Shopping Cart
Shop now
Login
Search for products on our site
See more
Navistar International Exhaust Aftertreatment System with DPF & SCR 9900 DuraStar Official Workshop Service Repair Manual
Navistar International Exhaust Aftertreatment System with DPF & SCR 9900 DuraStar Official Workshop Service Repair Manual
On Sale

Navistar International Exhaust Aftertreatment System with DPF & SCR 9900 DuraStar Official Workshop Service Repair Manual

Regular price $45.00

Navistar International Exhaust Aftertreatment System with DPF & SCR 9900 DuraStar Official Workshop Service Repair Manual

The Best  PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization ! 

This is the COMPLETE Official Service Repair Manual for the Navistar International DPF & SCR.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Navistar.
 

This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 

This Manual contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes, which give you complete step by step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop. 
 

Models And Serials :

exhaust aftertreatment systems
and removal / installation procedures for diesel particulate filters (DPF),
selective catalyst reduction (SCR) systems, and diesel exhaust fluid (DEF) systems.

9900
DuraStar
LoneStar
PayStar
ProStar +
TerraStar
TranStar
WorkStar

CONTENTS : 

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 Proces..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


======================================== 

File Format: PDF 
Compatible: All Versions of Windows & Mac 
Language: English 
Requirements: Adobe PDF Reader & WinZip 

 

Product reviews

Customer Reviews

Based on 1 review Write a review
Click to edit the product in Ali Orders.
Note: only show for shop owner