AllisonWanderland
Advanced Member
I have a 2011 international CE300 (PB105) with 2009 Maxxforce DT (466L - GDT210S) and Allison PTS 2500 transmission.
The bus is bought and the build has started so I must do my best to avoid the common issues experienced with the additional emissions. My goal in the hunt was to avoid 2010 emissions, so I must consider getting a rust free bus with 65K miles on the engine and no blowby a success.
To do this, I will be using the ScanGuage III to monitor the systems to ensure I catch any issues early enough to resolve at a lower cost.
Below is a guide I put together for myself to follow and posting in case others will find use in it.
Feel free to correct or add to the conversation so we can set those up that cannot locate earlier models with success as a community.
2011 International CE300 with 2009 MaxxForce DT Engine and Allison PTS 2500 Transmission Preventative Maintenance Guide
Table of Contents
1. Introduction
This manual provides a detailed guide for maintaining and monitoring your 2011 International CE300 school bus with a 2009 MaxxForce DT engine and Allison PTS 2500 transmission. The goal is to ensure longevity, optimal performance, and early detection of potential issues.
2. Engine Monitoring and Maintenance
2.1 Common Engine Issues
EGR Cleaning Steps:
3. DPF (Diesel Particulate Filter) Maintenance
3.1 Proper Regeneration Intervals
4. Transmission Monitoring and Maintenance
4.1 Nominal Operating Temperatures for the Allison PTS 2500
5. Best Practices for Overall Vehicle Maintenance
6. ScanGauge 3 Usage and Metrics
6.1 Key Metrics to Monitor
The bus is bought and the build has started so I must do my best to avoid the common issues experienced with the additional emissions. My goal in the hunt was to avoid 2010 emissions, so I must consider getting a rust free bus with 65K miles on the engine and no blowby a success.
To do this, I will be using the ScanGuage III to monitor the systems to ensure I catch any issues early enough to resolve at a lower cost.
Below is a guide I put together for myself to follow and posting in case others will find use in it.
Feel free to correct or add to the conversation so we can set those up that cannot locate earlier models with success as a community.
2011 International CE300 with 2009 MaxxForce DT Engine and Allison PTS 2500 Transmission Preventative Maintenance Guide
Table of Contents
- Introduction
- Engine Monitoring and Maintenance
- 2.1 Common Engine Issues
- 2.2 Recommended Metrics to Monitor
- 2.3 Cleaning the EGR and VGT Systems
- 2.4 Understanding Exhaust Gas Temperature (EGT) and Soot Buildup
- 2.5 Fuel Rail Pressure Specifications
- DPF (Diesel Particulate Filter) Maintenance
- 3.1 Proper Regeneration Intervals
- 3.2 Signs of Improper Regeneration
- Transmission Monitoring and Maintenance
- 4.1 Nominal Operating Temperatures for the Allison PTS 2500
- 4.2 Common Problems with the Allison PTS 2500
- 4.3 Maintenance Tips for the Transmission
- Best Practices for Overall Vehicle Maintenance
- ScanGauge 3 Usage and Metrics
- 6.1 Key Metrics to Monitor
- 6.2 Programming Warning Thresholds
1. Introduction
This manual provides a detailed guide for maintaining and monitoring your 2011 International CE300 school bus with a 2009 MaxxForce DT engine and Allison PTS 2500 transmission. The goal is to ensure longevity, optimal performance, and early detection of potential issues.
2. Engine Monitoring and Maintenance
2.1 Common Engine Issues
- EGR Cooler Failures: Caused by excessive soot buildup.
- Turbocharger Failures: Stemming from soot or carbon buildup in the VGT.
- High-Pressure Oil System Issues: Affecting pump and injectors.
- DPF Problems: Resulting in frequent regenerations or engine derates.
- Head Gasket Failures: Due to overheating or coolant issues.
- Sensor Failures: Crankshaft and camshaft position sensors can fail intermittently.
- Coolant Leaks: Poor seals or gaskets.
- Coolant Temperature: Ideal range: 180°F to 220°F.
- Oil Pressure: Monitor for steady pressure during operation.
- Exhaust Gas Temperature (EGT): Normal under load: 500°F to 1,200°F.
- Boost Pressure: Idle: 0-5 psi; Moderate load: 10-20 psi; High load: 20-35 psi.
- Fuel Rail Pressure: Idle: 4,000-6,000 psi; Moderate load: 10,000-15,000 psi; High load: 20,000-26,000 psi.
- Battery Voltage: Healthy range: 12.4V to 14.4V.
- DPF Regeneration Status.
- Transmission Temperature: Normal: 160°F to 200°F.
- Engine Load Percentage.
EGR Cleaning Steps:
- Prepare the Workspace:
- Ensure the engine is off and has cooled down.
- Disconnect the battery to prevent electrical shorts.
- Access the EGR Components:
- Locate the EGR valve, typically mounted on the intake manifold or near the EGR cooler.
- Remove any hoses, connectors, or bolts securing the EGR valve and cooler.
- Inspect the EGR Valve:
- Check for excessive carbon buildup.
- Test the valve’s movement manually; it should move smoothly without sticking. If it’s damaged, replace it.
- Clean the EGR Valve:
- Use an approved diesel EGR cleaner. Spray generously on the valve components.
- Let the cleaner soak for 15-20 minutes to loosen carbon deposits.
- Use a nylon brush or soft scraper to remove stubborn buildup. Avoid damaging the valve seat or any electronic components.
- Clean the EGR Cooler:
- Disconnect the cooler and inspect it for blockages.
- Flush the cooler with a power washer or soak it in an EGR-safe cleaning solution.
- Use pipe brushes to clean the internal passages thoroughly.
- Reassemble the EGR System:
- Reinstall the cleaned components, ensuring all gaskets and seals are intact.
- Tighten bolts to the manufacturer’s specifications and reconnect hoses and electrical connections.
- Test the System:
- Start the engine and let it idle. Check for leaks and monitor EGR functionality with diagnostic tools.
- Prepare for Cleaning:
- Allow the engine to cool and disconnect the battery.
- Remove the intake piping to access the turbocharger.
- Inspect the Turbocharger:
- Check for visible carbon deposits on the vanes and housing.
- Rotate the VGT vanes manually (if accessible) to ensure smooth movement.
- Inspect the actuator (electronic or pneumatic) for proper function.
- Clean the Turbo Vanes:
- Spray the turbo vanes with a diesel-specific turbo cleaner designed to dissolve carbon buildup.
- Let the cleaner soak for the recommended time, usually 15-30 minutes.
- If accessible, use a soft brush to carefully clean the vanes without scratching the surface.
- Reassemble the Turbocharger:
- Reinstall the intake and exhaust connections, ensuring all clamps are tightened securely.
- Replace any gaskets or seals as needed.
- Perform Turbo Calibration (if required):
- Some systems require a recalibration of the VGT actuator after cleaning. Use diagnostic tools to perform this step.
- Test the Turbo:
- Start the engine and monitor boost pressure during a short test drive. Look for consistent and responsive turbo performance.
- High EGT indicates restricted exhaust flow, poor heat dissipation, or incomplete combustion.
- Monitor for consistent spikes or elevated temperatures, which may indicate soot accumulation in the EGR, turbo, or DPF.
- Idle: 4,000-6,000 psi.
- Moderate load: 10,000-15,000 psi.
- High load: 20,000-26,000 psi.
- Regularly monitor using a ScanGauge 3 and address large deviations promptly.
3. DPF (Diesel Particulate Filter) Maintenance
3.1 Proper Regeneration Intervals
- Passive Regeneration: Occurs naturally during sustained high-temperature operation.
- Active Regeneration: Triggered approximately every 300-500 miles.
- Forced Regeneration: Required if the DPF becomes excessively clogged.
- Frequent active regenerations indicate excessive soot production.
- Missed regenerations lead to increased soot load and potential engine derates.
- Monitor soot load percentage and EGT spikes to confirm proper intervals.
4. Transmission Monitoring and Maintenance
4.1 Nominal Operating Temperatures for the Allison PTS 2500
- Normal Range: 160°F to 200°F.
- Maximum: 300°F.
- Warning: Above 250°F requires immediate attention.
- Overheating: Due to low fluid levels, cooler issues, or heavy loads.
- Torque Converter Issues: Resulting in power transfer problems.
- Electrical or Sensor Failures: Stuck in gear or erratic shifting.
- Clutch Wear: Causing slipping or harsh shifting.
- Fluid Contamination: From coolant leaks or debris.
- Valve Body or Solenoid Issues: Leading to erratic shifting.
- TCM (Transmission Control Module) Failures: Resulting in limp mode or improper operation.
- Use Allison-approved fluids (TES 295 or TES 668).
- Replace fluid and filters at recommended intervals.
- Inspect the transmission cooler regularly.
- Avoid excessive idling and heavy loads to prevent overheating.
- Monitor fluid levels and quality (check for discoloration or burnt smell).
5. Best Practices for Overall Vehicle Maintenance
- Perform regular inspections of the EGR, DPF, and turbo systems.
- Use high-quality diesel fuel and replace filters frequently.
- Incorporate highway driving to allow passive DPF regeneration.
- Monitor key metrics like EGT, boost pressure, and fuel rail pressure.
- Address issues early to avoid costly repairs.
6. ScanGauge 3 Usage and Metrics
6.1 Key Metrics to Monitor
- Coolant Temperature
- Normal: 180°F to 220°F.
- Warning Threshold: 230°F.
- Oil Pressure
- Normal: 30-70 psi (varies by RPM).
- Warning Threshold: Below 20 psi.
- Exhaust Gas Temperature (EGT)
- Normal: 500°F to 1,200°F under load.
- Warning Threshold: Above 1,250°F.
- Boost Pressure
- Normal: 10-20 psi under moderate load; 20-35 psi under high load.
- Warning Threshold: Below 5 psi or above 40 psi.
- Fuel Rail Pressure
- Normal: 4,000-6,000 psi (idle); 10,000-26,000 psi (load).
- Warning Threshold: Deviations beyond normal ranges.
- Battery Voltage
- Normal: 12.4V to 14.4V.
- Warning Threshold: Below 12.0V or above 14.8V.
- Transmission Temperature
- Normal: 160°F to 200°F.
- Warning Threshold: Above 250°F.
- DPF Soot Load Percentage
- Monitor for consistent regeneration.
- Warning Threshold: Above 80% load.
- Engine Load Percentage
- Normal: Varies with operation.
- Warning Threshold: Sustained operation above 90% under normal conditions.
- Use the ScanGauge 3 menu to set custom alerts for each metric.
- Refer to the key metrics and thresholds provided above.
- Test the alerts during operation to ensure functionality.