Overheating or DPF Regeneration issue ?

[plumcrazy]

We have a Mobile Shredding truck that is a 2009 International Durastar box truck with MaxxForce DT engine. It has a 100hp shredder in it that runs off the pto. We bought this truck used and are learning of all the issues...

First issue; the truck started to overheat while driving down the highway. My driver pulled over and let it cool, never got over 230. We replaced the radiator cap as soon as he got to next town. The truck was already scheduled for a transmission service so we had the shop test the fan clutch too which they stated was operating correctly. We have changed Coolant to Zerex heavy duty extended life formula "Diesel Ready". Now the driver has to pull over 2 or 3 times going up this same route.

Second issue; Regeneration light indicates it needs regenerating atleast 2 times weekly. The darn thing will run the regeneration for 25-40 minutes and never overheats the engine ( operates between 170 - 200 degrees) and completes the cycle but seems to want to regenerate frequently. (the first 4 months we owned the truck it only indicated a parked regen. was needed 1 time) now it seems constant.

Lastly, we changed the oil & filter since we did not have any history on last oil change. New oil is Delo Heavy Duty 400LE API CJ-4/SM 15w-40 and since the oil change the truck is now blowing black smoke/soot out the stack when taking off and/or when the shredder is running on the pto during higher rmp intervals. (shredder runs at 1700 rpms standard)

Oh and the truck has 171,000 miles on it (we have put 3,500 miles since November)

So I guess my question is...Any idea as to why it is suddenly smoking after the oil change? And, any help with this regeneration issue and overheating issue would be appreciated.

Thanks guys...

 

[Nebroch]

DPF + black smoke doesn't sound too good. Properly working engine with that filter shouldn't show any visible soot.

Combining overheating to that issue suggests that injection timing is way off or EGR isn't working.

 

[Rand]

major engine issues. Probably about ready for a new one.

oil change is unrelated.

Maybe got sold a dud.

 

[plumcrazy]

When driven around town and on flat highway, it doesn't overheat. Only when driver has to go up the hill (change in elevation of 2,400 feet).

Wondering if clogged DPF could be causing overheating and black smoke and constant regeneration light?

 

[Boomer]

DPFs will eventually fill up with non-combustible stuff which is why they usually require a special low SAPS oil. Are you/the previous owner using the right oil? Once the DPF reaches its limits, it has to be taken out and cleaned and/or replaced.

Also, this kind of behavior can indicate a problem with the turbocharger (smoke, loss of power, etc)

 

[Fleetmon]

It sounds like the DPF is clogged....I think the some of the Maxforce engines suffered premature DPF failures IIRC. A backpressure check would be the next step.

 

[440Magnum]

Sounds like the DPF has outright failed (it shouldn't allow visible soot to get through). The engine shouldn't be producing MUCH soot for the DPF to trap anyway, but the fact that it is doing so now could (possibly) be due to the failed DPF being the proverbial potato in the tailpipe.

Are you in an area where a DPF delete is even something that could be considered?

And you did say its a MaxxDT (DT-466 based) and not a 6.0 or 6.4 MaxxForce, right? I wouldn't throw the ENGINE under the bus so readily if its indeed a DT as I would if its a 6.4.

Whatever it is, the truck is a big enough investment that some careful diagnosis is warranted. A failed DPF can cascade to lots of other symptoms- loss of power, overheating, maybe even excessive sooting.

 

[plumcrazy]

Yes it is the MaxxDT and this is a huge investment for our small company. Just based on reading some other forums and one based on another shred truck (on this forum) I too am thinking the DPF is part of our problem, atleast with the smoke problem.

We are in Southern New Mexico which does not test emissions; however, the DOT pull trucks over constantly...don't know if they check DPF or not but this is a ticket happy county. I'll look up the fine first, then consider removal.

On the overheating, it's not the thermostat so the next thing we are checking is water pump and probably gonna remove the radiator and have it cleaned.

Any other suggestions are appreciated, and by the way this is a great forum with tons of knowledge and help and we really appreciate it. I will post results of our problem when we figure it out...perhaps it will help someone else in the future.

 

[plumcrazy]

We'll add that to our list of things to check, thanks for the response.

 

[artificialist]

The engine wears out, lets too much oil into the DPF, then the DPF is constantly regenerating. The engine then enters regeneration mode, floods the engine with fuel too often, and wears out the rings. Then even more oil enters the DPF and a vicious cycle happens.

Powerstrokehelp explains it in this video:
https://www.youtube.com/watch?v=KLsDTW5Y8Ao&list=UUQz2vFEc1m-WGKf6g-pz9DA

I'm not sure if the MAXXforce engine you have is related, but the physics are the same.

 

[Solarent]

Originally Posted By: Fleetmon
It sounds like the DPF is clogged....I think the some of the Maxforce engines suffered premature DPF failures IIRC. A backpressure check would be the next step.


I would take the filter from the DPF out and have it cleaned and checked. If it's cracked or failed completely it will need to be replaced. (the shop who does the cleaning should have a series of tests it can do to check the filter)

Sounds most likely (as was said) that the wrong oil was used, the filter is clogged and its having issues. This should be taken in ASAP though because I've seen similar issues turn into cabin fires if it gets too bad.

 

[440Magnum]

Originally Posted By: artificialist
The engine wears out, lets too much oil into the DPF, then the DPF is constantly regenerating. The engine then enters regeneration mode, floods the engine with fuel too often, and wears out the rings. Then even more oil enters the DPF and a vicious cycle happens.

Powerstrokehelp explains it in this video:
https://www.youtube.com/watch?v=KLsDTW5Y8Ao&list=UUQz2vFEc1m-WGKf6g-pz9DA

I'm not sure if the MAXXforce engine you have is related, but the physics are the same.


He has a MaxxForceDT, which is based on the (very) old International DT466 engine. Straight six, 466 to 509 cubic-inch, wet-sleeve, in-chassis rebuildable, "forever" engine, not a limited life automotive-style engine like the MaxxForce v8s. Which is why I strongly suspect that its an accessory problem more likely than a problem with the block or rotating assembly itself. That said, I actually don't know if Navistar implemented regeneration the same way on the MaxxDT as they did on the MaxxForce V8s (firing the injector on the exhaust stroke, which is what damages the engine hardware by washing down the cylinders and overheating exhaust valves). I thought that the DT had a dedicated regen injector in the exhaust plumbing, but I could be wrong.

 

[Michael_P]

MaxxForce DT engines struggle to regen and can overheat when the EGR cooler goes bad. This is a known problem and International has extended the warranty on EGR coolers for some models.