High Pressure Tube – Installation 121
9 1 25 Diesel Particulate Filter (DPF) Low Pressure Tube – Removal 122
9 1 26 Diesel Particulate Filter (DPF) Low Pressure Tube – Installation 122
10 VERTICAL / VERTICAL 123
10 1 NAVISTAR® N13 ENGINE 123
10 1 1 Vertical / Vertical 123
10 1 2 Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat
Shield – Removal 124
10 1 3 Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat
Shield – Installation 124
10 1 4 Power Distribution Module (PDM) – Removal 125
10 1 5 Power Distribution Module (PDM) – Installation 125
10 1 6 Aftertreatment Control Module (ACM) – Removal 126
10 1 7 Aftertreatment Control Module (ACM) – Installation 126
11 IN–LINE 127
11 1 CUMMINS ISB ENGINE 127
11 1 1 In–Line 127
12 DIESEL EXHAUST FLUID (DEF) SYSTEM 128
12 1 CUMMINS ISX15 OR NAVISTAR® N13 ENGINE 128
12 1 1 Diesel Exhaust Fluid (DEF) Tank – Removal 128
12 1 2 Diesel Exhaust Fluid (DEF) Tank – Installation 131
12 1 3 Aftertreatment Power Distribution Module (PDM) – Removal 132
12 1 4 Power Distribution Module (PDM) – Installation 132
12 1 5 Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal 133
12 1 6 Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation 136
12 1 7 Diesel Exhaust Fluid (DEF) Tank Lines – Removal 137
12 1 8 Diesel Exhaust Fluid (DEF) Tank Lines – Installation 139
12 1 9 Diesel Exhaust Fluid (DEF) Supply Module – Removal 140
12 1 10 Diesel Exhaust Fluid (DEF) Supply Module – Installation 142
12 1 11 Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal 143
12 1 12 Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation 143
12 1 13 Aftertreatment Control Module (ACM) – Removal 144
12 1 14 Aftertreatment Control Module (ACM) – Installation 145
12 1 15 Diesel Exhaust Fluid (DEF) Tank Bracket – Removal 146
12 1 16 Diesel Exhaust Fluid (DEF) Tank Bracket – Installation 147
12 1 17 Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal 148
12 1 18 Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation 149
12 1 19 Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal 150
12 1 20 Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation 151
12 1 21 Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal 152
12 1 22 Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation 154
12 1 23 Diesel Exhaust Fluid (DEF) System 155
13 ACRONYM LIST 156
TORQUE 157