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Navistar MaxxForce 15, Service Manual

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Navistar MaxxForce 15 Service Manual Download Page 1

ENGINE

SER

VICE

MANUAL

0000001746

MaxxForce®

15L

Diesel

Engine

Revision

1

EP
A
10
-

US,

Canada,

Mexico

January

2013

ENGINE SERVICE MANUAL

MaxxForce® 15L Diesel Engine

Navistar, Inc.

2701 Navistar Drive, Lisle, IL 60532 USA

© 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

Summary of Contents for MaxxForce 15

Page 1: ...sel Engine Revision 1 EPA 10 US Canada Mexico January 2013 ENGINE SERVICE MANUAL MaxxForce 15L Diesel Engine Navistar Inc 2701 Navistar Drive Lisle IL 60532 USA 2013 Navistar Inc All rights reserved A...

Page 2: ......

Page 3: ...haust Gas Recirculation EGR System 205 Oil Cooler Filter Housing and Crankcase Ventilation 257 Air Inlet and Exhaust Manifold 281 Front Cover High Mount Fan Drive Cooling System and Related Components...

Page 4: ...II ENGINE SERVICE MANUAL Appendix C Special Service Tools 573...

Page 5: ...photo illustration may not be exact See vehicle manuals and Technical Service Information TSI bulletins for additional information Technical Service Literature 1172042 MaxxForce 15 Engine Operation a...

Page 6: ...iagnostic information Prerequisites for Effective Diagnosis Availability of gauges diagnostic test equipment and diagnostic software Availability of current information for engine application and engi...

Page 7: ...t Use correct lifting devices Use safety blocks and stands Protective Measures Wear protective safety glasses and shoes Wear correct hearing protection Wear cotton work clothing Wear sleeved heat prot...

Page 8: ...ondition Make sure all standard electrical tools are grounded Check for frayed or damaged power cords before using power tools Fluids Under Pressure Use extreme caution when working on systems under p...

Page 9: ...circulation EGR System 20 Aftertreatment AFT System 22 Aftertreatment Fuel Injection Components 24 Fuel Management System 26 Chassis Mounted Components 27 Engine Mounted Components 29 Engine Lubricati...

Page 10: ...tuators 47 Coolant Flow Valve and Coolant Mixer Valve 47 Exhaust Gas Recirculation EGR Valve Assembly 47 Air Control Valve 47 Cold Start Relay CSR 47 Cold Start Fuel Solenoid CSFS 47 Engine Throttle V...

Page 11: ...r truck Y United States Huntsville 7 digit suffix Engine serial number sequence Engine Emission Label Figure 2 U S Environmental Protection Agency EPA exhaust emission label example The U S Environmen...

Page 12: ...tes The following engine accessories may have manufacturer s labels or identification plates Air compressor Air conditioning compressor Alternator Engine Control Module ECM Cooling fan clutch High pre...

Page 13: ...al Thermostat transition range start open full open 88 C 103 C 190 F 217 F Engine Description The MaxxForce 15 diesel engine has been designed for increased durability and reliability The cylinder hea...

Page 14: ...eam in the mixing duct This cools the combustion process and reduces the formation of Nitrogen Oxides NOX engine emissions The EGR cooler assembly cools the exhaust gas in two stages An open crankcase...

Page 15: ...mponent location top 1 Turbocharger interstage cooler assembly 2 Flywheel housing assembly 3 Valve cover assembly 4 Exhaust gas temperature sensor 5 Cold Start Fuel Igniter CSFI 6 Charge Air Cooler Ou...

Page 16: ...ocation front 1 Water pump pulley 2 Air inlet duct turbocharger 3 Front lifting eye 4 EGR crossover tube assembly 5 Engine throttle valve assembly 6 Oil filler pipe assembly 7 Camshaft gear cover 8 Lo...

Page 17: ...turbocharger assembly 5 Thermostat housing 6 Interstage cooler assembly 7 High pressure turbocharger compressor outlet 8 Oil supply tube for secondary filtration to soot filter 9 Coolant inlet from ra...

Page 18: ...ssembly 6 12V relay for cold start assist solenoid 7 Fuel Delivery Pressure FDP sensor 8 Fuel filter 9 Oil pan drain plug rear sump 10 Crankcase Pressure CPS sensor 11 Engine Oil Pressure EOP sensor 1...

Page 19: ...E SYSTEMS 15 Figure 7 Component location rear 1 Rear lifting eye 2 Exhaust Gas Recirculation EGR valve assembly 3 Fuel return tube assembly 4 EGR cooler supply tube 5 Flywheel 6 Oil pan 7 Flywheel hou...

Page 20: ...ws from the ISC into the high pressure turbocharger The high pressure turbocharger increases the intake air pressure up to 345 kPa 50 psi The hot compressed air flows into the Charge Air Cooler CAC wh...

Page 21: ...ure turbocharger through the vehicle aftertreatment system to the exhaust tail pipe Air Management Components Turbochargers The MaxxForce 15 engine is equipped with an electronically controlled pneuma...

Page 22: ...er is connected directly to the exhaust manifold through the high pressure turbine inlet The turbine input of the low pressure turbocharger is connected to the turbine outlet of the high pressure turb...

Page 23: ...air control valve Air pressure to the air control valve is supplied from an air tank mounted on the chassis The air control valve is controlled by the Engine Control Module ECM The air control valve...

Page 24: ......

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