Related Manuals for Navistar MaxxForce DT
Summary of Contents for Navistar MaxxForce DT
- Page 1 ® MaxxForce DT, 9, & 10 Engine Operation and Maintenance Manual Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532 USA © 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
- Page 2 The information, specifications, and illustrations contained in this manual are based on data that was current at the time of publication. Navistar, Inc. reserves the right to make changes and/or improvements at any time without notification, liability, or without applying those changes or improvements to vehicles previously manufactured and/or sold.
-
Page 3: Table Of Contents
TABLE OF CONTENTS FOREWORD..................1 SAFETY INFORMATION..............3 WARRANTY..................7 Federal Emission System Warranty............... . 7 Warranty Period. - Page 4 TABLE OF CONTENTS Engine Features................... .19 Engine Optional Features.
- Page 5 TABLE OF CONTENTS Wait to Start Lamp................... . .35 Idle Shutdown Indicator.
- Page 6 TABLE OF CONTENTS Cold Ambient Protection (CAP)................54 Hot Weather Operation.
- Page 7 TABLE OF CONTENTS Induction System...................81 Extended Life Coolant (ELC) Extender.
-
Page 9: Foreword
This manual contains information needed to correctly operate in a photo illustration may not be exact. and maintain your engine as recommended by Navistar, Inc. Numerous illustrations, symbols and feature descriptions This manual includes necessary information and specifications are used to aid in understanding the meaning of the text. - Page 10 FOREWORD Page 2...
-
Page 11: Safety Information
SAFETY INFORMATION Safety Information Safety Instructions Work Area This manual provides general and specific maintenance procedures essential for reliable engine operation and your • Keep work area clean, dry, and organized. safety. Since many variations in procedures, tools, and service •... - Page 12 SAFETY INFORMATION Vehicle NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be extinguished. • Shift transmission to park or neutral, set parking brake, and install wheel chocks before doing diagnostic or 1. Type A — Wood, paper, textiles, and rubbish service procedures.
- Page 13 SAFETY INFORMATION Tools Fuel • Make sure all tools are in good condition. • Do not over fill the fuel tank. Over fill creates a fire hazard. • Make sure all standard electrical tools are grounded. • Do not smoke in the work area. •...
- Page 14 SAFETY INFORMATION Page 6...
-
Page 15: Warranty
As the vehicle owner, you are responsible for all required maintenance described in this manual. Navistar recommends Federal Emission System Warranty that you retain all maintenance receipts. Navistar will not deny an emission warranty claim solely because you have no record WARRANTY PERIOD of maintenance. -
Page 16: Recommended Maintenance Or Repair Parts
Parts other than MaxxForce service parts or ReNEWed original quality of your emission certified engine. If parts not parts. recommended by Navistar cause damage to the engine or vehicle, the warranty is invalid and maintenance and repair • Aftermarket parts or service kits costs will not be covered. -
Page 17: Warranty Rights And Responsibilities
Accidents, acts of nature or other events beyond control of Navistar. WARRANTY PERIOD Conditions not covered by Warranty The California Air Resources Board and Navistar, Inc. • Loss of time, inconvenience, use of vehicle/engine or pleased to explain the emission control system warranty on commercial loss. -
Page 18: Required Maintenance
If parts not but Navistar cannot deny warranty solely for the lack of receipts recommended by Navistar cause damage to the engine or... -
Page 19: What Is Covered By Warranty
If any emission-related part on your diesel engine is defective, particulate control device) the part will be repaired or replaced by Navistar. This is your short-term emission control system Defects Warranty. •... -
Page 20: Warranty Rights And Responsibilities
WARRANTY • Parts requiring replacement at inspection or adjustment WARRANTY RIGHTS AND RESPONSIBILITIES maintenance intervals for reasons other than being Navistar assures that the emission warranty is being properly defective administered. If you have not received satisfactory service • Replacement of expendable items made in connection... -
Page 21: Section 1 - Engine Systems
SECTION 1 – ENGINE SYSTEMS Engine Serial Number Engine Serial Number Examples ® MaxxForce DT: 466HM2U3300001 ® MaxxForce 9 and 10: 570HM2U3300001 Engine Serial Number Codes 466 – Engine displacement 570 – Engine displacement H – Diesel, turbocharged, Charge Air Cooler (CAC) and electronically controlled M2 –... -
Page 22: Engine Emission Label
SECTION 1 – ENGINE SYSTEMS Engine Emission Label • Emission family and control systems • Valve lash specifications • Engine serial number • EPA, EURO, and reserved fields for specific applications Engine Accessory Labels and Identification Plates The following engine accessories may have manufacturer's labels or identification plates: •... -
Page 23: Engine Specifications
SECTION 1 – ENGINE SYSTEMS Engine Specifications ® MaxxForce DT, 9, & 10 Engines Engine Configuration 4 stroke, inline six cylinder diesel Advertised brake horsepower @ rpm See engine emission label Peak torque @ rpm See engine emission label Displacement ®... - Page 24 SECTION 1 – ENGINE SYSTEMS ® MaxxForce DT, 9, & 10 Engines Lube system capacity (including filter) 28 L (30 qts US) Lube system capacity (overhaul only, with filter) 32 L (34 qts US) Engine lubrication oil pressure at operating temperature with SAE 10W-30 oil •...
-
Page 25: Engine Description
Pressurized oil is supplied to engine turbochargers are installed as an assembly on the exhaust components and the high-pressure injection system. All Navistar manifold. DT, 9, and 10 engines use an engine oil cooler and spin-on engine oil filter. - Page 26 SECTION 1 – ENGINE SYSTEMS Crankshaft Electronic Control System The crankshaft has seven main bearings with fore and aft thrust An Engine Control Module (ECM) monitors and controls engine controlled at the rear bearing. One fractured cap connecting rod performance to ensure maximum performance and compliance is attached at each crankshaft journal.
-
Page 27: Engine Features
SECTION 1 – ENGINE SYSTEMS Fuel System For further information, see Aftertreatment System (page 50). The low-pressure electric fuel pump draws fuel from the fuel tank Cold Ambient Protection (CAP) through the fuel filter housing. The housing includes an electric CAP keeps the engine warm during cold temperatures and fuel pump, strainer, filter, drain valve, Water in Fuel (WIF) sensor, may provide better fuel economy, increased operator comfort,... - Page 28 SECTION 1 – ENGINE SYSTEMS Electronic Governor Control • Programming performance parameter values The governor controls engine rpm within a safe and stable • Programming engine and vehicle features operating range. • Programming calibrations and strategies in the ECM The low idle governor prevents engine rpm from dropping Electronic Speedometer and Tachometer below a stable speed to prevent stalling when various loads are demanded on the engine.
-
Page 29: Engine Optional Features
SECTION 1 – ENGINE SYSTEMS Fast Idle Advance Coolant Heater Fast idle advance increases engine idle speed for faster A coolant heater is available to raise the temperature of the warm-up to operating temperature. This occurs when the ECM coolant surrounding the cylinders for improved performance monitors Engine Coolant Temperature (ECT) sensor input and during cold weather startups. - Page 30 It is commonly used for powering auxiliary devices. engine during extended engine idle times. When control over engine speed is required from outside the ® Beginning with the 2008 Model Year engine, all Navistar vehicle's cab, remote mounted switches must be used to turn on ® MaxxForce engines certified for sale in the state of California PTO engine speed control and select the desired engine speed.
- Page 31 SECTION 1 – ENGINE SYSTEMS Radiator Shutter Enable (RSE) Service Interval RSE provides a signal to open or close the radiator shutters. The service interval feature is designed to provide a visual Closing the shutters will keep the engine warm during cold reminder to the operator that the engine oil change interval weather operation.
-
Page 32: Engine Component Locations
SECTION 1 – ENGINE SYSTEMS Engine Component Locations COMPONENT LOCATION - TOP Figure 3 Top Water outlet tube assembly Valve cover 13. Fuel filter assembly Interstage cooler inlet duct (245 HP and Exhaust emission label (location) 14. Electronic fuel pump (fuel strainer above) Air and Exhaust Gas Recirculation (EGR) location) -
Page 33: Component Location - Front
SECTION 1 – ENGINE SYSTEMS COMPONENT LOCATION - FRONT Figure 4 Front High-pressure turbo outlet EGR valve 10. Water inlet elbow Water outlet tube assembly Oil level gauge 11. Water pump pulley Deaeration hose elbow Front cover 12. Auto belt tensioner Air and Exhaust Gas Recirculation (EGR) Fan drive pulley 13. -
Page 34: Component Location - Intake Side
SECTION 1 – ENGINE SYSTEMS COMPONENT LOCATION - INTAKE SIDE Figure 5 Intake side Electric fuel pump (fuel strainer location) Air and EGR mixer duct Oil Pan Fuel filter assembly Intake manifold 10. Power steering pump Oil level gauge Engine Control Module (ECM) 11. -
Page 35: Component Location - Exhaust Side
SECTION 1 – ENGINE SYSTEMS COMPONENT LOCATION - EXHAUST SIDE Figure 6 Exhaust side Exhaust brake valve assembly Alternator bracket 14. Oil filter Low-pressure turbocharger Crankcase breather outlet tube 15. Low-pressure turbo oil drain tube High-pressure turbocharger 10. Crankcase breather assembly with 16. -
Page 36: Component Location - Rear
SECTION 1 – ENGINE SYSTEMS COMPONENT LOCATION - REAR Figure 7 Rear Air and Exhaust Gas Recirculation (EGR) Turbo air inlet duct Flywheel mixer EGR crossover tube assembly Injector feed tube assembly Exhaust brake valve Rear engine mounting bracket (2) 10. -
Page 37: Section 2 - Requirements For Fuel, Engine Oil, And Coolant
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT ® Fuel Ultra Low Sulfur Diesel (ULSD) fuel is required for all Navistar ® and MaxxForce engines with advanced aftertreatment systems. ULTRA LOW SULFUR DIESEL (ULSD) The fuel should meet all the specifications of ASTM D975 standard (current year revision), including the EPA specification for sulfur content (0.0015% mass or 15 ppm maximum). -
Page 38: Acceptable Fuel Blends
ASTM D7467-08 Standard. Fuels not meeting the specification (D975-08a designates the 2008 revision of the standard.) may cause fuel system deposits, plugged filters, contaminated Navistar, Inc. approves of blends up to B5, provided that the engine oil, and fuel degradation. two components satisfy current specifications. Quality biodiesel blends up to B5 should not cause engine or fuel system problems. -
Page 39: Unsafe Practices
To prevent engine damage, do not mix propane API CJ-4 oils are recommended for high speed diesel engines with diesel fuel. Navistar will not honor warranty with advanced exhaust aftertreatment systems that meet 2007 claims against engines that have used propane. -
Page 40: Sae Oil Viscosity Grades And Temperature Ranges
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT NOTE: Mineral and synthetic oils are acceptable for use SAE OIL VISCOSITY GRADES AND TEMPERATURE provided they meet the API category recommendations and RANGES ambient temperature guidelines. API CJ-4 oils provide protection against the following: •... -
Page 41: Coolant
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT Coolant Freeze Point Protection Levels Concentrate (ethylene glycol) and Water Mixtures COOLANT MIXTURES Concentrate and Water Freeze Point Protection Mixtures Engine coolant mixtures include water, glycol (ethylene or propylene), and inhibitors. Conventional and fully formulated 40% Concentrate and 60% -24.4 °C (-12 °F) coolants require regular testing of inhibitor levels to maintain... -
Page 42: Contamination Of Coolant
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT CONTAMINATION OF COOLANT The coolant color should indicate the condition of the coolant. • Coolant color should be a reddish orange (clear – not cloudy). • Coolant must not have floating debris or visible oil. Contamination of ELC with other coolant products will not be obvious. -
Page 43: Section 3 - Instruments, Indicators, And Switches
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Instrument Panel Gauge Cluster Wait to Start Lamp During engine starts and engine operation, gauges and indicator lamps should be checked periodically. Gauges may vary with vehicle applications. Warning and indicator lamps show conditions not indicated by the gauges. This manual does not describe indicator lamps for the drivetrain, chassis components, or cab interior. -
Page 44: Idle Shutdown Indicator
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Idle Shutdown Indicator Maintenance Lamp Figure 13 Maintenance Lamp. Figure 12 Idle Shutdown Indicator. The Maintenance lamp will illuminate in conjunction with other warning lights or general text and warning messages. It may be The IDLE SHUTDOWN indicator will illuminate when the vehicle accompanied by an audible alarm to indicate an alert condition shutdown timer will turn the engine off in 30 seconds. -
Page 45: Amber Warning Lamp (Awl)
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Amber Warning Lamp (AWL) RED Stop Lamp (RSL) Figure 14 Amber Warning Lamp (AWL). Figure 15 RED Stop Lamp (RSL). The Amber Warning Lamp (AWL) will illuminate by itself, or in conjunction with other warning lights or general text and warning CAUTION messages, to indicate an alert condition to the operator. -
Page 46: High Exhaust System Temperature (Hest) Lamp
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES High Exhaust System Temperature (HEST) Lamp Diesel Particulate Filter (DPF) Indicator Figure 16 HEST Lamp. Figure 17 DPF Indicator. The DPF indicator operates at three different levels. WARNING Level One Exhaust components are operating under normal •... -
Page 47: Malfunction Indicator Lamp (Mil)
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Malfunction Indicator Lamp (MIL) Level Two The DPF indicator will be flashing indicating the exhaust filter is full. The vehicle should be safely pulled off the roadway and parked. Start the Parked Regeneration process to prevent loss of engine power. -
Page 48: Typical Water Temperature Gauge
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Typical Water Temperature Gauge The indicator lamp will be activated at engine coolant temperatures above 109 °C (228 °F). If engine temperature suddenly rises shut down engine, and determine the cause of overheating. If necessary, contact an authorized service provider. -
Page 49: Oil Pressure Gauge
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Oil Pressure Gauge Lubrication Oil Pressure Lube Oil Pressure At normal operating temperature Low idle 15 psi (103 kPa) High idle 50 psi (344 kPa) CAUTION To prevent engine damage, shut down engine immediately if the gauge fluctuates or drops below 276 kPa (50 psi) under load. -
Page 50: Oil Temperature Gauge
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Oil Temperature Gauge Figure 21 Oil temperature gauge. The engine oil temperature gauge indicates the operating oil temperature of the engine. Page 42... -
Page 51: Switches
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Switches ENGINE EXHAUST BRAKE ON/OFF TOGGLE SWITCH ENGINE BRAKE ON/OFF SWITCH Figure 23 Exhaust brake toggle switch Figure 22 Engine brake ON / OFF switch The exhaust brake toggle switch turns engine exhaust brake ON or OFF. -
Page 52: Air Cleaner Restriction Indicator
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Air Cleaner Restriction Indicator Air Restriction Indicator Calibration • The indicator is calibrated in inches of water. Air restriction is resistance of airflow through the air cleaner. Accurate air restriction is measured at maximum airflow. •... -
Page 53: Section 4 - Engine Operation
SECTION 4 – ENGINE OPERATION Preoperation Checklist Figure 25 Oil level gauge (typical) GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and CAUTION other contaminated materials (e.g. filters, rags) in accordance with applicable regulations. -
Page 54: Priming The Fuel System
SECTION 4 – ENGINE OPERATION Priming the Fuel System WARNING To prevent personal injury or death, do not install WARNING ether start equipment, if an engine has a cold starting device or other cold climate starting aid. To prevent personal injury or death, do not smoke and keep fuel away from open flames and sparks. - Page 55 SECTION 4 – ENGINE OPERATION 1. Set parking brake and shift transmission to park or neutral. CAUTION If the engine fails to start within 30 seconds, to CAUTION prevent damage to the engine, do the following: To prevent damage to the engine, do not depress •...
-
Page 56: Emergency Starting
SECTION 4 – ENGINE OPERATION 10. After the engine has reached operating temperature, the oil • Protect against inhaling hydrogen gas fumes pressure, at a high idle, should be 50 psi (344 kPa) minimum. from battery. If oil pressure does not meet the minimum limit, stop the •... -
Page 57: Operation
SECTION 4 – ENGINE OPERATION Operation WARNING SUGGESTED WARM-UP TIME To prevent personal injury or death, do not attach jumper cable to the negative (-) dead NOTE: Before applying a load or increasing speed above battery terminal. This can cause sparks and an 1,000 rpm, warm up engine for a minimum of 5 minutes at explosion. -
Page 58: Extended Idling Periods
SECTION 4 – ENGINE OPERATION High idle speed is a nonadjustable factory setting. The high idle EXHAUST AFTERTREATMENT SYSTEM setting depends on the application of the engine and has the engine vehicle exhaust piping includes following ranges: Aftertreatment System to capture soot and other particulates ®... -
Page 59: Aftertreatment (Aft) High-Soot Auto Engine Shut Down
SECTION 4 – ENGINE OPERATION • If the Parked Regeneration process is ignored, the engine • Follow the Parked Regeneration process listed in the may derate or stop running. Vehicle Operator Manual. • See the “Safety Information” (page 3 ) section for safety •... -
Page 60: Engine Idle Shutdown Timer (California-Standard)
SECTION 4 – ENGINE OPERATION • Engine speed is not at idle speed (700 rpm). ENGINE IDLE SHUTDOWN TIMER (CALIFORNIA-STANDARD) • Vehicle movement or a Vehicle Speed Sensor (VSS) fault is detected. • Manual DPF Regeneration is enabled (Parked Regen). GOVERNMENT REGULATION: State and local •... -
Page 61: Cold Weather Operation
SECTION 4 – ENGINE OPERATION Thirty seconds before engine shutdown, the IDLE SHUTDOWN COLD WEATHER OPERATION indicator illuminates. This continues until the engine shuts down or the low idle shutdown timer is reset. The engine must be out of WARNING gear for the IST to work. -
Page 62: Cold Ambient Protection (Cap)
SECTION 4 – ENGINE OPERATION 2. At the end of each daily operation do the following: HOT WEATHER OPERATION • Fill the fuel tank with correct fuel. 1. Before operating the engine above 21 °C (70 °F), check or service the following: •... -
Page 63: Engine Shutdown
SECTION 4 – ENGINE OPERATION ENGINE SHUTDOWN RADIATOR SHUTTLE ENABLE (RSE) Before shutting down an engine that has reached operating RSE is an optional feature that provides a signal to open or close temperature, idle the engine for 2 to 3 minutes, allowing the the radiator shutters. -
Page 64: Downhill Operation
SECTION 4 – ENGINE OPERATION General guidelines for correct road operation DOWNHILL OPERATION 1. Use the lowest gear to get the vehicle moving. This allows CAUTION the engine to more easily move the load. To prevent engine damage when driving downhill, 2. -
Page 65: Section 5 - Maintenance Schedule And Service Procedures
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Maintenance Schedule NOTE: No maintenance is required on the Doser Injector, because it is not a serviceable component. Failed parts should be replaced, not serviced. The Doser is warranted under base mechanical and or emission warranty. ®... - Page 66 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES ® MaxxForce DT, 9, & 10 Diesel Engines (cont.) Service operation interval - which ever comes first: miles/kilometers, months, years, hours, or liters/gallons of fuel Service Interval Service Operation See service procedures in this section for more information. 30,000 miles (48,300 km) Change fuel filter.
- Page 67 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES ® MaxxForce DT, 9, & 10 Diesel Engines (cont.) Service operation interval - which ever comes first: miles/kilometers, months, years, hours, or liters/gallons of fuel Service Interval Service Operation See service procedures in this section for more information. 200,000 miles (322,000 km) Cleaning Diesel Particulate Filter (DPF) 30 months, 6,000 hours...
-
Page 68: Service Procedures
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures NOTE: Do not check oil level if engine is running or immediately after engine shutdown. 2. Shut down engine and wait 15 minutes. GOVERNMENT REGULATION: Engine fluids 3. Remove oil level gauge from fill tube. (oil, fuel, and coolant) may be a hazard to human health and the environment. -
Page 69: Coolant Level
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 4. If oil level is below operating range, fill with recommended Service Interval: Before Engine Operation oil for operating climate. The ADD mark indicates 2.8 liters Extended Life Coolant (ELC) 50/50 Premix is the standard (3 quarts US) of oil should be added. -
Page 70: Water Separator
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES WATER SEPARATOR WARNING Service Interval: Before Engine Operation To prevent personal injury or death, do the following when removing the radiator cap or coolant tank cap: GOVERNMENT REGULATION: Engine fluids • Allow the engine to cool for 15 minutes or more. (oil, fuel, and coolant) may be a hazard to human •... - Page 71 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 1. If necessary, connect a hose to the end of the water drain WARNING valve. To prevent personal injury or death, store diesel 2. Put a suitable container under water drain valve or drain fuel properly in an approved container designed hose.
-
Page 72: Charge Air Cooler (Cac)
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES CHARGE AIR COOLER (CAC) • Oil stains • Fuel stains Service Interval: Before Engine Operation • Leakage at water pump (wetness from the weep hole is normal) WARNING 2. Correct problems. To prevent personal injury or death, shut down engine, set parking brake, and install wheel AIR CLEANER RESTRICTION chocks before inspecting the Charge Air Cooler. -
Page 73: Engine Oil And Filter
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Push reset button to check air restriction indicator. If the air ENGINE OIL AND FILTER filter was not changed, the yellow indicator will return to the same reading when the vehicle is driven under normal driving WARNING conditions. - Page 74 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES ® ® MaxxForce DT Diesel Engine With Less Than or Equal to MaxxForce DT, 9, and 10 Diesel Engines With Greater 230 Horsepower (Without Centrifuge Filter) Than 230 Horsepower (Without Centrifuge Filter) Average Vehicle Speed Average Vehicle Speed Fuel Economy...
- Page 75 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and other contaminated materials (such as filters, rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other contaminated materials according to applicable regulations.
- Page 76 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 4. Discard oil pan drain plug O-ring. Inspect the oil pan drain 8. Put drain pan under oil filter. plug. If it is free of defects, it can be reused. Replace if 9.
-
Page 77: Centrifuge Filter (If Equipped)
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES CENTRIFUGE FILTER (IF EQUIPPED) Service Interval (based upon fuel consumption and specific engine application): Figure 32 Oil level gauge (typical) The centrifuge filter (if equipped) is located in one of the following positions: 14. - Page 78 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 1. Park the vehicle on level ground. Set the parking brake and shift the transmission to park or neutral. GOVERNMENT REGULATION: Engine fluids 2. Before attempting to open the centrifuge oil filter, wait 2 (oil, fuel, and coolant) may be a hazard to human minutes to assure the rotor has stopped spinning.
- Page 79 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Figure 33 Centrifuge filter assembly Cover assembly Band clamp handle Figure 34 Centrifuge rotor Body assembly Band clamp O-ring Rotor Body assembly Page 71...
-
Page 80: Resetting Change Engine Oil Service Interval Message
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 5. Remove and discard O-ring. RESETTING CHANGE ENGINE OIL SERVICE INTERVAL MESSAGE 6. Remove the rotor and allow the oil to drain out of it before discarding. Dispose of the rotor according to applicable Reset the Service Interval Message (change engine oil) per the regulations. -
Page 81: Belt, Air Intake Piping And Clamps
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES BELT, AIR INTAKE PIPING AND CLAMPS Inspect condition of all drive belts. For any of the following conditions install a new belt: Service Interval: 15,000 miles (24,000 km), 6 months, or 550 •... - Page 82 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Belt Installation 1. Attach a 1/2 inch drive breaker bar to square hole in auto tensioner. 2. Pull the breaker bar clockwise and install the belt over the auto tensioner pulley and other pulleys. 3.
-
Page 83: Coolant Freeze Point
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES COOLANT FREEZE POINT For vehicles operating in extremely cold climates, a coolant mixture of 60% Concentrate and 40% water or 67% Concentrate Service Interval: 15,000 miles (24,000 km), 6 months, or 550 and 33% water provide additional freeze protection as shown in hours the table above. - Page 84 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other contaminated materials according to applicable...
- Page 85 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 1. Set parking brake and shift transmission to park or neutral. 3. Clean engine compartment components in the area of the fuel filter housing using compressed air, before removing the fuel filter cover. Also, wipe the fuel filter cover clean WARNING to prevent contaminants from entering the fuel system.
- Page 86 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 12. Remove O-ring from the fuel filter cover. Discard O-ring. 13. Coat a new fuel filter O-ring for the fuel filter cover with clean diesel fuel and install onto the fuel filter cover. 14.
-
Page 87: Fuel Strainer
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 21. Wait for the WAIT TO START lamp to stop illuminating. WARNING Do not crank engine until the lamp is off. When the WAIT TO START lamp goes off, turn ignition switch to START. If To prevent personal injury or death, do not smoke the vehicle has push button starting, press and hold starter and keep fuel away from flames and sparks. - Page 88 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 1. Set parking brake and shift transmission to park or neutral. 3. Remove three pump cover bolts. Do not discard bolts, these will be reused when installing the fuel pump. 2. Disconnect the wiring harness to the electric fuel pump by pushing down on the tab of the wiring harness connector 4.
-
Page 89: Electrical System
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 12. Start the engine and check for leaks. See Starting the VIBRATION DAMPER Engine (page 47). Service Interval: 120,000 miles (193,000 km) or 5,000 hours 13. Check for leaks. If leaks are found, shut down the engine Have the vibration damper inspected by an authorized service and correct the problem. -
Page 90: Extended Life Coolant (Elc) Extender
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Pressure test the air induction system. 2. Confirm coolant system capacity. • For inspection procedures, see the applicable Engine 3. According to Cooling System Capacity in the ELC Extender Diagnostic Manual. table, drain the correct volume of coolant from the cooling system. -
Page 91: Crankcase Pressure
• For inspection procedures, see theapplicableEngine message on the integral digital display at or if necessary before Diagnostic Manual. the specified interval. Take vehicle to your Navistar certified • Have an authorized service provider measure the dealer for cleaning. crankcase pressure at the correct service interval. - Page 92 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 3. Remove coolant tank cap. WARNING 4. Place coolant drain pan under radiator drain valve and open To prevent personal injury or death, do not let radiator drain valve to drain coolant. engine fluids stay on your skin.
- Page 93 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 9. Slowly fill cooling system with new ELC 50/50 Premix or Concentrate and water mixture until coolant is at the mid point between the ADD and FULL levels of the coolant tank. 10.
- Page 94 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 15. After engine reaches normal operating temperature and the thermostat has opened, allow engine to run for 5 to 10 minutes, then shut engine off. 16. Connect electrical connector Exhaust recirculation (EGR) valve. Clear any Diagnostic Trouble Codes (DTC) that may have occurred.
-
Page 95: Section 6 - Long Term Storage
SECTION 6 – LONG TERM STORAGE General Information • Before storage, change the engine oil and filter with the appropriate engine oil for conditions the engine will To maintain warranty coverage, engines intended to be taken experience during storage. out of service or stored 30 days or longer require the following •... - Page 96 SECTION 6 – LONG TERM STORAGE Page 88...
-
Page 97: Section 7 - Service Records
SECTION 7 – SERVICE RECORDS Maintenance Service Record WARNING To prevent personal injury or death, shift WARNING transmission to park or neutral, set parking To prevent personal injury or death, read all brake, and install wheel chocks before doing safety instructions in the “Safety Information” diagnostic or service procedures. - Page 98 SECTION 7 – SERVICE RECORDS Maintenance Service Record Date Service Month Service Hours Miles (km) Item Serviced Page 90...
- Page 99 SECTION 7 – SERVICE RECORDS Maintenance Service Record Date Service Month Service Hours Miles (km) Item Serviced Page 91...
-
Page 100: Daily Care And Report
SECTION 7 – SERVICE RECORDS Daily Care and Report • Excessive use of crankcase lubricating oil, coolant, battery fluid or fuel WARNING • Unusual engine noise • Correct amount of electrolyte, if not a maintenance free To prevent personal injury or death, read all battery safety instructions in the “Safety Information”... - Page 101 SECTION 7 – SERVICE RECORDS Daily Care and Report Model Serial No. Date Miles Fuel Lube Parts Labor Service Performed Cost Parts Cost Time Cost Page 93...
- Page 102 SECTION 7 – SERVICE RECORDS Daily Care and Report Model Serial No. Date Miles Fuel Lube Parts Labor Service Performed Cost Parts Cost Time Cost Page 94...