EngineOperationandMaintenanceManual MaxxForce …

1 MaxxForce DT,9,&100000001837 EPA10,2013HD-OBD-US,Canada,Mexico4328100 R3 March2015 MaxxForce DT,9,&10 EngineOperationandMaintenanceManualNavis tar, ,Lisle,IL60532 USA 2015 Navistar, ,specifications, , ,liability, sregisteredowner,or,inthealternative,bya notherindividualorentityauthorizedbyther egisteredowner,( ,InternationalDealer) ,birthdefects, ,terminalsandrelatedaccessoriescontainle adandleadcompounds, REQUIREMENTSFORFUEL,ENGINEOIL, (ULSD).. (B6toB20).. (ELC) INSTRUMENTS,INDICATORS, (AWL)..37 REDStopLamp(RSL)..37 HighExhaustSystemTemperature(HEST) (DPF) (MIL).. (AFT) (Federal-Optional)..51 EngineIdleShutdownTimer(California-Stand ard).. (CAP).. (RSE)..55 RoadSpeedLimiting(RSL).. (CAC).. (IfEquipped).. , (ELC) , ,specifications, :Photoillustrationsidentifyspecificparts orassembliesthatsupporttextandprocedures ; ,refertotheapplicable: , , , ,symbols,orfeaturedescriptionswillnotbea vailableforallapplications, , , ,tools,andservicepartsareinvolved, ,Warnings,Cautions, ,cautions,andnotescanleadtoinjury, :Warning,Caution, :Awarningdescribesactionsnecessarytoprev entoreliminateconditions,hazards, :Anotedescribesactionsnecessaryforcorrec t, Keepworkareaclean,dry,andorganized.

2 Keeptoolsandpartsoffthefloor. Makesuretheworkareaisventilatedandwellli t. Usecorrectliftingdevices. Wearprotectivesafetyglassesandshoes. Wearcorrecthearingprotection. Wearcottonworkclothing. Wearsleevedheatprotectivegloves. Donotwearrings,watchesorotherjewelry. Shifttransmissiontoparkorneutral,setpark ingbrake,andinstallwheelchocksbeforedoin gdiagnosticorserviceprocedures. Theengineshouldbeoperatedorservicedonlyb yqualifiedindividuals. Providenecessaryventilationwhenoperating engineinaclosedarea. Keepcombustiblematerialawayfromengineexh austsystemandexhaustmanifolds. Installallshields,guards,andaccesscovers beforeoperatingengine. ,putprotectivescreensoverallopeningsbefo reservicingengine. Shutengineoffandrelieveallpressureinthes ystembeforeremovingpanels,housingcovers, andcaps. Ifanengineisnotsafetooperate, Wood,paper,textiles, ElectricalequipmentBatteries Alwaysdisconnectthemainnegativebatteryca blefirst.

3 Alwaysconnectthemainnegativebatterycable last. Avoidleaningoverbatteries. Protectyoureyes. Donotexposebatteriestoflamesorsparks. UseanOSHA approvedblowgunratedat207kPa(30psi). Limitshopairpressureto207kPa(30psi). Wearsafetyglassesorgoggles. Wearhearingprotection. Useshieldingtoprotectothersintheworkarea . Makesurealltoolsareingoodcondition. Makesureallstandardelectricaltoolsaregro unded. Useextremecautionwhenworkingonsystemsund erpressure. Donotsmokeintheworkarea. ,Parts,andEquipment Reinstallallsafetyguards,shields,andcove rsafterservicingtheengine. Makesurealltools,parts, (whichevercomesfirst): 5years 100,000miles(160,000km) Orifcoveredbyanybasicorextendedwarranty( ifgreaterthanabove) ,serviceclass, , , , ,labor, , ,neglect,impropermaintenance, servicepartsorMaxxForce ReNEWed , , , (includingdiagnostics)forthefollowing: Replacementpartsthatdonotexceedmanufactu rer'ssuggestedretailprice.

4 Laborchargesbasedonmanufacturer' PartsotherthanMaxxForce servicepartsorReNEWed parts. Aftermarketpartsorservicekits Non-defectivepartsreplacedbyanunauthoriz edserviceprovider. Partsrequiringreplacementatinspectionora djustmentmaintenanceintervalsforreasonso therthanbeingdefective. ,engine,andpartmalfunctionscausedbythefo llowing: Useofincorrectfuel,engineoil,orcoolant Failuretomaintaincorrectmaintenancesched ule Incorrectadjustments,modifications,alter ations,tamperingordisconnectionofvehicle components. AbuseormisuseofenginePage8 WARRANTY Accidents, Lossoftime,inconvenience,useofvehicle/en gineorcommercialloss. , , , ,CustomerRelationsNavistar, ,IL60532(Telephone1-800-448-7825)Califor niaEmissionSystemWarrantyWARRANTYPERIODT heCaliforniaAirResourcesBoardandNavistar , ,newmotorvehiclesmustbedesignated,builta ndequippedtomeettheState , (whichevercomesfirst): 5years 100,000miles(160,000km) 3,000hours Orifcoveredbyanybasicorextendedwarranty( ifgreaterthanabove)Yourmedium-heavydutyd ieselengineconformstoapplicableCaliforni aAirResourcesBoard(CARB) ,serviceclass, , , , ,aclaimmaybedeniedifNavistardemonstrates thatthe(engine/vehicle)hasbeenabused,neg lected,orimproperlymaintained,andthatsuc habuse,neglect, ,orthatfailtomeettherequirementsintheCal iforniaCodeofRegulations,Title13,Section s2700to2706, ,labor, , , ,neglect,impropermaintenance, servicepartsorMaxxForce ReNEWed , , , (includingdiagnostics)forthefollowing.

5 Replacementpartsthatdonotexceedmanufactu rer'ssuggestedretailprice. Laborchargesbasedonmanufacturer' ,Navistar, ,includingdiagnosis,parts, , , (exceptmedium-dutyvehicles),andmotorvehi cleenginesusedinsuchvehicles,aperiodofus eoffiveyears,100,000miles,or3,000hoursof operation, ,innocasemaythisperiodbelessthanthebasic mechanicalwarrantythatthemanufacturerpro vides(withorwithoutadditionalcharge) , ,registeredandcertifiedforsaleinCaliforn ia,havethefollowingitemscoveredbytheemis sionwarrantywhenfirstinstalledontheengin easoriginalequipmentbyNavistar,Inc: Fuelinjectionsystem Airinductionsystem(includesturbocharger, exhaustmanifold,ExhaustGasRecirculation[ EGR]system,EGRrateandfeedbackcontrolsyst em,andintakemanifold) Positivecrankcaseventilationsystem(inclu desCrankcaseVentilationValve[CCV]andoilf illcap) DieselParticulateControlSystem(includesc atalyticconverter,traps,fueladditivedevi ces,andotherdevicesusedtoregenerateoraid intheregenerationoftheparticulatecontrol device) ,clamps, ,belts, ,temperature, : PartsotherthanMaxxForce servicepartsorMaxxForce ReNEWed parts Aftermarketpartsorservicekits Non-defectivepartsreplacedbyotherthanyou rdealerPage11 WARRANTY Partsrequiringreplacementatinspectionora djustmentmaintenanceintervalsforreasonso therthanbeingdefective Replacementofexpendableitemsmadeinconnec tionwithscheduledmaintenanceVehicle,engi ne,andpartmalfunctionscausedbythefollowi ng.

6 Useofincorrectfuel,engineoil,orcoolant Failuretomaintaincorrectmaintenancesched ule Incorrectadjustments,modifications,alter ations,tamperingordisconnectionofvehicle components Abuseormisuseofengine Accidents, : Lossoftime,inconvenience,useofvehicle/en gineorcommercialloss , , ,CustomerRelationsNavistar, ,IL60532(Telephone1-800-448-7825)Iffurth erquestionsofwarrantyrightsandresponsibi litiesremain,contact:TheAirResourcesBoar d9528 TelstarAvenueElMonte,California91731 Page12 SECTION1 ENGINESYSTEMSE ngineSerialNumberFigure1 EngineserialnumberlocationTheengineseria lnumberisintwolocations: Stampedontherightsideofthecrankcase,just abovetheoilfilterheader. DT:466HM2U3300001 MaxxForce 9and10:570HM2U3300001 EngineSerialNumberCodes466 Enginedisplacement570 EnginedisplacementH Diesel,turbocharged,ChargeAirCooler(CAC) andelectronicallycontrolledM2 MotortruckU UnitedStates7digitsuffix Engineserialnumbersequencebeginningwith3 300001 Page13 SECTION1 (EPA)exhaustemissionlabel(example) (EPA) : Modelyear Enginefamily,model,anddisplacement Advertisedbrakehorsepowerandtorquerating Emissionfamilyandcontrolsystems Valvelashspecifications Engineserialnumber EPA,EURO,andreservedfieldsforspecificapp licationsEngineAccessoryLabelsandIdentif icationPlatesThefollowingengineaccessori esmayhavemanufacturer'slabelsoridentific ationplates.

7 Aircompressor Airconditioningcompressor Alternator Coolingfanclutch Powersteeringpump Startermotor EngineControlModule(ECM)Page14 SECTION1 ENGINESYSTEMSE ngineSpecificationsMaxxForce DT,9,&10 EnginesEngineConfiguration4stroke,inline sixcylinderdieselAdvertisedbrakehorsepow er@rpmSeeengineemissionlabelPeaktorque@r pmSeeengineemissionlabelDisplacement MaxxForce DTengines MaxxForce (466in3) (570in3)Compressionratio MaxxForce DTengines MaxxForce :1 Stroke MaxxForce DTengines MaxxForce 9and10engines119mm( )146mm( )Bore(sleevediameter) ( )Firingorder1-5-3-6-2-4 AspirationDualturbochargedandchargeairco oledCombustionsystemDirectinjectionturbo chargedFuelsystemElectro-hydraulicinject ionPage15 SECTION1 ENGINESYSTEMSMaxxForce DT,9,&10 EnginesLubesystemcapacity(includingfilte r)Lubesystemcapacity(overhaulonly,withfi lter)28L(30qtsUS)132L(34qtsUS)2 Enginelubricationoilpressureatoperatingt emperaturewithSAE10W-30oil Lowidle Highidle15psi(103kPa)minimum50psi(344kPa )minimumIdlespeed(noload)700rpm 50(nonadjustable)Thermostatoperatingtemp erature96 C(205 F) ENGINESYSTEMSE ngineDescriptionMaxxForce DT,9,&10enginesareinlinesixcylinderdiese lengineswhichhavebeendesignedforincrease ddurability,reliability, DT,9,& (CAC) ,theMaxxForce DT,9,& (EGR) (IAH) , ,pushrods,rockerarms, ,9, DT,9,& ,fuelinjectors, , (ECM)

8 (HD-OBD) (GVWR)of14, ,theMalfunctionIndicatorLamp(MIL) , (CKP)sensorandtheCamshaftPosition(CMP)se nsorareusedbytheECMtocalculaterpm,fuelti ming,fuelquantity, ,strainer,filter,drainvalve,WaterinFuel( WIF)sensor,andEngineFuel(EFP) , , (AFT) (soot)usingaDieselParticulateFilter(DPF) . ,seeAftertreatmentSystem(page50).ColdAmb ientProtection(CAP)CAPkeepstheenginewarm duringcoldtemperaturesandmayprovidebette rfueleconomy,increasedoperatorcomfort, C(32 F),coolanttemperatureisbelow65 C(149 F), ,seeColdAmbientProtection(CAP)(page54).P age19 SECTION1 (EST)InterfaceEnginesareequippedwiththeE STinterfaceforcommunicationbetweentheEng ineControlModule(ECM) , (CAN) ,throughthepublicCAN,isabletoretrieveDia gnosticTroubleCodes(DTCs),rundiagnostict ests,andviewParameterIdentifiers(PIDs) : Transmissionofengineparameterdata TransmissionandclearingofDTCs Diagnosticsandtroubleshooting Programmingperformanceparametervalues Programmingengineandvehiclefeatures ,numberofteethonthetailshaft,rearaxlerat io, (EST)withServiceMaxx (CMP)sensorandCrankshaftPosition(CKP) (ECI) (overspeed),lowcoolantlevel,highcoolantt emperature, (ECT) C(158 F)at700rpmtobelow-10 C(14 F) (EST) ,actuators,electroniccomponents, ,andaredisplayedasDiagnosticTroubleCodes (DTCs) , (A/C) (EWPS)EWPS isdesignedtoprotecttheenginefromdamageby monitoringcriticalenginedatasuchasengine speed,temperature,oilpressure, (IST)Federal-OptionalorCalifornia-Standa rdISTallowstheEngineControlModule(ECM) ,allNavistar andMaxxForce enginescertifiedforsaleinthestateofCalif orniawillconformtomandatoryCaliforniaAir ResourcesBoard(CARB)EngineShutdownSystem (ESS) (non-California)

9 FederalNavistar andMaxxForce ,seeEngineShutdown(page51).PowerTakeOff( PTO)InCabPowerTake-off(PTO)ControlTheinc abenginespeedcontrolfeature,commonlyrefe rredtoasPowerTake-off(PTO), (ECM)providein-cabenginespeedcontrolrela tedoptionsthatcanbeadjustedtosuitthecust omer' (RESC)RESC,commonlyreferredtoasremotePTO , 'scab, ,theRESC featureincludestwoadditionalswitches(rem otepresetandremotevariable) ' ENGINESYSTEMSR adiatorShutterEnable(RSE) (RSL) (ECM)providevehiclespeedgovernorrelatedo ptionsthatcanbeadjustedtosuitthecustomer ' interval inthiscaseisusedtodescribethedistance,ti me, (page72).Page23 SECTION1 (245 HPandabove) (245 HPandabove) (location) (EGR) (fuelstrainerlocation) (EGR) (fuelstrainerlocation) (EGR) (ECM) (EGR) (EGR) (2) REQUIREMENTSFORFUEL,ENGINEOIL,ANDCOOLANT FuelULTRALOWSULFURDIESEL(ULSD)GOVERNMENT REGULATION:Dieselfuelsoldforusein2007and laterhighwayvehiclesmustbelimitedtoasulf urcontentof15partspermillion(ppm).

10 Figure8 AmericanPetroleumInstitute(API)DieselPum pLabelTheAPID ieselPumpLabeliscompliantwithEnvironment alProtectionAgency(EPA) (ULSD)fuelisrequiredforallNavistar andMaxxForce (currentyearrevision),includingtheEPAspe cificationforsulfurcontent( ). ; Offroaddieselfuel LowSulfurDiesel(LSD) (500ppm) CommercialJetAorJP8aviationfuel Heatingorfurnaceoil BiodieselB100(neatbiodiesel) Biodieselblendshigherthan20% ,animalfats, REQUIREMENTSFORFUEL,ENGINEOIL,ANDCOOLANT ACCEPTABLEFUELBLENDS Ultralowsulfurkerosene( ) LowerbiodieselblendsuptoB5(ablendof5%nea tbiodieselwith95%dieselfuel).Suchblendsh avecharacteristicsindistinguishablefromd ieselfuel,ifthetwocomponentsmeettherequi rementsoftheirrespectivestandards:ASTMD6 751currentrevision,forneatbiodieselandAS TMD975currentrevision, ,2008blendsofupto5%biodieselareincludedi nthedieselfuelstandardASTMD975-08a.(D975 -08adesignatesthe2008revisionofthestanda rd.)