2015 Navistar 9900 Exhaust Aftertreatment System With Scr Service Repair Workshop Manual – PDF Download

Description

2015 Navistar 9900 Exhaust Aftertreatment System With Scr Service Repair Workshop Manual

FILE DETAILS:

2015 Navistar 9900 Exhaust Aftertreatment System With Scr Service Repair Workshop Manual

FILE TYPE:PDF
MANUAL LANGUAGE:ENGLISH
DOWNLOADABLE:YES
PAGES:125

DESCRIPTION:

2015 Navistar 9900 Exhaust Aftertreatment System With Scr Service Repair Workshop Manual

This manual is for general instructions on exhaust aftertreatment systems and removal / installation procedures for diesel particulate filters (DPF), selective catalyst reduction (SCR) systems, and diesel exhaust fluid (DEF) systems. Refer to applicable Engine Diagnostic Manual or Engine Service Manual for specific system inspection and diagnostic procedures. For 2010 vehicles, the Environmental Protection Agency requires a 50% reduction in emissions of nitrogen oxides and a 90% reduction in particulate matter. Oxides of nitrogen are created by the high temperature and speed of combustion. Once in the atmosphere, nitrogen oxide emissions result in ground-level ozone formation and smog. Emission particulates include unburned fuel and lube oil (liquid hydrocarbons), carbon soot from incomplete combustion (main contributor to smoke), water from combustion, and sulfur compounds from the fuel and lubrication oil. To comply with these new regulations, many changes were made to truck specifications, including ultra-low sulfur diesel fuel, the engine, engine oil, vehicle design, and the exhaust system. The new exhaust system treats the engine exhaust and is referred to as an exhaust aftertreatment system. Stainless-steel tubing, used for heat and corrosion resistance, must be used throughout the system

TABLE OF CONTENTS:

2015 Navistar 9900 Exhaust Aftertreatment System With Scr Service Repair Workshop Manual

DESCRIPTION 1
THEORY OF OPERATION 7
Cummins ISX15, ISB6 7 and Navistar® N9, N10, and N13 7
SWITCHBACK / HORIZONTAL 8
VERTICAL / VERTICAL 9
IN-LINE 10
GENERAL SERVICE INFORMATION 11
EXHAUST AFTERTREATMENT SYSTEM MODIFICATIONS 12
GASKETS AND FASTENERS 13
DIESEL PARTICULATE FILTER (DPF) INDEXING 13
DPF AND DOC CLEANING 13
DPF GENERAL INSPECTION 14
DPF Inspection Points 15
DOC GENERAL INSPECTION 18
DOC Inspection Points 18
DPF / DOC THREAD REPAIR 22
12 MM Thread Replacement 22
14 MM Thread Replacement 26
DOC AND DPF REUSE GUIDELINES 30
General Information 30
Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted 31
Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged 32
Diesel Particulate Filter (DPF) Inlet / Outlet – New 33
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1) 34
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2) 35
Diesel Particulate Filter (DPF) Inlet – Clean 36
Diesel Particulate Filter (DPF) Inlet – Gouged 37
Diesel Particulate Filter (DPF) Inlet – Ash 38
Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings 39
Diesel Particulate Filter (DPF) Outlet – Soot Stains 40
Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process 41
Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains 42
Diesel Particulate Filter (DPF) Outlet – Face Cracked 43
Diesel Particulate Filter (DPF) Outlet – Coolant Staining 44
Diesel Particulate Filter (DPF) Outlet – Melted 45
DECOMPOSITION REACTOR TUBE CLEANING 46
DIESEL EXHAUST FLUID (DEF) DOSING VALVE CLEANING 47
DEF SUPPLY MODULE FILTER INSPECTION 49
DIESEL EXHAUST FLUID (DEF) SYSTEM CONTAMINATION 51
DEF SYSTEM DECONTAMINATION PROCEDURE 54
DIESEL EXHAUST FLUID (DEF) REFRACTOMETER TOOL 55
DIESEL EXHAUST FLUID (DEF) DOSING SYSTEM REUSE GUIDELINES 58
DIESEL EXHAUST FLUID (DEF) TANK DRAINING 61
SWITCHBACK / HORIZONTAL 62
CUMMINS ISX15 AND ISB6 7 OR NAVISTAR® N13, N9, AND N10 ENGINES 62
Switchback / Horizontal – Removal 62
Switchback / Horizontal – Installation 64
Diesel Exhaust Fluid (DEF) Dosing Valve – Removal 65
Diesel Exhaust Fluid (DEF) Dosing Valve – Installation 66
i
TABLE OF CONTENTS
TABLE OF CONTENTS (CONT )
Decomposition Reactor Tube – Removal 67
Decomposition Reactor Tube – Installation 68
Aftertreatment Assembly Mounting Bracket – Removal 69
Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly
Mounting Bracket – Installation 70
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal 71
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation 71
Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal 73
Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation 73
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal (If Equipped) 74
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If Equipped) 74
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped) 75
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped) 75
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal 76
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation 76
Diesel Particulate Filter (DPF) Temperature Sensors and Module – Removal 78
Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation 78
Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal 80
Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation 81
Diesel Particulate Filter (DPF) High Pressure Tube – Removal 82
Diesel Particulate Filter (DPF) High Pressure Tube – Installation 82
Diesel Particulate Filter (DPF) Low Pressure Tube – Removal 83
Diesel Particulate Filter (DPF) Low Pressure Tube – Installation 83
VERTICAL / VERTICAL 84
NAVISTAR® N13 ENGINE 84
Vertical / Vertical 84
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal 85
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield –
Installation 85
Power Distribution Module (PDM) – Removal 86
Power Distribution Module (PDM) – Installation 86
Aftertreatment Control Module (ACM) – Removal 87
Aftertreatment Control Module (ACM) – Installation 87
IN–LINE 88
CUMMINS ISB6 7 OR NAVISTAR® N9 AND N10 ENGINES 88
In -Line 88
DIESEL EXHAUST FLUID (DEF) SYSTEM 89
CUMMINS ISX15 AND ISB6 7 OR NAVISTAR® N13, N9, AND N10 ENGINES 89
Diesel Exhaust Fluid (DEF) Tank – Removal 89
Diesel Exhaust Fluid (DEF) Tank – Installation 92
Aftertreatment Power Distribution Module (PDM) – Removal 93
Power Distribution Module (PDM) – Installation 93
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal 94
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation 97
Diesel Exhaust Fluid (DEF) Tank Lines – Removal 98
Diesel Exhaust Fluid (DEF) Tank Lines – Installation 100
Diesel Exhaust Fluid (DEF) Supply Module – Removal 101
Diesel Exhaust Fluid (DEF) Supply Module – Installation 102
Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal 103
Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation 103
Aftertreatment Control Module (ACM) – Removal 104
Aftertreatment Control Module (ACM) – Installation 105
Diesel Exhaust Fluid (DEF) Tank Bracket – Removal 106
Diesel Exhaust Fluid (DEF) Tank Bracket – Installation 107
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal 108
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation 109
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal 110
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation 111
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal 112
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation 114
Diesel Exhaust Fluid (DEF) System 115
ACRONYM LIST 116
TORQUE 117

SCREENSHOT OF THE MANUAL:

2015 NAVISTAR 9900 EXHAUST AFTERTREATMENT SYSTEM WITH SCR SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:

 PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]