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Navistar MaxxForce DT 9, Operation And Maintenance Manual

The Operation and Maintenance Manual for Navistar MaxxForce DT 9, a high-performance diesel engine, is now available for free download. This comprehensive manual provides detailed instructions on operating and maintaining the product efficiently. Visit manualshive.com to access this valuable resource and optimize your engine's performance.

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TABLE OF CONTENTS

Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Cold Ambient Protection (CAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Engine Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Engine Warning Protection System (EWPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Radiator Shuttle Enable (RSE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Road Speed Limiting (RSL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Road Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Service Procedures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Charge Air Cooler (CAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
External Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Air Cleaner Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Centrifuge Filter (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Resetting Change Engine Oil Service Interval Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Belt, Air Intake Piping and Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Coolant Freeze Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Fuel Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Engine Valve Lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Form No. 1172040R1

Printed in the United States of America

Summary of Contents for MaxxForce DT 9

Page 1: ...ust 2011 MaxxForce DT 9 and 10 Diesel Engines For 2010 EPA Emission Compliant Model Year Truck and Derivative Vehicle Applications Engine Operation and Maintenance Manual 2011 Navistar Inc All rights reserved Form No 1172040R1 Printed in the United States of America ...

Page 2: ...Form No 1172040R1 Printed in the United States of America ...

Page 3: ...ies 8 California Emission System Warranty 10 Warranty Period 10 Required Maintenance 10 Warranty Repairs and Service 10 Recommended Maintenance or Repair Parts 10 Emergency Repairs 10 What is Covered by Warranty 11 What is not Covered by Warranty 11 Warranty Rights and Responsibilities 12 SECTION 1 ENGINE SYSTEMS Engine Serial Number 13 Engine Emission Label 14 Engine Accessory Labels and Identifi...

Page 4: ...ow Sulfur Diesel ULSD 29 Unacceptable Fuel and Blends 29 Acceptable Fuel Blends 30 Use of Higher Biodiesel Fuel Blends B6 to B20 30 Unsafe Practices 31 Engine Oil 32 Engine Oil Quality and Service Categories 32 API CJ 4 for High Performance Diesel Engines 32 SAE Oil Viscosity Grades And Temperature Ranges 33 Coolant 34 Coolant Mixtures 34 Extended Life Coolant ELC Red 34 Contamination of Coolant 3...

Page 5: ...emperature Gauge 44 Switches 45 Engine Brake ON OFF Switch 45 Engine Exhaust Brake ON OFF Toggle Switch 45 Air Cleaner Restriction Indicator 46 SECTION 4 ENGINE OPERATION Preoperation Checklist 47 Priming the Fuel System 48 Starting the Engine 48 Emergency Starting 50 Operation 51 Suggested Warm up Time 51 Idle Speed 51 Extended Idling Periods 51 Aftertreatment System 52 Engine Idle Shutdown Timer...

Page 6: ...ROCEDURES Maintenance Schedule 59 Service Procedures 62 Oil Level 62 Coolant Level 63 Water Separator 65 Charge Air Cooler CAC 66 External Leakage 67 Air Cleaner Restriction 68 Engine Oil and Filter 69 Centrifuge Filter If Equipped 73 Resetting Change Engine Oil Service Interval Message 76 Belt Air Intake Piping and Clamps 77 Coolant Freeze Point 79 Fuel Filter 79 Fuel Strainer 83 Electrical Syste...

Page 7: ...88 Crankcase Pressure 89 Turbochargers 89 Cleaning Diesel Particulate Filter 89 Service Cooling System 90 SECTION 6 LONG TERM STORAGE General Information 93 SECTION 7 SERVICE RECORDS Maintenance Service Record 95 Daily Care and Report 98 Form No 1172040R1 Printed in the United States of America ...

Page 8: ...Form No 1172040R1 Printed in the United States of America ...

Page 9: ...ics Form Technical Service Literature is revised periodically Use only up to date service information To order technical service literature contact your dealer All marks are trademarks of their respective owners About the Manual This manual contains information needed to correctly operate and maintain your engine as recommended by Navistar Inc Numerous illustrations symbols and feature description...

Page 10: ...FOREWORD Form No 1172040R1 Page 2 Printed in the United States of America ...

Page 11: ... to prevent or eliminate conditions hazards and unsafe practices that can cause personal injury or death Caution A caution describes actions necessary to prevent or eliminate conditions that can cause damage to the engine or vehicle Note A note describes actions necessary for correct efficient engine operation Safety Instructions Work Area Keep work area clean dry and organized Keep tools and part...

Page 12: ...arged fire extinguishers are in the work area NOTE Check the classification of each fire extinguisher to ensure that the following fire types can be extinguished 1 Type A Wood paper textiles and rubbish 2 Type B Flammable liquids 3 Type C Electrical equipment Batteries Always disconnect the main negative battery cable first Always connect the main negative battery cable last Avoid leaning over bat...

Page 13: ...he fuel tank Over fill creates a fire hazard Do not smoke in the work area Do not refuel the tank when the engine is running Removal of Tools Parts and Equipment Reinstall all safety guards shields and covers after servicing the engine Make sure all tools parts and service equipment are removed from the engine and vehicle after all work is done Form No 1172040R1 Printed in the United States of Ame...

Page 14: ...SAFETY INFORMATION Form No 1172040R1 Page 6 Printed in the United States of America ...

Page 15: ...intenance However a claim may be denied if your failure to perform proper maintenance resulted in the failure of a warranted part and you cannot provide appropriate evidence of maintenance Take your vehicle to an authorized service provider when a problem occurs WARRANTY REPAIRS AND SERVICE All emission control system parts proven defective during normal use will be repaired or replaced during the...

Page 16: ... kits Non defective parts replaced by an unauthorized service provider Parts requiring replacement at inspection or adjustment maintenance intervals for reasons other than being defective Replacement of expendable items made in connection with scheduled maintenance Vehicle engine and part malfunctions caused by the following Use of incorrect fuel engine oil or coolant Failure to maintain correct m...

Page 17: ...onal office for assistance The address and phone number of each regional office is listed in your Vehicle Operator Manual If additional assistance is required contact the Manager of Customer Relations Manager Customer Relations Navistar Inc 4201 Winfield Road Warrenville Illinois 60555 Telephone 1 800 448 7825 Form No 1172040R1 Printed in the United States of America Page 9 ...

Page 18: ...has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for the repair or replacement of the part Take your vehicle to an authorized service provider when a problem occurs WARRANTY REPAIRS AND SERVICE All emission control system parts proven defective during normal use will be repaired or replaced during the warranty p...

Page 19: ...l equipment by Navistar Fuel injection system Air induction system includes turbocharger exhaust manifold and intake manifold Diesel Particulate Filter DPF Hoses clamps fittings and tubing Pulleys belts and idlers Vacuum temperature and time sensitive valves and switches WHAT IS NOT COVERED BY WARRANTY Unauthorized parts or expendable parts Parts other than MaxxForce service parts or ReNEWed parts...

Page 20: ...NTY RIGHTS AND RESPONSIBILITIES Navistar assures that the emission warranty is being properly administered If you have not received satisfactory service or have questions regarding your warranty rights and responsibilities contact the regional office for assistance The address and phone number of each regional office is listed in your Vehicle Operator Manual If additional assistance is required co...

Page 21: ...label on the valve cover 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 Motor truck U United States 7 digit suffix Engine serial number sequence beginning with 3300001 Form No 1172040R1 Printed in the Un...

Page 22: ...ent Advertised brake horsepower and torque rating 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 Air compressor Air conditioning compressor Alternator Cooling fan clutch ...

Page 23: ...xxForce DT MaxxForce 9 and 10 7 6 L 466 in3 9 3 L 570 in3 Compression ratio MaxxForce DT MaxxForce 9 and 10 16 9 1 16 5 1 Stroke MaxxForce DT MaxxForce 9 and 10 119 mm 4 68 in 146 mm 5 75 in Bore sleeve diameter 116 6 mm 4 59 in Firing order 1 5 3 6 2 4 Aspiration Dual turbocharged and charge air cooled Combustion system Direct injection turbocharged Fuel system Electro hydraulic injection Form No...

Page 24: ... pressure at operating temperature with SAE 10W 30 oil Low idle High idle 214 kPa 31 psi minimum 276 kPa 40 psi minimum Idle speed no load 700 rpm 50 nonadjustable Thermostat operating temperature 96 C 205 F 1 Verify engine lubrication capacities if additional equipment added to system 2 Verify engine lubrication capacities if additional equipment added to system Form No 1172040R1 Page 16 Printed ...

Page 25: ...IAH system will initially illuminate the WAIT TO START lamp When the lamp turns off the engine can be started Crankcase Assembly The camshaft is supported by four insert bushings pressed into the crankcase The camshaft gear is driven from the front of the engine A thrust flange is located between the camshaft and the drive gear The overhead valve train includes mechanical roller lifters push rods ...

Page 26: ...ion The pad mounting design of the alternator and refrigerant compressor brackets provide easy removal and improved durability Electronic Control System An Engine Control Module ECM monitors and controls sensors actuators and valves to ensure maximum engine performance and compliance with EPA emissions requirements The Crankshaft Position CKP sensor and the Camshaft Position CMP sensor are used by...

Page 27: ... within a safe and stable operating range The low idle governor prevents engine rpm from dropping below a stable speed to prevent stalling when various loads are demanded on the engine The high idle governor prevents engine rpm from going above a safe speed that would cause engine damage Electronic Service Tool EST Interface Engines are equipped with the EST interface for communication between the...

Page 28: ... odometer and hourmeter are stored in the ECM memory at the time of an event and can be retrieved using the EST Fast Idle Advance Fast idle advance increases engine idle speed for faster warm up to operating temperature This occurs when the ECM monitors Engine Coolant Temperature ECT sensor input and adjusts fuel injector operation accordingly Low idle speed is increased proportionally when the EC...

Page 29: ...ditioner A C is on or when the coolant or inlet air temperature goes above a set temperature Engine Warning Protection System EWPS EWPS is designed to protect the engine from damage by monitoring critical engine data such as engine speed temperature oil pressure and coolant levels This feature will alert the operator by using a combination of visual and audible warnings when critical engine parame...

Page 30: ... set and maintain engine speed without using the accelerator pedal It is commonly used for powering auxiliary devices When control over engine speed is required from outside the vehicle s cab remote mounted switches must be used to turn on PTO engine speed control and select the desired engine speed Engine speed can be ramped up and down with RESC similar to the way the in cab PTO feature works ho...

Page 31: ... this case is used to describe the distance time or fuel used between the last maintenance performed on the vehicle and the next maintenance which is due It is essential that operators are trained to know the maintenance schedules and instructions regarding the operation and reset functionality of the service interval for the feature to be effective See Resetting Change Engine Oil Service Interval...

Page 32: ...r air inlet duct 5 High pressure turbocharger outlet 6 Exhaust brake valve assembly 7 Valve cover 8 Exhaust emission label location 9 Air and Exhaust Gas Recirculation EGR mixer duct 10 Oil filler tube 11 Oil level gauge 12 EGR valve 13 Fuel filter assembly 14 Electronic fuel pump fuel strainer location 15 Throttle coupling 16 Deaeration hose elbow Form No 1172040R1 Page 24 Printed in the United S...

Page 33: ... tube assembly 3 Deaeration hose elbow 4 Air and Exhaust Gas Recirculation EGR mixer duct 5 EGR valve 6 Oil level gauge 7 Front cover 8 Fan drive pulley 9 Vibration damper assembly 10 Water inlet elbow 11 Water pump pulley 12 Auto belt tensioner 13 Turbocharger air inlet duct Form No 1172040R1 Printed in the United States of America Page 25 ...

Page 34: ... strainer location 2 Fuel filter assembly 3 Oil level gauge 4 Exhaust Gas Recirculation EGR valve 5 Air and EGR mixer duct 6 Intake manifold 7 Engine Control Module ECM 8 Oil pan drain plug 9 Oil Pan 10 Power steering pump 11 Air compressor assembly 12 Water drain valve Form No 1172040R1 Page 26 Printed in the United States of America ...

Page 35: ...r port 7 Water supply housing refrigerant compressor mount 8 Alternator bracket 9 Crankcase breather outlet tube 10 Crankcase breather assembly with turbine 11 Exhaust Gas Recirculation EGR coolant drain plug 12 Coolant drain plug 13 Oil cooler module 14 Oil filter 15 Low pressure turbo oil drain tube 16 High pressure turbo oil drain tube 17 Exhaust brake assembly 18 Turbocharger oil supply tube F...

Page 36: ...irculation EGR mixer 2 Exhaust brake valve 3 Cylinder head 4 Turbo air inlet duct 5 EGR crossover tube assembly 6 Rear engine mounting bracket 2 7 Flywheel housing 8 Flywheel 9 Injector feed tube assembly 10 Exhaust brake valve supply hose 11 Oil fill tube Form No 1172040R1 Page 28 Printed in the United States of America ...

Page 37: ...5 ppm maximum These specifications are included in the standard under the designation No 2 D S15 fuel and No 1 D S15 fuel Grade No 1 D fuel is a lighter fuel with higher volatility than grade No 2 D it may be blended with grade No 2 D in wintertime to provide engine operability under low ambient temperature UNACCEPTABLE FUEL AND BLENDS Off road diesel fuel Low Sulfur Diesel LSD fuel 0 05 500 ppm C...

Page 38: ...ehicles that operate in populated areas or in fleets which are required to use alternative fuels to reduce urban pollution Use of B6 to B20 blends is at the discretion of the customer operator and will not automatically void an engine warranty However if engine component failure can be directly attributable to use of a B6 to B20 blend not provided by a BQ9000 certified fuel supplier or not meeting...

Page 39: ...ith diesel fuel An open heat source spark cell phone or electronic device can ignite these fuel mixtures This creates a fire hazard and possible explosion CAUTION To prevent engine damage do not mix propane with diesel fuel Navistar will not honor warranty claims against engines that have used propane Form No 1172040R1 Printed in the United States of America Page 31 ...

Page 40: ...the API category recommendations and ambient temperature guidelines API CJ 4 oils provide protection against the following Catalyst poisoning and particulate blockage Engine wear Piston deposits Soot related viscosity increase deposits and wear Viscosity loss due to shear Oxidative thickening Oil foaming and aeration API CJ 4 oil in combination with Ultra Low Sulfur Diesel ULSD fuel 0 0015 15 ppm ...

Page 41: ...ckness by grade Colder temperatures require lower grade oils for correct flow during starting Higher temperatures require higher grade oils for satisfactory lubrication An oil pan and block coolant heater is required for temperatures below 12 C 10 F For heavy duty driving or trailer towing higher oil grades 15W 40 and 5W 40 oils are required if temperatures are over 10 C 50 F Form No 1172040R1 Pri...

Page 42: ...ndard factory fill for the cooling system The coolant should minimally meet ASTM D6210 Standard Specification for fully Formulated Glycol Base Engine Coolant for Heavy Duty Engines ELC 50 50 Extender is added at the designated service interval For further information see Extended Life Coolant ELC Extender page 88 Freeze Point Protection Levels Concentrate ethylene glycol and Water Mixtures Concent...

Page 43: ...oolant 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 To verify coolant quality contact an authorized service provider or use a refractometer to verify coolant strength Form No 1172040R1 Printed in the United States of America Page 35 ...

Page 44: ...SECTION 2 REQUIREMENTS FOR FUEL ENGINE OIL AND COOLANT Form No 1172040R1 Page 36 Printed in the United States of America ...

Page 45: ...r the drivetrain chassis components or cab interior See the Vehicle Operator Manual Warning Lights Warning lights signal when a reading is outside preset limits Warning lamps indicate situations that must be inspected before operating the vehicle Wait to Start Lamp Figure 11 Wait to Start Lamp The WAIT TO START lamp will illuminate when inlet air heater is required Wait until the lamp goes off bef...

Page 46: ...gine off in 30 seconds See Engine Idle Shutdown Timer page 52 for further information Maintenance Lamp Figure 13 Maintenance lamp The Maintenance lamp will illuminate in conjunction with other warning lights or general text and warning messages It may be accompanied by an audible alarm to indicate an alert condition to the operator Form No 1172040R1 Page 38 Printed in the United States of America ...

Page 47: ... However if the lamp continues to light or remains on contact an authorized service provider immediately to have the problem corrected Stop Engine Lamp Figure 15 Stop engine lamp CAUTION To prevent engine damage shutdown engine immediately if the Stop Engine lamp flashes The Stop Engine lamp will flash and an alarm will sound when a serious problem arises The lamp is used in conjunction with other...

Page 48: ...r Manual Diesel Particulate Filter DPF Indicator Figure 17 DPF indicator The DPF indicator operates at three different levels Level One The DPF indicator will illuminate solid and remain on when the levels of soot exceed acceptable levels The regeneration process should begin by using either of the following two methods The lamp will turn off when the regeneration process is complete The vehicle c...

Page 49: ...sly while the ignition is on This indicates the exhaust filter is full and engine performance is limited Pull the vehicle safely off the roadway and start Parked Regeneration process to prevent the engine from stopping For additional information see the applicable Vehicle Operator Manual Malfunction Indicator Lamp Figure 18 MIL The MALFUNCTION INDICATOR LAMP MIL illuminates to notify the vehicle o...

Page 50: ...d to ON Normal engine operating temperature is 96 C 205 F CAUTION To prevent engine damage do not operate engine above 112 C 234 F this may cause internal damage 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 Form No...

Page 51: ... the engine immediately if the lamp and alarm are activated Contact an authorized service provider immediately to have the problem corrected Lubrication Oil Pressure Lube Oil Pressure At normal operating temperature Low idle 214 kPa 31 psi min High idle 276 kPa 40 psi CAUTION To prevent engine damage shut down engine immediately if the gauge fluctuates or drops below 276 kPa 40 psi under load Corr...

Page 52: ...ICATORS AND SWITCHES Oil Temperature Gauge Figure 21 Oil temperature gauge The engine oil temperature gauge indicates the operating oil temperature of the engine Form No 1172040R1 Page 44 Printed in the United States of America ...

Page 53: ...s engine compression brake ON or OFF ENGINE EXHAUST BRAKE ON OFF TOGGLE SWITCH Figure 23 Exhaust brake toggle switch The exhaust brake toggle switch turns engine exhaust brake ON or OFF NOTE The Exhaust Brake and Engine Exhaust Brake can not be used together Form No 1172040R1 Printed in the United States of America Page 45 ...

Page 54: ...periodically using a master vacuum gauge to ensure a correct calibration Air Restriction Indicator Operation The yellow position indicator progressively fills the window as air filter restriction increases locking at the highest restriction at full load When the yellow position indicator reaches and locks in the red zone a new air filter element should be installed NOTE If the yellow indicator loc...

Page 55: ...understand the use and function of all controls and instruments 1 Check cooling system level Figure 25 Oil level gauge typical 2 Check for correct oil level CAUTION To prevent engine damage do not overfill with oil 3 If oil level is below operating range fill with recommended oil for operating climate The ADD mark indicates 2 8 liters 3 quarts US of oil should be added See Engine Oil Quality and S...

Page 56: ...as a cold starting device or other cold climate starting aid WARNING To prevent personal injury or death do not use ether starting fluid to start engine Figure 26 Ignition switch positions 1 Set parking brake and shift transmission to park or neutral CAUTION To prevent damage to the engine do not depress the accelerator pedal 2 Depress clutch pedal if equipped 3 Turn ignition switch to ON to prehe...

Page 57: ...idle speed is 700 rpm nonadjustable Extended idling periods should be avoided See Extended Idling Periods in this section Check all gauges during warm up CAUTION To prevent engine damage do not increase engine speed until oil pressure gauge indicates above 214 kPa 31 psi If oil pressure does not reach the minimum limit within 20 seconds shutdown the engine 8 Within 20 seconds after engine start en...

Page 58: ...h always connect jumper cable for positive battery terminals first 4 Connect one end of the first jumper cable to the positive terminal of the dead battery or to the positive terminal of the jump start stud Connect the other end to the positive terminal of the booster battery WARNING To prevent personal injury or death do not attach jumper cable to the negative dead battery terminal This can cause...

Page 59: ... the low idle speed from 700 rpm to a maximum of 875 rpm High idle speed is a nonadjustable factory setting High idle speed is a nonadjustable factory setting The high idle setting depends on the application of the engine and has the following ranges MaxxForce DT 2600 rpm through 2770 rpm MaxxForce 9 and 10 2325 rpm through 2425 rpm EXTENDED IDLING PERIODS CAUTION To prevent engine damage do not e...

Page 60: ...egeneration process listed in the Vehicle Operator Manual If the Parked Regeneration process is ignored the engine may stop running See the Safety Information page 3 section for safety precautions A Preliminary Diesel Oxidation Catalyst PDOC and a DOC operates together to oxidize the injected fuel to increase the exhaust gas temperature as needed for DPF Regen ENGINE IDLE SHUTDOWN TIMER FEDERAL OP...

Page 61: ... not function ENGINE IDLE SHUTDOWN TIMER CALIFORNIA STANDARD GOVERNMENT REGULATION State and local regulations may limit engine idle time The vehicle owner or operator is responsible for compliance with these regulations Your heavy duty diesel engine conforms to applicable California Air Resources Board CARB Engine Shutdown System ESS regulations This vehicle is registered and certified for sale i...

Page 62: ...detected Clutch pedal is pressed or clutch pedal switch fault is detected manual transmissions if equipped with a clutch switch Shift selector is moved from neutral automatic transmissions If the IST is enabled the Cold Ambient Protection CAP will not function COLD WEATHER OPERATION WARNING To prevent personal injury or death do not use ether propane gasoline or gasohol as starting aids NOTE If op...

Page 63: ...MBIENT PROTECTION CAP CAP safeguards the engine from damage caused by prolonged idle at no load during cold weather This feature should only be disabled for specialized applications Engine damage may occur if CAP is disabled CAP maintains engine coolant temperature by increasing engine rpm to a programmed value when ambient air temperature is below 0 C 32 F coolant temperature is below 65 C 149 F ...

Page 64: ...ached operating temperature idle the engine for 2 to 3 minutes allowing the hottest engine components to dissipate some of their internal heat Idling is recommended if an engine has been running at maximum horsepower ENGINE WARNING PROTECTION SYSTEM EWPS The Engine Warning Protection System EWPS warns the operator of engine conditions that can damage the engine Optional engine shutdown is availabl...

Page 65: ...libration that can be added to the EWPS by an authorized service provider Engine shut down is available if critical condition is detected ECT Engine overheat warning EOP Low engine oil pressure warning ECL Low engine coolant level warning Warning Temperature above specific threshold will illuminate the STOP ENGINE lamp and set a DTC Critical Temperature above specific threshold will shutdown the e...

Page 66: ...ne to more easily move the load 2 Accelerate smoothly and evenly to engine s rated speed Rapid acceleration causes high fuel consumption 3 To prevent lugging do not allow engine speed to drop below 1 200 rpm during full throttle 4 When approaching a hill press accelerator smoothly to start the upgrade at full power Downshift to maintain maximum vehicle speed DOWNHILL OPERATION CAUTION To prevent e...

Page 67: ... or liters gallons of fuel Service Interval Service Operation See service procedures in this section for more information Before Engine Operation Check engine oil level Check coolant level Drain water separator 1 Inspect Charge Air Cooler CAC Check for external leaks Check air restriction indicator Engine oil drain engine oil filter and centrifuge filter change intervals based on engine family and...

Page 68: ...allons of fuel Inspect belt air intake piping and clamps Check coolant freeze point 48 300 km 30 000 miles 12 months 1 100 hours 15 898 liters 4 200 gallons of fuel Change fuel filter Clean or change fuel strainer Annually Inspect electrical system 193 000 km 120 000 miles 5 000 hours Inspect vibration damper Adjust engine valve lash Adjust engine brake lash if equipped 24 months Pressurize air in...

Page 69: ...re crankcase pressure Inspect sequential turbochargers 322 000 km 200 000 miles 30 months 6 000 hours Cleaning Diesel Particulate Filter DPF 2 500 000 km 300 000 miles 5 years 12 000 hours Service cooling system3 1 Drain water separator Daily 2 Reduced service interval required if allowed CI 4 engine lubrication oil is used If using CI 4 oil reduce DPF cleaning interval to 240 000 km 150 000 miles...

Page 70: ...nterval Before Engine Operation 1 Park vehicle on level ground NOTE Do not check oil level if engine is running or immediately after engine shutdown 2 Shut down engine and wait 5 minutes 3 Remove oil level gauge from fill tube Figure 27 Oil level gauge typical CAUTION To prevent engine damage do the following Assure oil level readings are within the crosshatched operating range on the oil level ga...

Page 71: ...entional non OAT ELC coolant it should minimally meet ASTM D6210 Standard Specification for fully Formulated Glycol Base Engine Coolant for Heavy Duty Engines NOTE Never add ELC to the expansion tank Only add ELC to the coolant tank WARNING To prevent personal injury or death do the following when removing the radiator cap or coolant tank cap Allow the engine to cool for 15 minutes or more Wrap a ...

Page 72: ... to turn cap counterclockwise to remove 4 Check coolant level in the coolant tank For cold engine check coolant level should be between COLD MIN and COLD MAX marks For hot engine check make sure the vehicle is on level ground coolant level should be between the midpoint of the COLD MIN and COLD MAX marks or up to the COLD MAX mark If coolant level is below the COLD MIN mark continue with step 5 an...

Page 73: ...ers and other contaminated materials according to applicable regulations WARNING To prevent personal injury or death do not smoke and keep fuel away from flames and sparks WARNING To prevent personal injury or death store diesel fuel properly in an approved container designed for and clearly marked DIESEL FUEL Figure 28 Fuel filter header assembly 1 Electric fuel pump 2 Fuel filter cover 3 Exhaust...

Page 74: ...10 seconds If the 10 seconds waiting period is not observed the electric fuel pump will not restart 5 Fuel will only flow as long as the fuel pump is running If additional fuel pump run time is desired turn the ignition switch to OFF wait 10 seconds then turn the ignition switch to ON to continue draining water 6 Once fuel water draining is complete close water drain valve and turn the ignition sw...

Page 75: ...nt personal injury or death shut down engine set parking brake and block wheels before inspecting for external leakage 1 Check for the following Cracked hoses Loose clamps Coolant stains Oil stains Fuel stains Leakage at water pump wetness from the weep hole is normal 2 Correct problems Form No 1172040R1 Printed in the United States of America Page 67 ...

Page 76: ...ion indicator has locked in the red zone a new air filter should be installed to prevent low engine power or engine damage 1 Remove restricted air filter element and discard CAUTION To prevent engine damage do not use compressed air to clean filter housing 2 Use a clean water dampened cloth to clean inside of air filter housing 3 Inspect air filter housing for damage or distortion Install new hous...

Page 77: ...consumption and specific engine application If 8 5 miles per gallon of fuel See charts for specific engine family and service interval If 4 5 to 8 5 miles per gallon of fuel See charts for specific engine family and service interval If 4 5 miles per gallon of fuel See charts for specific engine family and service interval CAUTION To prevent engine damage do not extend recommended oil change interv...

Page 78: ...9 and 10 Diesel Engines With Greater Than 230 Horsepower Without Centrifuge Filter Average Vehicle Speed 48 kmpl 30 mph 48 kmpl 30 mph 8 5 650 hours 32187 km 20 000 miles 4 5 to 8 5 575 hours See Figure 30 Fuel Economy mpg 4 5 500 hours 9656 km 6 000 miles MaxxForce DT 9 and 10 Diesel Engine With Greater Than 230 Horsepower With Centrifuge Filter Average Vehicle Speed 48 kmpl 30 mph 48 kmpl 30 mph...

Page 79: ...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 regulations WARNING To prevent personal injury or death wear protective clothing when draining hot oil WARNING To prevent personal injury or death do not let engine fluids s...

Page 80: ...if necessary 5 Using clean engine oil lubricate a new oil pan drain plug O ring Put O ring onto the oil pan drain plug 6 Install oil pan drain plug and tighten to 68 N m 50 lbf ft 7 Recycle or dispose of oil according to applicable regulations Figure 31 Oil cooler module assembly 1 Oil cooler housing 2 Oil cooler 3 Oil filter 8 Put drain pan under oil filter 9 Remove old oil filter and recycle or ...

Page 81: ... DPF cleaning interval see Maintenance Schedule page 59 Add oil through the engine oil fill tube Figure 32 Oil level gauge typical 14 Check oil level gauge Oil level must be within the crosshatched operating range 15 Start engine and run at low idle 16 Check reading on oil pressure gauge Minimum lube oil pressure is 214 kPa 31 psi minimum 700 rpm If there is no gauge reading shut engine down immed...

Page 82: ... e g filters rags in accordance with applicable regulations Recycle or dispose of engine fluids filters and other contaminated materials according to applicable regulations WARNING To prevent personal injury or death wear protective clothing when draining hot oil WARNING To prevent personal injury or death do not let engine fluids stay on your skin Clean skin and nails using hand cleaner and wash ...

Page 83: ...es cont CENTRIFUGE FILTER IF EQUIPPED cont Figure 33 Centrifuge filter assembly 1 Cover assembly 2 Band clamp handle 3 Body assembly 4 Band clamp Figure 34 Centrifuge rotor 1 O ring 2 Rotor 3 Body assembly Form No 1172040R1 Printed in the United States of America Page 75 ...

Page 84: ...he cover and body flanges Engage the tee bolt and turn the band clamp handle and tighten securely 13 Start the engine and check all connections for leaks If no leaks are observed shutdown engine If leaks are observed shutdown engine and correct leaks Start engine again and observe for leaks If no leaks are observed shutdown engine RESETTING CHANGE ENGINE OIL SERVICE INTERVAL MESSAGE Reset the Serv...

Page 85: ...ive belts For any of the following conditions install a new belt Excessive wear Missing material Grease or oil contamination Over three cracks per inch in a belt rib Belt Removal 1 Attach a 1 2 inch drive breaker bar to square hole in auto tensioner 2 Pull the breaker bar clockwise and remove the belt from the auto tensioner pulley and other pulleys 3 Slowly release the breaker bar the auto tensio...

Page 86: ...ker bar clockwise and install the belt over the auto tensioner pulley and other pulleys 3 Slowly release the breaker bar the auto tensioner automatically adjusts 4 Remove the breaker bar Air Intake Piping and Clamps Inspect hoses pipes and clamps For any of the following conditions install new parts Loose hoses or clamps tighten or replace as required Ruptured hoses Cracked air cleaner housing For...

Page 87: ...C 12 F 50 Concentrate and 50 water 36 7 C 34 F 60 Concentrate and 40 water 52 0 C 62 F 67 Concentrate and 33 water 70 6 C 95 F For vehicles operating in extremely cold climates a coolant mixture of 60 Concentrate and 40 water or 67 Concentrate and 33 water provide additional freeze protection as shown in the table above Mixtures having more than 67 Concentrate are not recommended due to the risk o...

Page 88: ... filters and other contaminated materials according to applicable regulations WARNING To prevent personal injury or death store diesel fuel properly in an approved container designed for and clearly marked DIESEL FUEL CAUTION To prevent engine damage do not add fuel to the fuel filter housing this can add contaminants to the fuel Figure 37 Fuel filter header assembly 1 Electric fuel pump 2 Fuel fi...

Page 89: ...and blow out fuel filter housing with compressed air before installing a new filter element Contaminants reaching high pressure fuel system components may cause component failure 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 to prevent contaminants from entering the fuel ...

Page 90: ...ve 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 Attach fuel filter cover to the fuel filter element Secure the fuel filter cover to the fuel filter element by pushing the fuel filter cover onto the fuel filter element The fuel filter cover will snap onto the fuel filter e...

Page 91: ...press and hold starter button 22 When the engine starts release the ignition switch or starter button The ignition switch will return to ON and the engine will continue to run Check for leaks Turn the ignition switch to OFF FUEL STRAINER Service Interval 43 300 km 30 000 miles 12 months 1 100 hours or 15898 liters 4200 gallons of fuel NOTE If fuel used has more than average impurities shorter serv...

Page 92: ...l fuel pump wiring harness connector 2 Fuel filter cap 3 Fuel filter housing 1 Set parking brake and shift transmission to park or neutral 2 Disconnect the wiring harness to the electric fuel pump by pushing down on the tab of the wiring harness connector and pulling away from the electric fuel pump Form No 1172040R1 Page 84 Printed in the United States of America ...

Page 93: ... one of the following If fuel strainer is not damaged clean fuel strainer coat two new O rings with clean diesel fuel and install O rings onto fuel pump If strainer is damaged coat two new O rings with clean diesel fuel and install O rings onto fuel pump Install a new fuel strainer onto the fuel pump 8 Lower fuel pump assembly with strainer into the fuel filter housing Align the three bolt holes i...

Page 94: ...he engine ELECTRICAL SYSTEM Service Interval Annually 1 Check wiring harness for cracks rubbing and loose connections 2 Check sensors for loose connections corrosion or cracks 3 Check battery cables for the following conditions Broken insulation Rubbing or chaffing Corroded or loose connections 4 Repair items identified Electronics Check for diagnostic fault codes and repair as required After repa...

Page 95: ...authorized service provider adjust the valve lash at the correct service interval ENGINE BRAKE LASH Service Interval 193 000 km 120 000 miles or 5 000 hours For inspection procedures see the MaxxForce DT 9 and 10 Engine Service Manual Have an authorized service provider adjust the valve lash at the correct service interval INDUCTION SYSTEM Service Interval 24 months Pressure test the air induction...

Page 96: ...ooling System Capacity Drain ELC Coolant Add ELC Extender 22 30 liters 6 8 gallons 0 2 liter 0 5 quart US 0 2 liter 0 5 quart US 30 49 liters 8 13 gallons 0 5 liter 1 0 quart US 0 5 liter 1 0 quart US 49 83 liters 13 22 gallons 0 7 liter 1 5 quart US 0 7 liter 1 5 quart US NOTE ELC 50 50 Premix is the standard factory fill for the cooling system ELC 50 50 Premix is used to replenish coolant loss a...

Page 97: ...el rub damage Wheel blade damage bent or broken tips 3 Check condition of turbochargers Consult with an authorized service provide if questionable CLEANING DIESEL PARTICULATE FILTER For Engine Using CJ 4 Engine Oil Service Interval 322 000 km 200 000 miles 30 months or 6 000 hours Clean DPF at designated service interval The ECM will illuminate the MIL and generate an Ash Servicing Required messag...

Page 98: ...y or death do the following when removing the radiator cap or coolant tank cap Allow the engine to cool for 15 minutes or more Wrap a thick cloth around the radiator cap or coolant tank cap Loosen cap slowly a quarter to half turn to vent pressure Pause for a moment to avoid being scalded by steam Continue to turn cap counterclockwise to remove 1 Park vehicle on level ground Set parking brake and ...

Page 99: ...e the coolant should be drained before removal See Engine Service Manual for the removal and installation procedure Figure 42 Coolant drain plug for oil system module 7 Remove coolant drain plug from bottom of oil system module 8 After coolant has drained install the coolant drain plug and tighten to 28 N m 18 lbf ft Form No 1172040R1 Printed in the United States of America Page 91 ...

Page 100: ...1 Disconnect electrical connector at the EGR valve 12 Start the engine 13 Allow the engine to operate at a fast idle until the engine reaches normal operating temperature 14 As the engine warms up make sure coolant is flowing through coolant line the coolant line will feel warm to the touch 15 After engine reaches normal operating temperature and the thermostat has opened allow engine to run for 5...

Page 101: ...30 days or less run engine until full operating temperature has been maintained Before storage change the engine oil and filter with the appropriate engine oil for conditions the engine will experience during storage Cover air intake ducts to prevent moisture and debris intrusion during storage Cover vertical exhaust stack Check the battery charge and recharge if needed Disconnect the battery cabl...

Page 102: ...SECTION 6 LONG TERM STORAGE Form No 1172040R1 Page 94 Printed in the United States of America ...

Page 103: ...To prevent personal injury or death shift transmission to park or neutral set parking brake and block wheels before doing diagnostic or service procedures Save scheduled maintenance work orders and receipts for proof of correct maintenance Failure to maintain work orders and receipts may affect your warranty coverage Form No 1172040R1 Printed in the United States of America Page 95 ...

Page 104: ...CTION 7 SERVICE RECORDS Maintenance Service Record cont Maintenance Service Record Date Service Month Service Hours km Miles Item Serviced Form No 1172040R1 Page 96 Printed in the United States of America ...

Page 105: ...CTION 7 SERVICE RECORDS Maintenance Service Record cont Maintenance Service Record Date Service Month Service Hours km Miles Item Serviced Form No 1172040R1 Printed in the United States of America Page 97 ...

Page 106: ... level Excessive use of crankcase lubricating oil coolant battery fluid or fuel Unusual engine noise Correct amount of electrolyte if not a maintenance free battery Condition of electrical equipment Do the following before engine operation to prevent engine failure Add coolant if necessary Make sure filler cap seal is in good condition and the cap is installed tightly Check air cleaner indicator w...

Page 107: ...CORDS Daily Care and Report cont Daily Care and Report Model Serial No Fuel Parts Labor Date Miles Qty Cost Lube Oil Parts Cost Time Cost Service Performed Form No 1172040R1 Printed in the United States of America Page 99 ...

Page 108: ...CORDS Daily Care and Report cont Daily Care and Report Model Serial No Fuel Parts Labor Date Miles Qty Cost Lube Oil Parts Cost Time Cost Service Performed Form No 1172040R1 Page 100 Printed in the United States of America ...

Page 109: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

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