Study Guide

A N AV I S TA R C O M PA N Y

MaxxForceTM Aftertreatment
MaxxForceTM Aftertreatment
Study Guide
TMT-120711

TMT-120711
©2007 International Truck and Engine Corporation
4201 Winfield Road, Warrenville, IL 60555

All rights reserved.

No part of this publication may be duplicated

or stored in an information retrieval system
without the express written permission of
International Truck and Engine Corporation.
 Table of Contents
Introduction...................................................................... 1
Module 1: Aftertreatment System Overview........... 3
Components.................................................................................. 3
Fuel Injector......................................................................... 3
Intake Throttle Valve (ITV)................................................. 4
Exhaust Gas Temperature (EGT) Sensor..................... 4
Exhaust Gas Differential Pressure (EGDP) Sensor... 5
Diesel Particulate Filter (DPF)......................................... 5
Diesel Oxydation Catalyst (DOC).................................. 6
Module 2: Aftertreatment System Operation.......... 7
ECM controlled Operations...................................................... 7
Monitor Function.......................................................................... 7
Regeneration Function................................................................ 8
Passive Regeneration - Low Soot Load........................ 8
Active Regeneration - Moderate Soot Load................ 9
Operator Notification - Full Soot Load..................................10
Parked Regen.............................................................................11
Conclusion...................................................................... 13
MaxxForceTM Aftertreatment
 Introduction 

Introduction
Welcome to the International® 2007 Objectives
MaxxForceTM Aftertreatment Web
Based Training Course. The objective Upon Completion of this .
program, you will be able to:
of this program is to provide you
with specific information about the • Identify AFT component
Aftertreatment (AFT) system used on locations
the 2007 mid-range diesel MaxxForce™ • Recall AFT system
engines. operation
• Utilize AFT system
functions
To recieve credit for completing this
• Perform AFT Diagnostic
training course, you must take a post Procedures
test on ISIS®/Education/Service/Online
Testing.
 MaxxForceTM Aftertreatment

NOTES
 Module 1: Aftertreatment System Overview 

Aftertreatment System Module 1

Overview
MaxxForce™ engines require an
Aftertreatment system to reduce the
amount of particulate matter in the
engine exhaust to meet the 2007
emissions standards.

The Aftertreatment system is made up

of a Diesel Oxydation Catalyst (DOC),
Diesel Particulate Filter (DPF), Exhaust
Gas Temperature (EGT) sensors, and
an Exhaust Gas Differential Pressure
sensor.

Both the DOC and DPF are

constructed of ceramic materials with a
wash coat of precious metals.

Components

The Aftertreatment system consists

of the Fuel Injector, Intake Throttle
Valve (ITV), Exhaust Gas Temperature
(EGT) Sensor, Exhaust Gas Differential
Pressure (EGDP) Sensor, Diesel
Particulate Filter (DPF), and the Diesel
Oxydation Catalyst (DOC).

Fuel Injector

During the active regeneration process,

 Module 1: Aftertreatment System Overview

the ECM commands the injectors to

add fuel to the cylinder during the
exhaust stroke. This causes a very
rich mixture to pass through the AFT
system, which fuels the catalyst and
produces high amounts of heat in the
DOC and DPF, causing soot particles
to be reduced.

Intake Throttle Valve (ITV)

“The Intake Throttle The Intake Throttle Valve (ITV) is

Valve (ITV) is installed on the air intake between
installed on the air the air filter housing and the Exhaust
Gas Recirculation (EGR) mixer. The
intake between the
ITV is used to control the air/fuel
air filter housing mixture during a Regen process of
and the Exhaust the Aftertreatment system. The ITV is
Gas Recirculation common for all medium duty MaxxForce
(EGR) mixer.” engines.

Exhaust Gas Temperature (EGT)

Sensor

The Exhaust Gas Temperature (EGT)

Sensors are inserted into the exhaust
system just in front of the Diesel
Oxidation Catalyst (DOC) (sensor 1)
and immediately before and just after
the Diesel Particulate Filter (DPF)
(sensors 2 and 3).

These sensors produce an electronic

signal based on temperature. The
signals are sent to the Engine Control
 Module 1: Aftertreatment System Overview 

Module (ECM) and are used to regulate

the Aftertreatment function.

Exhaust Gas Differential Pressure

(EGDP) Sensor

The Exhaust Gas Differential Pressure

(EGDP) Sensor utilizes two tap-offs
downstream of the turbocharger. One
tap-off is located before the DPF and
one after.

The EGDP sensor provides a feedback “The EGDP sensor

signal to the ECM indicating the provides a feedback
pressure difference between the inlet signal to the ECM
and outlet of the DPF. This signal is
indicating the
used to calculate the soot level in the
DPF. pressure difference
between the inlet
Diesel Particulate Filter (DPF) and outlet of the
DPF.”
The Diesel Particulate filter (DPF) is
located in the exhaust system under the
vehicle.

In the DPF, exhaust gases are forced

to flow through small passages in the
ceramic material. This allows the DPF
to catch all ash and particulate matter
leaving the DOC.

The DPF allows for oxidation or

regeneration of the stored particulates
once loading gets to a particular level. It
also stores noncombustible ash.
 Module 1: Aftertreatment System Overview

Diesel Oxidation Catalyst (DOC)

The Diesel Oxidation Catalyst (DOC)

is located in the exhaust pipe,
downstream of the turbocharger and
just before the Diesel Particulate Filter
(DPF).

“The DOC uses The DOC uses a series of small

a series of small passages that route the exhaust
gas to come in contact with the
passages that route
precious metals. The DOC reduces
the exhaust gas to the unburned hydrocarbons and
come in contact carbon monoxide (CO) by burning
with the precious (oxidizing) them over a catalyst. This
metals” catalyst aids the reaction of the CO
and hydrocarbons with the remaining
oxygen in the exhaust gas. This
process can be used to increase the
temperature of the exhaust system.
 Module 2: Aftertreatment System Operation 

Aftertreatment System Module 2

Operation
The Aftertreatment system operates
using the Engine Control Module
(ECM), three Exhaust Gas Temperature
(EGT) Sensors, Exhaust Gas
Differential Pressure (EGDP) Sensor,
Intake Throttle Valve, Fuel Injectors,
Operator Indicator Lamps, Operator
Parked Regen Switch, Optional
Operator Regen Inhibit Switch.

ECM Controlled Operations

During Aftertreatment operation the

ECM monitors the Aftertreatment
sensors for proper operation, controls
the Active Regeneration Process,
monitors the level of soot accumulation
in the DPF, allows the operator to enter
Parked Regen mode when directed
by the indicator lamps, and allows the
operator to override Parked or Active
Regen mode (optional on ambulances,
ect.).

Monitor Function

There are four levels of indication

that the vehicle’s exhaust filter is
accumulating soot and needs to be
cleaned, each with an increasing
 Module 2: Aftertreatment System Operation

urgency for action.

Level 1: Regen required, drive at

highway speeds or pull vehicle safely
off the roadway and start Parked Regen
to prevent loss of engine power.

Level 2: Pull vehicle safely off the

roadway and start Parked Regen to
prevent loss of engine power.

Level 3: WARNING! Pull the vehicle

safely off the roadway and start
Parked Regen to prevent loss of
engine power.

Level 4: WARNING! Pull the vehicle

safely off the roadway, turn on the
emergency flashers, place warning
devices. DO NOT USE Parked
Regen. Call for Service.

Regeneration Function

“Periodically, Periodically, the soot and ash

the soot and ash particulates in the DPF must be burned
off. This process is called Regeneration
particulates in the
and it can occur during passive or
DPF must be burned active Regen. It will also occur during a
off.” driver-initiated Parked Regen.

Passive Regeneration - Low Soot

Load

When the AFT system reaches the

 Module 2: Aftertreatment System Operation 

Low Soot Load level, the DPF indicator

lamp will illuminate, indicating that DPF
Regen is required. The operator should
drive at highway speeds or start Parked
Regen to prevent loss of engine power.

Passive Regeneration or Regen of the “Passive

AFT System occurs when the exhaust Regeneration or
system gets hot enough to ignite the Regen of the AFT
soot particles in the DOC and the
System occurs
DPF. This automatically cleans, or
regenerates, the ceramic material in the
when the exhaust
DPF. The advantage of Passive Regen system gets hot
is that soot is burned to ash without enough to ignite the
additional fuel being introduced into the soot particles in the
system. DOC and the DPF.”

Passive Regen starts to occur at

catalyst temperatures of about 270° C.
Higher temperatures will increase the
efficiency of Passive Regen with the
most efficient Regen occurring anytime
the temperature is above 550° C.

When passive Regen occurs, it does

not necessarily mean the soot level in
the DPF goes down.

Active Regeneration - Moderate

Soot Load

During the Active Regeneration or

Regen process, the ECM commands
the injector to inject extra fuel into the
cylinder during the exhaust stroke. The
10 Module 2: Aftertreatment System Operation

catalytic reaction between the fuel

and the precious metals in the DOC
creates heat, raising the temperature in
the DOC and the DPF. This increase
in temperature will cause the soot
particles to be turned to ash.

“Active Regen is Active Regen is initiated when the

initiated when the ECM senses Regen is required
and the vehicle is within the correct
ECM senses Regen
operating conditions. Active Regen
is required and the can be necessary in cold climates or
vehicle is within the during light duty cycles in which normal
correct operating operating temperatures are not always
conditions.” reached.

When the Diesel Particulate Filter

(DPF) becomes full, the DPF indicator
lamp will begin to flash, notifying the
operator to pull the vehicle safely off
the roadway and start Parked Regen to
prevent loss of engine power.

The Exhaust High Temperature (EHT)

lamp illuminates to indicate that system
temperatures are high enough to
support Regeneration.

Operator Notification - Full

Soot Load

When the DPF becomes so full that

it causes engine performance to be
limited, the yellow “CHECK ENGINE”
lamp will illuminate and the DPF
 Module 2: Aftertreatment System Operation 11

indicator lamp will continue to flash.

The engine may moderately de-rate or
lose power.

The operator should pull the vehicle

safely off the roadway and start Parked
Regen to prevent the engine from
stopping.

Operator Notification - Over-

Full Soot Load

If the DPF is allowed to become over- “If the DPF is

full, a serious engine problem has allowed to become
occurred, the red STOP ENGINE lamp over-full, a serious
will illuminate, and the engine may shut engine problem has
down soon.
occurred, the red
The operator must pull the vehicle STOP ENGINE lamp
safely off the roadway, turn on the will illuminate, and
emergency flashers, place warning the engine may shut
devices, and STOP THE ENGINE. down soon.”

Do NOT use Parked Regen, call for

service.

Parked Regen

There is a third, driver-initiated method

referred to as Parked Regen. When
the opportunities for effective passive
and active strategies aren’t adequate
enough to reduce the soot level, Parked
Regen is required. Parked Regen will
raised the engine RPM, inject extra fuel
12 Module 2: Aftertreatment System Operation

into the cylinders, and close the Intake

Throttle Valve as required to raise
exhaust temperatures for Regen.

To perform a Parked Regen, you must

park the vehicle safely off the roadway
away from any flammable materials.
Before initiating Parked Regen (by
pressing the Parked Regen switch),
you must set the parking brake, put the
transmission in neutral (manual) or park
(automatic), and have no foot pedals
applied.

NOTE: If any of the above conditions

are altered during the Parked Regen
process, Regen will be halted and must
be restarted.

Press and hold the PARKD REGEN

switch for 2 seconds to initiate the
Regen cycle. The engine speed will
automatically ramp up to a preset RPM
and the switch indicator will illuminate
solidly when the cycle is started. If the
indicator is blinking, check to be sure
that all conditions in step 2 are met.
Once started, the Regen cycle will last
approximately 20 minutes under normal
operating conditions. This will vary
according to the vehicle drive cycle.

NOTE: In the event of an emergency

situation where the vehicle must be
moved after beginning Parked Regen,
 Module 2: Aftertreatment System Operation 13

press the PARKD REGEN switch OFF

to cancel Parked Regen.

When the Regen cycle is complete,

the switch light will go off, the engine
RPM will return to normal idle and the
AFT and EOT indicators should go off
(this may take some driving as the ECM
must sample the AFT Sensor signals
over time). The vehicle may now be
driven normally.

System Maintenance

The DPF is designed to last at least “The DPF is

150,000 miles before it must be designed to last at
removed from the vehicle and cleaned least 150,000 miles
by the International dealer. Additional
before it must be
servicing may be required at 100,000
mile intervals. removed from the
vehicle and cleaned
Note: See vehicle Operator’s by the International
Manual for service and maintenance dealer.”
procedures for the DPF.

Conclusion

This concludes the International®

MaxxForceTM Aftertreatment WBT. The
information and techniques presented
here are pivotal when becoming a
certified International® technician. You
are now required to take a post-test
via ISIS®/Education/Service/Online
Testing.
14 MaxxForceTM Aftertreatment

NOTES
MaxxForceTM Aftertreatment 15

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16 MaxxForceTM Aftertreatment

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MaxxForceTM Aftertreatment 17

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