EPA 10, 2013 HD-OBD - US, Canada, Mexico

MaxxForce® DT, 9, & 10

®
MaxxForce DT, 9, & 10

Engine Operation and Maintenance Manual

Navistar, Inc.
2701 Navistar Drive, Lisle, IL 60532 USA

0000001837
March 2015
4328100R3
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
 IMPORTANT
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.

NOTICE CALIFORNIA
Be advised that this motor vehicle may be equipped with Proposition 65 Warning
computer / recording devices. Their function is to allow an
authorized individual to download data or information relating Diesel engine exhaust and some of its constituents are
to the operation or performance of this vehicle. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
The stored data or information may be neither downloaded
nor retrieved except by the vehicle’s registered owner, or, in Battery posts, terminals and related accessories contain
the alternative, by another individual or entity authorized by lead and lead compounds, chemicals known to the State
the registered owner, (e.g., International Dealer) who may of California to cause cancer and reproductive harm.
need this data or information to properly service or diagnose Wash hands after handling.
this vehicle for repair or following an accident.
Any access to this information without the owner’s consent
may be in violation of law and may subject that person or
entity to criminal penalties.
 TABLE OF CONTENTS

FOREWORD.................................................................................... 1

SAFETY INFORMATION...................................................................... 3

WARRANTY..................................................................................... 7
Federal Emission System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warranty Repairs and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Maintenance or Repair Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Emergency Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
What is not Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Warranty Rights and Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
California Emission System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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 Identification Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
 TABLE OF CONTENTS

Engine Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Engine Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Engine Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Component Location - Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Component Location - Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Component Location - Intake Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Component Location - Exhaust Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Component Location - Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Ultra Low 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Engine Oil Quality and Service Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
API CJ-4 for High Performance Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
SAE Oil Viscosity Grades And Temperature Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Coolant Mixtures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Extended Life Coolant (ELC) – Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Contamination of Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Warning Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
 TABLE OF CONTENTS

Wait to Start Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Idle Shutdown Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Maintenance Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Amber Warning Lamp (AWL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
RED Stop Lamp (RSL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
High Exhaust System Temperature (HEST) Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Diesel Particulate Filter (DPF) Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Malfunction Indicator Lamp (MIL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Typical Water Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Engine Brake ON/OFF Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Engine Exhaust Brake ON/OFF Toggle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Air Cleaner Restriction Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

SECTION 4 – ENGINE OPERATION

Preoperation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Priming the Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Emergency Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Suggested Warm-up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Extended Idling Periods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Exhaust Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Aftertreatment (AFT) High-Soot Auto Engine Shut Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Engine Idle Shutdown Timer (Federal-Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Engine Idle Shutdown Timer (California-Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
 TABLE OF CONTENTS

Cold Ambient Protection (CAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Engine Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
HD-OBD Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Radiator Shuttle Enable (RSE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Road Speed Limiting (RSL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Road Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Charge Air Cooler (CAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
External Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Air Cleaner Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Centrifuge Filter (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Resetting Change Engine Oil Service Interval Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Belt, Air Intake Piping and Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Coolant Freeze Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Fuel Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Engine Valve Lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Engine Brake Lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
 TABLE OF CONTENTS

Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Extended Life Coolant (ELC) Extender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Crankcase Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Cleaning Diesel Particulate Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Service Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

SECTION 6 – LONG TERM STORAGE

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

SECTION 7 – SERVICE RECORDS

Maintenance Service Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Daily Care and Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
 FOREWORD

Foreword Technical Service Literature is revised periodically. Use only up

to date service information.
Navistar, Inc. is committed to continuous research and
development to improve products and introduce technological To order technical service literature, contact your dealer.
advances. Procedures, specifications, and parts defined in
All marks are trademarks of their respective owners.
published technical service literature may be altered.
About the Manual
NOTE: Photo illustrations identify specific parts or
assemblies that support text and procedures; other areas 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.
for operators to operate and maintain Navistar diesel engines.
The illustrations, symbols, or feature descriptions will not be
Contact your dealer for more information.
available for all applications, please reference your vehicle
operations manuals for complete information. Both metric and
For Technical Service Information, refer to the applicable:
U.S. customary values are listed in this manual. The U.S.
customary value is listed first, followed by the metric value in
Engine Service Manual brackets. For additional service literature, refer to Technical
Service Information noted in this manual. This manual does not
Engine Diagnostic Manual
cover vehicle or equipment maintenance procedures. Consult
Hard Start / No Start Diagnostic Form the original vehicle or equipment manufacturer for specific
Electronic Control System Diagnostics Form maintenance recommendations.

Performance Diagnostics Form

Page 1
 FOREWORD

Page 2
 SAFETY INFORMATION

Safety Information Safety Instructions

This manual provides general and specific maintenance Work Area

procedures essential for reliable engine operation and your • Keep work area clean, dry, and organized.
safety. Since many variations in procedures, tools, and service
parts are involved, advice for all possible safety conditions and • Keep tools and parts off the floor.
hazards cannot be stated. • Make sure the work area is ventilated and well lit.
Read safety instructions before doing any service and test • Make sure a First Aid Kit is available.
procedures for the engine or vehicle. See related application
manuals for more information. Safety Equipment

Obey Safety Instructions, Warnings, Cautions, and Notes in this • Use correct lifting devices.
manual. Not following warnings, cautions, and notes can lead to • Use safety wheel chocks and stands.
injury, death or damage to the engine or vehicle.
Protective Measures
Safety Terminology • Wear protective safety glasses and shoes.
Three terms are used to stress your safety and safe operation of • Wear correct hearing protection.
the engine: Warning, Caution, and Note.
• Wear cotton work clothing.
Warning: A warning describes actions necessary to prevent
or eliminate conditions, hazards, and unsafe practices that can • Wear sleeved heat protective gloves.
cause personal injury or death. • Do not wear rings, watches or other jewelry.
Caution: A caution describes actions necessary to prevent or • Restrain long hair.
eliminate conditions that can cause damage to the engine or
vehicle.
Note: A note describes actions necessary for correct, efficient
engine operation.

Page 3
 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.
2. Type B — Flammable liquids
• Clear the area before starting the engine.
3. Type C — Electrical equipment
Engine
Batteries
• The engine should be operated or serviced only by
• Always disconnect the main negative battery cable first.
qualified individuals.
• Always connect the main negative battery cable last.
• Provide necessary ventilation when operating engine in a
closed area. • Avoid leaning over batteries.
• Keep combustible material away from engine exhaust • Protect your eyes.
system and exhaust manifolds.
• Do not expose batteries to flames or sparks.
• Install all shields, guards, and access covers before
• Do not smoke in workplace.
operating engine.
Compressed Air
• Do not run engine with unprotected air inlets or exhaust
openings. If unavoidable for service reasons, put • Use an OSHA approved blow gun rated at 207 kPa (30
protective screens over all openings before servicing psi).
engine.
• Limit shop air pressure to 207 kPa (30 psi).
• Shut engine off and relieve all pressure in the system
• Wear safety glasses or goggles.
before removing panels, housing covers, and caps.
• Wear hearing protection.
• If an engine is not safe to operate, tag the engine and
ignition key. • Use shielding to protect others in the work area.
Fire Prevention • Do not direct compressed air at body or clothing.
• Make sure charged fire extinguishers are in the work area.

Page 4
 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.
• Check for frayed power cords before using power tools. • Do not refuel the tank when the engine is running.
Fluids Under Pressure Removal of Tools, Parts, and Equipment
• Use extreme caution when working on systems under • Reinstall all safety guards, shields, and covers after
pressure. servicing the engine.
• Follow approved procedures only. • Make sure all tools, parts, and service equipment are
removed from the engine and vehicle after all work is
done.

Page 5
 SAFETY INFORMATION

Page 6
 WARRANTY

Warranty REQUIRED MAINTENANCE

As the vehicle owner, you are responsible for all required

Federal Emission System Warranty maintenance described in this manual. Navistar recommends
that you retain all maintenance receipts. Navistar will not deny
WARRANTY PERIOD an emission warranty claim solely because you have no record
of maintenance. However, a claim may be denied if your failure
Navistar Inc. warrants your medium-heavy duty diesel engine to perform proper maintenance resulted in the failure of a
conforms with applicable emission regulations and is free from warranted part and you cannot provide appropriate evidence
defects in materials and workmanship which would cause such of maintenance. Take your vehicle to an authorized service
engine to fail to conform with applicable emission regulations for provider when a problem occurs.
the following warranty period (whichever comes first):
WARRANTY REPAIRS AND SERVICE
• 5 years
• 100,000 miles (160,000 km) All emission control system parts proven defective during normal
use will be repaired or replaced during the warranty period.
• Or if covered by any basic or extended warranty (if greater Warranty repairs and service will be done by an authorized
than above) service provider with no charge for parts, labor, and diagnostics.
Your medium-heavy duty diesel engine conforms to U.S. Warranty repairs should be completed in a reasonable time, not
Environmental Protection Agency regulations for emission to exceed 30 days. Navistar may deny warranty coverage if
systems. your vehicle or a part has failed due to abuse, neglect, improper
maintenance, or unapproved modifications.
The engine model year, service class, and required emission
information is on the emission label attached on top of the valve
cover. This warranty is based on the engine model year, not the
model year of the vehicle. The warranty period begins on the
date the new vehicle is delivered to the first retail purchaser.

Page 7
 WARRANTY

RECOMMENDED MAINTENANCE OR REPAIR PARTS WHAT IS NOT COVERED BY WARRANTY

MaxxForce®service parts or MaxxForce® ReNEWed® parts Unauthorized parts or expendable parts

are recommended for maintenance or repairs to maintain the
• 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.
• Non-defective parts replaced by an unauthorized service
provider.
EMERGENCY REPAIRS
• Parts requiring replacement at inspection or adjustment
Emergency repairs are recognized, if parts are not available maintenance intervals for reasons other than being
within 30 days or repairs are not completed within 30 days. defective.
If an authorized service provider is not reasonably available,
the vehicle owner or any service establishment can install any • Replacement of expendable items made in connection
replacement part. with scheduled maintenance.

Navistar will reimburse you for emergency repairs (including Vehicle, engine, and part malfunctions caused by the
diagnostics) for the following: following:

• Replacement parts that do not exceed manufacturer's • Use of incorrect fuel, engine oil, or coolant
suggested retail price. • Failure to maintain correct maintenance schedule
• Labor charges based on manufacturer's recommended • Incorrect adjustments, modifications, alterations,
time allowance and geographic hourly rate. tampering or disconnection of vehicle components.
Replaced parts and paid invoices must be given to your dealer • Abuse or misuse of engine
for reimbursement of emergency repairs.

Page 8
 WARRANTY

• Accidents, acts of nature or other events beyond control California Emission System Warranty
of Navistar.
WARRANTY PERIOD
Conditions not covered by Warranty
• Loss of time, inconvenience, use of vehicle/engine or The California Air Resources Board and Navistar, Inc. are
commercial loss. pleased to explain the emission control system warranty on
your 2014 heavy-duty diesel engine. In California, new motor
• Vehicles with an altered or disconnected odometer or vehicles must be designated, built and equipped to meet the
hourmeter when mileage or hours cannot be determined. State’s stringent anti-smog standards.
WARRANTY RIGHTS AND RESPONSIBILITIES Navistar, Inc. warrants your medium-heavy duty diesel engine
for the following warranty period (whichever comes first):
Navistar, Inc. assures that the emission warranty is being
• 5 years
properly administered. If you have not received satisfactory
service or have questions regarding your warranty rights and • 100,000 miles (160,000 km)
responsibilities, contact the regional office for assistance. The
• 3,000 hours
address and phone number of each regional office is listed
in your Vehicle Operator Manual. If additional assistance is • Or if covered by any basic or extended warranty (if greater
required, contact the Manager of Customer Relations. than above)
Manager, Customer Relations Your medium-heavy duty diesel engine conforms to applicable
Navistar, Inc. California Air Resources Board (CARB) regulations. This vehicle
2701 Navistar Drive is registered and certified for sale in California.
Lisle, IL 60532
The engine model year, service class, and required emission
(Telephone 1-800-448-7825)
information is on the emission label attached on top of the valve
cover. This warranty is based on the engine model year, not the
model year of the vehicle. The warranty period begins on the
date the new vehicle is delivered to the first retail purchaser.

Page 9
 WARRANTY

REQUIRED MAINTENANCE RECOMMENDED MAINTENANCE OR REPAIR PARTS

As the vehicle owner, you are responsible for all required MaxxForce® service parts or MaxxForce® ReNEWed® parts
maintenance described in this manual. Navistar recommends are recommended for maintenance or repairs to maintain the
that you retain all receipts covering maintenance on your truck, original quality of your emission certified engine. If parts not
but Navistar cannot deny warranty solely for the lack of receipts recommended by Navistar cause damage to the engine or
or your failure to ensure the performance of all scheduled vehicle, the warranty is invalid and maintenance and repair
maintenance. However, a claim may be denied if Navistar costs will not be covered.
demonstrates that the (engine / vehicle) has been abused,
neglected, or improperly maintained, and that such abuse, EMERGENCY REPAIRS
neglect, or improper maintenance was the direct cause of the
need for the repair or replacement of the part. Take your vehicle Emergency repairs are recognized, if parts are not available
to an authorized service provider when a problem occurs. within 30 days or repairs are not completed within 30 days.
If an authorized service provider is not reasonably available,
WARRANTY REPAIRS AND SERVICE the vehicle owner or any service establishment can install
replacement part.
All emission control system parts proven defective, or that fail
Navistar will reimburse you for emergency repairs (including
to meet the requirements in the California Code of Regulations,
diagnostics) for the following:
Title 13, Sections 2700 to 2706, and 2710 during normal
use will be repaired or replaced during the warranty period. • Replacement parts that do not exceed manufacturer's
Warranty repairs and service will be done by an authorized suggested retail price.
service provider with no charge for parts, labor, and diagnostics.
• Labor charges based on manufacturer's recommended
Warranty repairs should be completed in a reasonable time,
time allowance and geographic hourly rate.
not to exceed 30 days. Navistar, Inc. may deny you warranty
coverage if your vehicle or a part has failed due to abuse, Replaced parts and paid invoices must be given to a
neglect, improper maintenance, or unapproved modifications. International dealer for reimbursement of emergency repairs.

Page 10
 WARRANTY

WHAT IS COVERED BY WARRANTY • Air induction system (includes turbocharger, exhaust

manifold, Exhaust Gas Recirculation [EGR] system, EGR
Where a warrantable condition exists, Navistar, Inc. will repair rate and feedback control system, and intake manifold)
your diesel engine at no cost to you, including diagnosis, parts,
and labor. If your vehicle or truck fails a Smog Check inspection, • Positive crankcase ventilation system (includes
all necessary repairs and adjustments will be made by Navistar Crankcase Ventilation Valve [CCV] and oil fill cap)
to ensure that your emission control system Performance • Diesel Particulate Control System (includes catalytic
Warranty. converter, traps, fuel additive devices, and other devices
If any emission-related part on your diesel engine is defective, used to regenerate or aid in the regeneration of the
the part will be repaired or replaced by Navistar. This is your particulate control device)
short-term emission control system Defects Warranty. For • Miscellaneous items used in above systems
diesel-powered heavy-duty vehicles (except medium-duty
vehicles), and motor vehicle engines used in such vehicles, a A. Hoses, clamps, fittings and tubing
period of use of five years, 100,000 miles, or 3,000 hours of B. Pulleys, belts, and idlers
operation, whichever first occurs. However, in no case may
this period be less than the basic mechanical warranty that the C. Vacuum, temperature, and time sensitive valves
manufacturer provides (with or without additional charge) to the and switches
purchaser of the engine. Extended warranties on select parts do D. Electronic controls
not extend the emissions warranty requirements for the entire
engine but only for those parts. In cases where responsibility WHAT IS NOT COVERED BY WARRANTY
for an extended warranty is shared between the owner and the
manufacturer, the emission warranty shall also be shared in the Unauthorized parts or expendable parts:
same manner as specified in the warranty agreement.
• Parts other than MaxxForce® service parts or MaxxForce®
New vehicles and engines, registered and certified for sale in ReNEWed® parts
California, have the following items covered by the emission
• Aftermarket parts or service kits
warranty when first installed on the engine as original equipment
by Navistar, Inc: • Non-defective parts replaced by other than your dealer
• Fuel injection system

Page 11
 WARRANTY

• Parts requiring replacement at inspection or adjustment WARRANTY RIGHTS AND RESPONSIBILITIES

maintenance intervals for reasons other than being
defective Navistar assures that the emission warranty is being properly
administered. If you have not received satisfactory service
• Replacement of expendable items made in connection or have questions regarding your warranty rights and
with scheduled maintenance responsibilities, contact the regional office for assistance. The
Vehicle, engine, and part malfunctions caused by the address and phone number of each regional office is listed
following: in your Vehicle Operator Manual. If additional assistance is
required, contact the Manager of Customer Relations.
• Use of incorrect fuel, engine oil, or coolant
Manager, Customer Relations
• Failure to maintain correct maintenance schedule Navistar, Inc.
• Incorrect adjustments, modifications, alterations, 2701 Navistar Drive
tampering or disconnection of vehicle components Lisle, IL 60532
(Telephone 1-800-448-7825)
• Abuse or misuse of engine
If further questions of warranty rights and responsibilities remain,
• Accidents, acts of nature or other events beyond control contact:
of Navistar Inc.
The Air Resources Board
Conditions not Covered by Warranty: 9528 Telstar Avenue
• Loss of time, inconvenience, use of vehicle / engine or El Monte, California 91731
commercial loss
• Vehicles with an altered or disconnected odometer or
hourmeter when mileage or hours cannot be determined

Page 12
 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 – Motor truck
U – United States
7 digit suffix – Engine serial number sequence beginning with
3300001

Figure 1 Engine serial number location

The engine serial number is in two locations:

• Stamped on the right side of the crankcase, just above
the oil filter header.
• On the engine emission label on the valve cover.

Page 13
 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:
• Air compressor
• Air conditioning compressor
• Alternator
• Cooling fan clutch
Figure 2 U.S. Environmental Protection Agency (EPA)
exhaust emission label (example) • Power steering pump
• Starter motor

The U.S. Environmental Protection Agency (EPA) exhaust • Engine Control Module (ECM)
emission label is attached on top of the valve cover. The EPA
label typically includes the following:
• Model year
• Engine family, model, and displacement
• Advertised brake horsepower and torque rating

Page 14
 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
• MaxxForce® DT engines 7.6 L (466 in3)
• MaxxForce® 9 and 10 engines 9.3 L (570 in3)
Compression ratio
• MaxxForce® DT engines 16.9: 1
®
• MaxxForce 9 and 10 engines 16.5 : 1
Stroke
• MaxxForce® DT engines 119 mm (4.68 in)
®
• MaxxForce 9 and 10 engines 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

Page 15
 SECTION 1 – ENGINE SYSTEMS

MaxxForce® DT, 9, & 10 Engines

1
Lube system capacity (including filter) 28 L (30 qts US)
2
Lube system capacity (overhaul only, with filter) 32 L (34 qts US)
Engine lubrication oil pressure at operating temperature with SAE 10W-30 oil
• Low idle 15 psi (103 kPa) minimum

• High idle 50 psi (344 kPa) 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.

Page 16
 SECTION 1 – ENGINE SYSTEMS

Engine Description Crankcase Assembly

MaxxForce® DT, 9, & 10 engines are inline six cylinder diesel The camshaft is supported by four insert bushings pressed into
engines which have been designed for increased durability, the crankcase. The camshaft gear is driven from the front of the
reliability, and ease of maintenance. engine. A thrust flange is located between the camshaft and the
drive gear. The overhead valve train includes mechanical roller
Air Management System lifters, push rods, rocker arms, and dual valves that open using
MaxxForce® DT, 9, & 10 engines use an electronically controlled a valve bridge.
two stage turbocharging system consisting of a high-pressure A gerotor lube oil pump is mounted on the front cover and is
and low-pressure turbocharger. The high and low-pressure driven by the crankshaft. 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
A Charge Air Cooler (CAC) is an air-to-air heat exchanger which engine oil filter.
cools and increases the density of the air charge. In addition MaxxForce® DT engines use a one piece aluminum alloy piston.
to the CAC, the MaxxForce® DT, 9, & 10 diesel engines have The MaxxForce® DT, 9, & 10 engines use a one piece steel
an engine mounted interstage cooler. The cooler has a low piston. The pistons have a 0.0 offset and are fully symmetric.
temperature radiator and a low temperature thermostat.
The one piece crankcase uses replaceable wet cylinder sleeves
The Exhaust Gas Recirculation (EGR) system circulates cooled that are sealed by a single crevice seal. Some applications
exhaust into the intake air stream in the intake manifold. This include a crankcase ladder which is designed to absorb heavier
cools the combustion process and reduces the formation of NOX loads and reduce engine noise.
engine emissions.
A closed crankcase breather system uses an engine mounted
Cold Start Assist oil separator to return oil to the crankcase and vent crankcase
The Inlet Air Heater (IAH) system warms the incoming air supply pressure into the intake system.
to aid cold engine starting and reduce white smoke during
warm-up. The IAH system will initially illuminate the WAIT TO
START lamp. When the lamp turns off, the engine can be
started.

Page 17
 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. The piston pin moves with EPA emissions requirements.
freely inside the connecting rod and piston. Piston pin retaining
Heavy-Duty On-Board Diagnostics (HD-OBD) is a U.S.
rings secure the piston pin in the piston. The rear oil seal carrier
Government mandated standard for all 2013 and later Class 4
is part of the flywheel housing.
and above vehicles with a Gross Vehicle Weight Rating (GVWR)
Cylinder Head of 14,001 pounds or more. The HD-OBD system monitors the
engine and aftertreatment systems to verify they are operating
The cylinder head has four valves per cylinder with centrally
within emissions limits. If an emissions fault is logged, the
located fuel injectors directing fuel over the pistons. This
Malfunction Indicator Lamp (MIL) will illuminate and one or more
configuration provides improved performance and reduces
fault codes will be set.
emissions.
The HD-OBD system operates similarly to previous power train
The fuel injection system is electro-hydraulic. The system
control systems by storing fault codes and turning on the MIL. If
includes an under-valve-cover high-pressure oil manifold, fuel
the problem that caused the fault goes away, the code will clear
injectors, and a high-pressure oil pump. The injectors are
and the MIL will go out after certain operating conditions have
installed in the cylinder head, under the valve cover and under
been met. This may take several times operating the vehicle.
the high-pressure oil manifold.
The Crankshaft Position (CKP) sensor and the Camshaft
The water supply housing serves as the mounting bracket for
Position (CMP) sensor are used by the ECM to calculate rpm,
the refrigerant compressor. Mounting capabilities for a dual
fuel timing, fuel quantity, and duration of fuel injection.
refrigerant compressor are available as an option. The pad
mounting design of the alternator and refrigerant compressor
brackets provide easy removal and improved durability.

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 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,
and Engine Fuel (EFP) sensor. If equipped, an optional fuel
and improved engine performance. This feature should only
heater element is located in the fuel filter housing. Conditioned
be disabled for specialized applications. Engine damage may
fuel is pumped through the intake manifold and cylinder head to
occur if CAP is disabled.
the fuel injectors.
CAP maintains engine coolant temperature by increasing engine
The WIF sensor detects water in the fuel system. When a
rpm to a programmed value when ambient air temperature is
programmed value of water is collected in the fuel filter housing,
below 0 °C (32 °F), coolant temperature is below 65 °C (149 °F),
the FUEL FILTER lamp will illuminate. The collected water must
and engine has been idling at no load for over 5 minutes.
be removed immediately. The water is drained by using the
drain valve located on the fuel filter housing. For further information, see Cold Ambient Protection (CAP)
(page 54).

Engine Features

Exhaust Aftertreatment (AFT) System

The exhaust AFT system processes engine exhaust to meet
tailpipe emission requirements. The AFT system traps
particulate matter (soot) using a Diesel Particulate Filter (DPF).
The trapped particulate matter is then rendered to ash by
heating the exhaust and injecting fuel through a process called
regeneration. Regeneration reduces the frequency of AFT
system maintenance without adversely affecting emissions.

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 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. The engine control system calibrates vehicle speed. The
calculated vehicle speed is a function of transmission tail shaft
The high idle governor prevents engine rpm from going above a
speed, number of teeth on the tail shaft, rear axle ratio, and tire
safe speed that would cause engine damage.
revolutions per mile. Use the Electronic Service Tool (EST) with
Electronic Service Tool (EST) Interface ServiceMaxx™ software to program new speed calibrations into
the ECM.
Engines are equipped with the EST interface for communication
between the Engine Control Module (ECM) and the EST. The tachometer signal is generated by the ECM by computing
signals for the Camshaft Position (CMP) sensor and Crankshaft
CAN is a J1939 serial bus system, also know as the Drivetrain
Position (CKP) sensor.
Datalink. The public Controller Area Network (CAN) provides a
communication link between all connecting modules by sending Engine Crank Inhibit (ECI)
and receiving messages.
ECI prevents starter engagement when the engine is running or
The EST with ServiceMaxx™ software communicates with the when the transmission is in gear.
ECM through the EST interface. The EST, through the public
Event Logging System
CAN, is able to retrieve Diagnostic Trouble Codes (DTCs), run
diagnostic tests, and view Parameter Identifiers (PIDs) from all The event logging system records engine operation above
inputs and outputs of the ECM. maximum rpm (over speed), low coolant level, high coolant
temperature, or low oil pressure. The readings for the odometer
CAN public supports the following functions:
and hourmeter are stored in the ECM memory at the time of an
• Transmission of engine parameter data event and can be retrieved using the EST.
• Transmission and clearing of DTCs
• Diagnostics and troubleshooting

Page 20
 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.
adjusts fuel injector operation accordingly.
Cruise Control
Low idle speed is increased proportionally when the ECT is
The ECM controls the cruise control feature. The cruise control
below 70 °C (158 °F) at 700 rpm to below -10 °C (14 °F) at 875
system functions similarly for all electronic engines. Maximum
rpm maximum.
and minimum allowable cruise control speeds will vary based on
Service Diagnostics application. To operate cruise control, see appropriate Vehicle
Operator Manual.
The Electronic Service Tool (EST) provides diagnostic
information using the J1939 datalink. Engine Brake
Faults from sensors, actuators, electronic components, and An optional exhaust or engine brake is available to aid in the
engine systems are detected by the ECM. The faults are deceleration rate of vehicles. The exhaust and engine brake
accessed by the EST through the Diagnostic Connector, and provides improved braking performance. These options are
are displayed as Diagnostic Trouble Codes (DTCs) on the EST. mutually exclusive and are available for all ratings.
Effective engine diagnostics require and rely on DTCs. See the
Engine Fan Control
applicable Engine Diagnostic Manual.
The engine fan control commands higher air flow through the
radiator when the Air Conditioner (A/C) is on or when the coolant
Engine Optional Features or inlet air temperature goes above a set temperature.

Air Compressor Engine Warning Protection System (EWPS)

An air compressor is available for applications that require air EWPS is designed to protect the engine from damage
brakes or air suspension. A hydraulic power steering pump can by monitoring critical engine data such as engine speed,
be used with or without the air compressor. temperature, oil pressure, and coolant levels. This feature will
alert the operator by using a combination of visual and audible
warnings when critical engine parameters have been exceeded.

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 SECTION 1 – ENGINE SYSTEMS

For further information see Engine Warning Protection System Customer programmable parameters within the Engine Control
EWPS . Module (ECM) provide in-cab engine speed control related
options that can be adjusted to suit the customer's needs.
Fuel Heater
Choosing whether the operator is allowed to increase engine
A fuel heater is available and installed in the fuel filter assembly. speed using the accelerator pedal with out disengaging the PTO
The heater warms the supply fuel to prevent waxing during cold is an example.
conditions.
Remote Engine Speed Control (RESC)
Idle Shutdown Timer (IST) Federal - Optional or California -
RESC, commonly referred to as remote PTO, allows the operator
Standard
to set and maintain engine speed without using the accelerator
IST allows the Engine Control Module (ECM) to shut down the pedal. 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® and 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.
will conform to mandatory California Air Resources Board
Engine speed can be ramped up and down with RESC similar
(CARB) Engine Shutdown System (ESS) regulations.
to the way the in-cab PTO feature works. However, the RESC
All (non-California) Federal Navistar® and MaxxForce® engines feature includes two additional switches (remote preset and
can have idle time that can be programmed from 2 to 120 remote variable) which allow the operator to choose the mode
minutes. of engine speed control operation.
For further information, see Engine Shutdown (page 51). Customer programmable parameters within the ECM provide
RESC options that can be adjusted to suit the customer's
Power Take Off (PTO) needs. Choosing whether a remote throttle pedal is used for
PTO operation is an example.
In Cab Power Take-off (PTO) Control
Oil Pan Heater
The in cab engine speed control feature, commonly referred to
as Power Take-off (PTO), allows the operator to set and maintain The oil pan heater warms engine oil in the pan to ensure optimum
a constant engine speed without using the accelerator pedal. It oil flow.
is commonly used for powering auxiliary devices.

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 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. has expired and routine maintenance procedures should be
performed.
Road Speed Limiting (RSL)
The term “interval” in this case is used to describe the distance,
RSL is designed to regulate the maximum vehicle speed as
time, or fuel used between the last maintenance performed on
controlled by the accelerator pedal.
the vehicle and the next maintenance which is due.
Customer programmable parameters within the Engine Control
It is essential that operators are trained to know the maintenance
Module (ECM) provide vehicle speed governor related options
schedules and instructions regarding the operation and reset
that can be adjusted to suit the customer's needs. A parameter
functionality of the service interval for the feature to be effective.
is used to set the maximum accelerator controlled vehicle speed.
See Resetting Change Engine Oil Service Interval Message
(page 72).

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 SECTION 1 – ENGINE SYSTEMS

Engine Component Locations

COMPONENT LOCATION - TOP

Figure 3 Top
1. Water outlet tube assembly 7. Valve cover 13. Fuel filter assembly
2. Interstage cooler inlet duct (245 HP and 8. Exhaust emission label (location) 14. Electronic fuel pump (fuel strainer
above) 9. Air and Exhaust Gas Recirculation (EGR) location)
3. Interstage cooler (245 HP and above) mixer duct 15. Throttle coupling
4. Turbocharger air inlet duct 10. Oil filler tube 16. Deaeration hose elbow
5. High-pressure turbocharger outlet 11. Oil level gauge
6. Exhaust brake valve assembly 12. EGR valve

Page 24
 SECTION 1 – ENGINE SYSTEMS

COMPONENT LOCATION - FRONT

Figure 4 Front
1. High-pressure turbo outlet 5. EGR valve 10. Water inlet elbow
2. Water outlet tube assembly 6. Oil level gauge 11. Water pump pulley
3. Deaeration hose elbow 7. Front cover 12. Auto belt tensioner
4. Air and Exhaust Gas Recirculation (EGR) 8. Fan drive pulley 13. Turbocharger air inlet duct
mixer duct 9. Vibration damper assembly

Page 25
 SECTION 1 – ENGINE SYSTEMS

COMPONENT LOCATION - INTAKE SIDE

Figure 5 Intake side

1. Electric fuel pump (fuel strainer location) 5. Air and EGR mixer duct 9. Oil Pan
2. Fuel filter assembly 6. Intake manifold 10. Power steering pump
3. Oil level gauge 7. Engine Control Module (ECM) 11. Air compressor assembly
4. Exhaust Gas Recirculation (EGR) valve 8. Oil pan drain plug 12. Water drain valve

Page 26
 SECTION 1 – ENGINE SYSTEMS

COMPONENT LOCATION - EXHAUST SIDE

Figure 6 Exhaust side

1. Exhaust brake valve assembly 8. Alternator bracket 14. Oil filter
2. Low-pressure turbocharger 9. Crankcase breather outlet tube 15. Low-pressure turbo oil drain tube
3. High-pressure turbocharger 10. Crankcase breather assembly with 16. High-pressure turbo oil drain tube
4. Turbocharger wastegate actuator turbine 17. Exhaust brake assembly
5. Lifting eye 11. Exhaust Gas Recirculation (EGR) coolant 18. Turbocharger oil supply tube
6. Vehicle heater port drain plug
7. Water supply housing refrigerant 12. Coolant drain plug
compressor mount 13. Oil cooler module

Page 27
 SECTION 1 – ENGINE SYSTEMS

COMPONENT LOCATION - REAR

Figure 7 Rear
1. Air and Exhaust Gas Recirculation (EGR) 4. Turbo air inlet duct 8. Flywheel
mixer 5. EGR crossover tube assembly 9. Injector feed tube assembly
2. Exhaust brake valve 6. Rear engine mounting bracket (2) 10. Exhaust brake valve supply hose
3. Cylinder head 7. Flywheel housing 11. Oil fill tube

Page 28
 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). These
specifications are included in the standard under the designation
GOVERNMENT REGULATION: Diesel fuel sold for No. 2-D S15 fuel and No. 1-D S15 fuel. Grade No. 1-D fuel is
use in 2007 and later highway vehicles must be limited a lighter fuel with higher volatility than grade No. 2-D; it may
to a sulfur content of 15 parts per million (ppm). 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)
• Commercial Jet A or JP8 aviation fuel
• Heating or furnace oil
• Biodiesel B100 (neat biodiesel)
• Biodiesel blends higher than 20%
• Any fuel mixed with used motor oil.
Biodiesel fuels are methyl or ethyl esters derived from a broad
Figure 8 American Petroleum Institute (API) Diesel Pump variety of renewable sources such as vegetable oils, animal fats,
Label and waste cooking oils. These oxygenated organic compounds
have key properties that are comparable to those in diesel fuel.

The API Diesel Pump Label is compliant with Environmental

Protection Agency (EPA) CFR 80.570.

Page 29
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

ACCEPTABLE FUEL BLENDS USE OF HIGHER BIODIESEL FUEL BLENDS (B6 TO B20)

• Ultra low sulfur kerosene (No. 1-D S15 diesel fuel) Standard ASTM D7467-08 covers the specifications for blends
blended with No. 2-D S15 fuel to improve cold weather between 6% and 20% (B6 to B20). These blends may be used
performance. Blend rate would depend upon regional in vehicles that operate in populated areas or in fleets which are
low temperatures. required to use alternative fuels to reduce urban pollution.
• Lower biodiesel blends up to B5 (a blend of 5% neat Use of B6 to B20 blends is at the discretion of the
biodiesel with 95% diesel fuel). customer/operator and will not automatically void an engine
warranty. However, if engine component failure can be directly
Such blends have characteristics indistinguishable from
attributable to use of a B6 to B20 blend not provided by
diesel fuel, if the two components meet the requirements
a BQ9000 certified fuel supplier or not meeting the ASTM
of their respective standards: ASTM D6751 current
D7467-08 Standard, Navistar may, at its option, deny warranty
revision, for neat biodiesel and ASTM D975 current
on the affected engine or engine component.
revision, for ultra low sulfur diesel fuel.
Navistar recommends users of B20 select a BQ9000 certified
As of October 1, 2008 blends of up to 5% biodiesel are
fuel supplier and request proof from the supplier the fuel meets
included in the diesel fuel standard ASTM D975-08a.
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 30
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

If providers and customers follow correct storage and Engine Oil

maintenance procedures for fuel and equipment, blends
of B6 to B20 that meet ASTM D7467-08 Standard should ENGINE OIL QUALITY AND SERVICE CATEGORIES
perform satisfactorily in diesel engines. Contact your dealer
for recommendations for correct storage and maintenance The American Petroleum Institute (API) defines engine oil quality
procedures. by service categories that define oil performance measured in
standardized engine tests.
Navistar, Inc. follows the official position of the Engine
Manufacturers Association (EMA) on biodiesel fuel. See API CJ-4 FOR HIGH PERFORMANCE DIESEL ENGINES
www.enginemanufacturers.org for more information.

UNSAFE PRACTICES

WARNING

To prevent personal injury or death, do not mix

gasoline, gasohol, or alcohol with 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.
Figure 9 API Identification symbol
CAUTION
To prevent engine damage, do not mix propane
with diesel fuel. Navistar will not honor warranty API CJ-4 oils are recommended for high speed diesel engines
claims against engines that have used propane. with advanced exhaust aftertreatment systems that meet 2007
and beyond on-highway exhaust emission standards.

Page 31
 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:
• 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) maximum sulfur content],
is recommended to maintain performance and durability of
aftertreatment systems meeting 2007 and beyond diesel
emission regulations.
The Society of Automotive Engineers (SAE) defines oil viscosity
API CI-4 oils are allowed in diesel engines that meet these (thickness) by grade. Colder temperatures require lower grade
regulations. Use of the CI-4 engine oil shortens Diesel oils for correct flow during starting. Higher temperatures require
Particulate Filter (DPF) cleaning service intervals. 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).

Page 32
 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
Engine coolant mixtures include water, glycol (ethylene or Mixtures
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 water
safe levels of protection. Testing of conventional coolant
50% Concentrate and 50% -36.7 °C (-34 °F)
determines levels of nitrite, nitrite / molybdate, and freeze
water
point protection. If necessary, Supplemental Coolant Additives
(SCAs) are added to replenish inhibitors. 60% Concentrate and 40% -52.0 °C (-62 °F)
water
Extended life coolant mixtures (water and ethylene glycol) do not
require regular testing of inhibitor levels or addition of SCAs. 67% Concentrate and 33% -70.6 °C (-95 °F)
water
EXTENDED LIFE COOLANT (ELC) – RED
For vehicles operating in extremely cold climates, a coolant
Heavy Duty RED Extended Life Coolant (ELC) 50/50 Premix mixture of 60% Concentrate and 40% water or 67% Concentrate
meeting CEMS B-1 Type III is the standard factory fill for the and 33% water provide freeze protection as shown in previous
cooling system. The coolant should minimally meet ASTM table. Mixtures having more than 67% Concentrate are not
D6210, Standard Specification for fully - Formulated Glycol recommended.
Base Engine Coolant for Heavy Duty Engines. For cooling system service, see
ELC 50/50 Extender is added at the designated service interval.
For further information see Extended Life Coolant (ELC)
Extender (page 82).

Page 33
 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.
To verify coolant quality, contact an authorized service provider
or use a refractometer to verify coolant strength.

Page 34
 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. See the Vehicle Operator
Manual. Figure 11 Wait to Start Lamp.

Warning Lights The WAIT TO START lamp will illuminate when inlet air heater
is required. Wait until the lamp goes off before starting engine.
Warning lights signal when a reading is outside preset limits. See Starting the Engine (page 47) for further information.
• Warning lamps indicate situations that must be inspected
before operating the vehicle.

Page 35
 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. See
to the operator.
Engine Idle Shutdown Timer (page 51) for further information.

Page 36
 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. This
lamp indicates the Engine Control Module (ECM) is taking action To prevent engine damage, shut down engine
to protect the engine. It is normal for this lamp to illuminate under immediately , if the Stop Engine lamp flashes.
certain high load and/or high ambient temperature conditions. The RED Stop Lamp (RSL) will flash and an alarm will sound
It is safe to drive the vehicle. However, if the lamp continues when a serious problem arises. The lamp is used in conjunction
to light or remains on, contact an authorized service provider with other warning lights or general text and warning messages
immediately to have the problem corrected. to indicate a red STOP alert. See Engine Warning Protection
System (EWPS) for further information. Consult an authorized
service provider immediately to correct the problem.

Page 37
 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
conditions and exhaust gases are at extremely • The DPF indicator will illuminate solid YELLOW and
high temperatures. When stationary, keep away remain on when the levels of soot exceed acceptable
from people and flammable materials, vapors, or levels. The regeneration process should begin by using
structures, or stop the engine. either of the following two methods. The lamp will turn
off when the regeneration process is complete.
HEST lamp will illuminate when the exhaust system is hot and
regeneration is in progress. For additional information, see the • The vehicle can be safely driven on the highway at
applicable Vehicle Operator Manual. highway speeds while the regeneration process is
in operation.
• Or the vehicle should be parked in a safe location
and start the Parked Regeneration process to
prevent loss of power.

Page 38
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Level Two Malfunction Indicator Lamp (MIL)

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. The lamp will stop flashing when the
regeneration process is complete. For additional information
see the applicable Vehicle Operator Manual.
Level Three

WARNING

Pull vehicle safely off roadway and start Parked

Regeneration to prevent engine stopping.
The DPF indicator will be flashing and an alarm will beep
continuously while the ignition is on. This indicates the exhaust Figure 18 Malfunction Indicator Lamp (MIL)
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 The Malfunction Indicator Lamp (MIL) illuminates when the
see the applicable Vehicle Operator Manual. Heavy-Duty On-Board Diagnostics (HD-OBD) system detects
a malfunction related to the emissions control system. The
illuminated MIL indicates the vehicle needs to be serviced at
the first convenient opportunity. Lamp may remain active after
repair until system operation confirms repair.

Page 39
 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.

Figure 19 Water temperature gauge

The water temperature gauge indicates the temperature of

coolant in the cooling system. The gauge operates only when
the ignition switch is turned 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.

Page 40
 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. Correct the
problem.

Figure 20 Oil pressure gauge.

The engine oil pressure gauge indicates operating oil pressure.

The engine oil pressure indicator lamp and alarm will be
activated when oil pressure falls below acceptable levels.
Shut down the engine immediately if the lamp and alarm are
activated. Contact an authorized service provider immediately
to have the problem corrected.

Page 41
 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
 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.
Turns engine compression brake ON or OFF.
NOTE: The Exhaust Brake and Engine Exhaust Brake can
not be used together.

Page 43
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Air Cleaner Restriction Indicator Air Restriction Indicator Calibration

Air restriction is resistance of airflow through the air cleaner. • The indicator is calibrated in inches of water.
Accurate air restriction is measured at maximum airflow. • The indicator should be tested 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 locks in the red zone, it is

not necessary to shut down the engine immediately, but
a new air filter element should be installed at the earliest
convenience.
Air Restriction Indicator Reset
• Once the filter has been changed reset the air restriction
Figure 24 Air cleaner restriction indicator
indicator as follows:
• Push the button on the indicator to reset.
Air cleaner restriction is measured by an air restriction indicator.
The restriction indicator may be located anywhere within the air
induction system or instrument panel depending on your specific
application.

Page 44
 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. Recycle To prevent engine damage, do not overfill with oil.
or dispose of engine fluids, filters, and other
2. Check for correct oil level.
contaminated materials according to applicable
regulations. 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
WARNING and Service Categories (page 31).
4. Inspect for coolant, fuel or oil leaks.
To prevent personal injury or death, provide
ventilation when operating an engine in a closed 5. Inspect air cleaner and piping for tightness and correct
area. Inhalation of exhaust gas can be fatal. installation of filter element.

This engine has been given predelivery and delivery service by 6. Check for loose or hanging electrical connections.
your International dealer and is ready for operation. The operator 7. Check belt condition and alignment.
should fully understand the use and function of all controls and
instruments. 8. Fill the tank with recommended fuel. See Acceptable Fuel
Blends (page 30).
1. Check cooling system level.
9. Inspect exhaust system for obstruction or damage.
10. Drain water from fuel system.

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 SECTION 4 – ENGINE OPERATION

Priming the Fuel System WARNING

WARNING To prevent personal injury or death, do not install

ether start equipment, if an engine has a cold
To prevent personal injury or death, do not smoke starting device or other cold climate starting aid.
and keep fuel away from open flames and sparks.
WARNING
CAUTION
To prevent engine damage, do not add fuel to the To prevent personal injury or death, do not use
fuel filter header. this can contaminate the fuel. ether starting fluid to start engine.

1. Set parking brake and shift transmission to park or neutral.

2. Verify water drain valve on primary fuel filter housing is
closed and fuel filter caps are on tight.
3. Turn ignition switch to ON for approximately 60 seconds
allowing electric fuel pump to prime the fuel system.

Starting the Engine

WARNING Figure 26 Ignition switch positions.

To prevent personal injury or death, do not use
ether, propane, gasoline, or gasohol as starting
aids.

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 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
• Turn ignition switch to OFF and wait 2 - 3
the accelerator pedal.
minutes.
2. Depress clutch pedal if equipped.
• Repeat Steps 1 through 5.
3. Turn ignition switch to ON to activate the cold start assist
• If after three attempts the engine does not start,
/ inlet air heater system. The WAIT TO START lamp will
determine the cause.
illuminate continuously. Do not crank engine while lamp is
on continuously. • If starting attempts are continued, the starter
motor can be damaged.
NOTE: The ECM normally does not energize the inlet air
8. Low idle speed is 700 rpm (nonadjustable). Extended idling
heater element during hot starts. However, the ECM senses
periods should be avoided. See Extended Idling Periods in
reduced atmospheric pressure at high altitude and could
this section. Check all gauges during warm-up.
energize the air heater element during hot starts.
9. Within 20 seconds after engine start, engine oil pressure
4. When the WAIT TO START lamp begins flashing, turn
should exceed 15 psi (103 kPa).
ignition switch to START. If the vehicle has pushbutton
starting, press and hold starter button.
CAUTION
5. When the engine starts, release the ignition switch or starter
To prevent engine damage – do not increase
button. The ignition switch will return to ON and the engine
engine speed until oil pressure gauge indicates
will continue to run.
above 15 psi (103 kPa). If oil pressure does not
6. With the transmission in neutral, release clutch pedal if reach the minimum limit within 20 seconds, shut
equipped. down the engine.
7. Until oil pressure is achieved, the engine will not accelerate
and the WAIT TO START lamp will flash.

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 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
• Use a 12 volt system with a negative ground.
engine and correct the problem.
• Do not exceed 16.0 volts, if the ignition switch
NOTE: If engine starts and then stops, repeat engine is turned to OFF, ACC or ON during engine
starting procedure. If more than three attempts are cranking.
required, correct cause of no-start.
CAUTION
To prevent engine damage, do not allow metal
Emergency Starting tools to contact positive terminal of battery.
1. Set parking brake and shift transmission to park or neutral.
WARNING
2. Shut off lights, heater, air conditioner, and other electrical
To prevent personal injury or death, do not use loads in both vehicles.
ether starting fluid to start engine.
3. Make sure vehicles are not touching.

WARNING
WARNING
To prevent personal injury or death, do the
To prevent personal injury or death, always
following when jump starting an engine:
connect jumper cable for positive battery
• Wear eye protection. terminals first.
• Do not smoke 4. Connect one end of the first jumper cable to the positive (+)
terminal of the dead battery or to the positive (+) terminal of
• Keep flames or sparks away from battery.
the jump start stud. Connect the other end to the positive (+)
terminal of the booster battery.

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 SECTION 4 – ENGINE OPERATION

WARNING Operation

To prevent personal injury or death, do not SUGGESTED WARM-UP TIME

attach jumper cable to the negative (-) dead
battery terminal. This can cause sparks and an NOTE: Before applying a load or increasing speed above
explosion. 1,000 rpm, warm up engine for a minimum of 5 minutes at
or below 1,000 rpm. The warm-up period allows lubricating
5. Connect one end of the second jumper cable to the negative oil to establish a film between moving parts.
(-) terminal of the booster battery and the other end to
chassis frame of the vehicle with the dead battery. After allowing the engine to warm up for 5 minutes, begin
6. Start engine in vehicle that has the charged battery. operating the vehicle at reduced engine speeds and load
until it reaches operating temperature. Once operating
7. Start engine in vehicle that has the dead battery. temperature is reached, begin normal operation. The Cold
Ambient Protection (CAP) system aids in engine warm up
WARNING and maintains engine heat during extended idling periods.
See Cold Ambient Protection (CAP) (page 54).
To prevent personal injury or death, always
disconnect jumper cable from negative contacts IDLE SPEED
first.
8. Disconnect jumper cable from negative terminal and chassis WARNING
frame.
To prevent personal injury or death, provide
9. Disconnect jumper cable from positive battery terminals or ventilation when operating an engine in a closed
one terminal and jump start stud. area. Inhalation of exhaust gas can be fatal.
Low idle speed forMaxxForce® DT, 9, & 10 Diesel Engines is 700
rpm (nonadjustable). If the engine coolant temperature is below
70 °C (158 °F), the Engine Control Module (ECM) will adjust the
low idle speed from 700 rpm to a maximum of 875 rpm. High
idle speed is a nonadjustable factory setting.

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 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
following ranges: The engine and vehicle exhaust piping includes an
® Aftertreatment System to capture soot and other particulates
MaxxForce DT: 2600 rpm through 2770 rpm before they exit the exhaust pipe. The soot is captured by the
MaxxForce® 9 and 10: 2325 rpm through 2425 rpm Diesel Particulate Filter (DPF) and is periodically converted to
carbon dioxide (CO2) by a Regeneration (Regen) process.
EXTENDED IDLING PERIODS The Regen process may take place during vehicle operation
(Active Regen). The Regen process will be triggered by either a
CAUTION time-based or a soot mass buildup-based strategy.
To prevent engine damage, do not extend low idle A Parked Regen process occurs when a Moving Regen is not
periods. possible, such as when there is not enough thermal energy for
Idling periods over 15 minutes should be avoided. Diesel engine Diesel Oxidation Catalyst (DOC) light off. The vehicle is parked
efficiency is improved when the cylinder temperature remains (stationary).
high. Low temperature in cylinders may cause the following: When a Regen is required, the ECM commands the
• Unburned fuel may seep from exhaust manifold gaskets Aftertreatment Fuel Injector (AFTFI) to inject fuel into the
and vehicle exhaust system connections. This seepage exhaust system. A DOC oxidizes the injected fuel to increase
has the dark colored appearance of lubricating oil. the exhaust gas temperature as needed for DPF Regen.

• Incomplete combustion and unburned fuel washes • A Parked Regeneration will be requested if the Passive
lubricating oil from cylinder sleeves. Unburned fuel Regeneration cannot be completed during driving.
will be carried into the lubricating oil, dilute the oil, and • In this case, a lamp will be lit to alert the operator to
change oil viscosity. perform a Parked Regeneration.
• Carbon forms on internal components of turbochargers • The operator must park the vehicle and then perform the
and Exhaust Gas Recirculation (EGR), reducing engine Regen as required.
efficiency.
• Follow the Parked Regeneration process listed in the
• Carbon clogs and damages the Diesel Particulate Filter Vehicle Operator Manual.
(DPF).

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 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 • If the Parked Regeneration process is ignored, the engine
precautions. may stop running.
A Preliminary Diesel Oxidation Catalyst (PDOC) (if equipped), • See Safety Information (page 3 ) for safety precautions.
and a DOC operate together to oxidize the injected fuel to
increase the exhaust gas temperature as needed for DPF ENGINE IDLE SHUTDOWN TIMER (FEDERAL-OPTIONAL)
Regen.

AFTERTREATMENT (AFT) HIGH-SOOT AUTO ENGINE

SHUT DOWN GOVERNMENT REGULATION: State and local
regulations may limit engine idle time. The vehicle
When Diesel Particulate Filter (DPF) soot level is high and owner or operator is responsible for compliance with
extended idling periods occur, the engine performance will be these regulations.
limited, and if left uncorrected, the engine may shut down. The
DPF indicator will flash and an alarm will beep continuously
while the ignition is on. This indicates the DPF is full and The optional Idle Shutdown Timer (IST) allows the Engine
engine performance will be limited. Pull the vehicle safely off Control Module (ECM) to shut down the engine during extended
the roadway and start Parked Regeneration process to prevent idle. Idle time can be programmed from 5 - 120 minutes. The
the engine from stopping. ECM can be programmed to deactivate the IST when the Power
Takeoff (PTO) is active.
When the Diesel Particulate Filter Indicator exceeds level three
and the vehicle is idling, engine performance will be severely Thirty seconds before engine shutdown, the IDLE SHUTDOWN
limited, and a Parked Regeneration will be required to prevent indicator illuminates. This continues until the engine shuts down
engine shut down. When a Regen occurs, do the following: or the low idle shutdown timer is reset. The engine must be out of
gear for the IST to work. Engine shutdown timer will deactivate
• The operator must park the vehicle and then perform the for one or more of the following conditions:
Regen as required.

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 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
• Accelerator pedal movement or an Accelerator Pedal regulations may limit engine idle time. The vehicle
Sensor (APS) fault is detected. owner or operator is responsible for compliance with
• Engine coolant operating temperature is below 60 °C (140 these regulations.
°F).
• Ambient temperature below 16 °C (60 °F) or above 44 °C Your heavy duty diesel engine conforms to applicable California
(110 °F). Air Resources Board (CARB) Engine Shutdown System (ESS)
regulations. This vehicle is registered and certified for sale in
• Brake pedal movement or a brake switch fault is detected.
California.
• Parking brake transition is detected.
The CARB Idle Shutdown Timer (IST) allows the Engine Control
• Clutch pedal is pressed or clutch pedal switch fault is Module (ECM) to shut down the engine during extended idle.
detected (manual transmissions, if equipped with a clutch When parking brake is set, the idle time can be programmed up
switch). to 5 minutes. When parking brake is released, the idle time can
be programmed up to 15 minutes. No parking brake, the idle
• Shift selector is moved from neutral (automatic
time can be programmed up to 15 minutes. During service, the
transmissions).
idle time can be programmed up to 60 minutes. The ECM will
• If the IST is enabled, the Cold Ambient Protection (CAP) deactivate the IST when the PTO is active.
will not function.

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 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. Engine shutdown timer will deactivate
for one or more of the following conditions: To prevent personal injury or death, do not use
• Engine speed is not at idle speed (700 rpm). ether, propane, gasoline or gasohol as starting
aids.
• Vehicle movement or a Vehicle Speed Sensor (VSS) fault
is detected. NOTE: If operating in temperatures below -12 °C (10 °F),
• Manual DPF Regeneration is enabled (Parked Regen). contact an authorized service provider for information
about special cold weather equipment and precautions.
• Accelerator pedal movement or an Accelerator Pedal
Sensor (APS) fault is detected. At temperatures below -12 °C (10 °F) a block coolant heater and
oil pan heater is required for cold starting.
• Engine coolant operating temperature is below 16 °C (60
°F). 1. Before operating the engine at 0 °C (32 °F) or lower, check
or service the following:
• Brake pedal movement or a brake switch fault is detected.
• Correct battery size
• Parking brake transition is detected.
• Correct amount of electrolyte, if not a maintenance
• Clutch pedal is pressed or clutch pedal switch fault is free battery.
detected (manual transmissions, if equipped with a clutch
switch). • Full battery charge

• Shift selector is moved from neutral (automatic • Condition of other electrical equipment
transmissions). • Cooling system leaks
• If the IST is enabled, the Cold Ambient Protection (CAP) • Correct coolant and cooling system level
will not function.
• Recommended oil grade

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 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
• Drain water from the fuel filter housing. service the following:

• Check oil level • Full battery charge

• Clean external surfaces of the engine and • Condition of other electrical equipment
accessories to prevent dirt or snow build up. • Check belts for severe cracks, excessive wear, or
• Clean outside and in between radiators to prevent dirt missing material
or build up. • Cooling system leaks
COLD AMBIENT PROTECTION (CAP) • Correct coolant and cooling system level
2. At the end of each daily operation do the following:
CAP safeguards the engine from damage caused by prolonged
idle at no load during cold weather. This feature should only be • Fill the fuel tank with correct fuel.
disabled for specialized applications. Engine damage may occur
• Drain water from the fuel filter housing.
if CAP is disabled.
• Check oil level.
CAP maintains engine coolant temperature by increasing engine
rpm to a programmed value when ambient air temperature is • Clean external surfaces of the engine and
below 0 °C (32 °F), coolant temperature is below 65 °C (149 °F), accessories to prevent dirt build up.
and engine has been idling at no load for over 5 minutes.
• Clean outside and in between radiator to prevent dirt
Engine speed will ramp up to 1,400 rpm and will maintain at build up.
1,400 rpm until coolant temperature has reached 75 °C (167 °F).

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 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. Closing the shutters will keep the engine
hottest engine components to dissipate some of their internal warm during cold weather operation.
heat.
ROAD SPEED LIMITING (RSL)
Idling is recommended, if an engine has been running at
maximum horsepower. RSL is an optional feature that limits the top vehicle speed the
ECM allows. RSL is set to one of the following two positions:
HD-OBD OVERVIEW
• OFF
The HD-OBD system uses many individual pre-programmed
• Vehicle speed to be determined by customer, up to a
“monitors” to ensure the vehicle is meeting emissions standards.
maximum of 204 kph (127 mph).
An HD-OBD monitor is a strategy to evaluate the performance
of an emissions related system or component. All monitors To have the RSL set, changed, or turned off, see an authorized
are designed for execution in a prescribed frequency; some service provider.
monitors run continuously, while some run a specific ratio
against the number of drive cycles. ROAD OPERATION
The operator will be alerted to emissions or other system Correct road operation of your vehicle will provide the following:
problems when the Malfunction Indicator Lamp (MIL) illuminates.
When the MIL illuminates, bring the vehicle in for service at • Satisfactory engine performance
the next available opportunity. The HD-OBD system does not • Maximum fuel economy
change the way the vehicle should be driven, the recommended
driving style, or the way you use the vehicle. • Long service life

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 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. Accelerate smoothly and evenly to engine's rated speed.
do not operate the engine above high idle.
Rapid acceleration causes high fuel consumption.
Protect your engine when driving downhill as follows:
3. To prevent lugging, do not allow engine speed to drop below
1,200 rpm during full throttle. • Prevent overspeeding of engine when going down long
and steep grades.
4. When approaching a hill, press accelerator smoothly to start
the upgrade at full power. Downshift to maintain maximum • Operate the engine closest to high idle for maximum
vehicle speed. retarder system operation.
• See Vehicle Operator Manual for engine retarder system
operation procedures.

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 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.

MaxxForce® DT, 9, & 10 Diesel Engines

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.
Before Engine Operation Check engine oil level.
Check coolant level.
1
Drain water separator.
Inspect Charge Air Cooler (CAC).
Check for external leaks.
Check air restriction indicator.

Engine oil drain, engine oil filter and centrifuge Change engine oil and filter
filter change intervals based on engine family Change centrifuge filter. See Centrifuge Filter (page 69)
and fuel consumption. See Engine Oil and Filter
(page 65).
15,000 miles (24,140 km) Inspect belt, air intake piping, and clamps.
6 months, 550 hours Check coolant freeze point.
7949 liters (2,100 gallons) of fuel

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 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.
12 months, 1,100 hours Clean or change fuel strainer.
15,898 liters (4,200 gallons) of fuel

Annually Inspect electrical system.

120,000 miles (193,000 km) Inspect vibration damper.

5,000 hours Adjust engine valve lash.
Adjust engine brake lash (if equipped).

24 months Pressurize air induction system.

150,000 miles (240,000 km) Add Extended Life Coolant (ECL) Extender to ELC maintained systems.
30 months, 6,000 hours

180,000 - 200,000 miles Measure crankcase pressure.

(290,000 - 322,000 km) Inspect sequential turbochargers.
6,700 - 7,500 hours

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 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.
2
200,000 miles (322,000 km) Cleaning Diesel Particulate Filter (DPF)
30 months, 6,000 hours

3
300,000 miles (500,000 km) Service cooling system .
5 years, 12,000 hours

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) 22 months, or 4,500 hours.
3 For Extended Life Coolants (ELC). Coolant service intervals are more frequent with conventional coolants.

Page 59
 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. 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 Figure 27 Oil level gauge (typical)
regulations.

CAUTION
WARNING To prevent engine damage do the following:
• Assure oil level readings are within the
To prevent personal injury or death, shift
crosshatched operating range on the oil level
transmission to park or neutral, set parking
gauge.
brake, and install wheel chocks before doing
diagnostic or service procedures. • Do not overfill the engine with oil.
• Do not operate engine if oil level is above or
OIL LEVEL
below the operating range.
Service Interval: Before Engine Operation
1. Park vehicle on level ground.

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 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. See Engine Oil Quality
factory fill for the cooling system. ELC 50/50 Premix is
and Service Categories(page 31).
used to replenish coolant loss and ensure that glycol / water
concentrations stay in balance. If a customer wishes to use a
COOLANT LEVEL
conventional (non-OAT ELC) coolant, it should minimally meet
ASTM D6210, Standard Specification for fully - Formulated
Glycol Base Engine Coolant for Heavy Duty Engines.
GOVERNMENT REGULATION: Engine fluids
(oil, fuel, and coolant) may be a hazard to human NOTE: Never add ELC to the expansion tank. Only add ELC
health and the environment. Handle all fluids to the coolant tank.
and other contaminated materials (such as filters, 1. Park vehicle on level ground, set the parking brake, and shut
rags) in accordance with applicable regulations. down the engine.
Recycle or dispose of engine fluids, filters, and
other contaminated materials according to applicable 2. Check coolant level in the opaque plastic coolant tank.
regulations. • Coolant level should be at midpoint of ADD and MAX.
• If coolant level is below the ADD mark, continue with
Step 3.
WARNING

To prevent personal injury or death, shift

transmission to park or neutral, set parking
brake, and install wheel chocks before doing
diagnostic or service procedures.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

WARNING WATER SEPARATOR

To prevent personal injury or death, do the Service Interval: Before Engine Operation
following when removing the radiator cap or
coolant tank cap:
• Allow the engine to cool for 15 minutes or more. GOVERNMENT REGULATION: Engine fluids
(oil, fuel, and coolant) may be a hazard to human
• Wrap a thick cloth around the radiator cap or
health and the environment. Handle all fluids
coolant tank cap.
and other contaminated materials (such as filters,
• Loosen cap slowly a quarter to half turn to vent rags) in accordance with applicable regulations.
pressure. Recycle or dispose of engine fluids, filters, and
other contaminated materials according to applicable
• Pause for a moment until all pressure has
regulations.
escaped to avoid being scalded by steam.
• Continue to turn cap counterclockwise to
remove. WARNING
3. Add ELC 50/50 Premix to the correct coolant level (midpoint
of ADD and MAX). To prevent personal injury or death, do not smoke
and keep fuel away from flames and sparks.
4. Install and tighten coolant tank cap until the plastic cap clicks
or the metal caps runs up against the detent.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

WARNING 1. If necessary, connect a hose to the end of the water drain

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.
for and clearly marked DIESEL FUEL.
3. Turn ignition switch to ON. This will start the electric fuel
pump. Do not start engine.

NOTE: The water / fuel mixture will drain slowly and may
take up to a minute to attain pure fuel flow.
4. Turn water drain valve to open and allow water/fuel mixture
to drain. Continue draining until only fuel is draining.

NOTE: Fuel will only drain from the water drain valve as
long as the electric fuel pump is running. The electric
fuel pump can run from 10 to 20 seconds. Do not turn the
ignition switch to OFF then ON again without waiting the 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
Figure 28 Fuel filter header assembly switch to OFF, wait 10 seconds then turn the ignition switch
to ON to continue draining water.
1. Electric fuel pump
2. Fuel filter cover 6. Once fuel-water draining is complete, close water drain
3. Exhaust Gas Recirculation (EGR) valve valve and turn the ignition switch to OFF.
4. Oil fill tube 7. Recycle or dispose of drained fluids properly according to
5. Water drain valve applicable regulations.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

CHARGE AIR COOLER (CAC) • Oil stains

Service Interval: Before Engine Operation • Fuel stains

• Leakage at water pump (wetness from the weep hole
WARNING is normal)
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.
1. Inspect Charge Air Cooler (CAC) core for debris, damaged, Service Interval: Before Engine Operation
and clogged external fins.
2. Before starting engine remove any debris blocking the core.

EXTERNAL LEAKAGE

Service Interval: Before Engine Operation

WARNING

To prevent personal injury or death, shut down

engine, set parking brake, and install wheel
chocks before inspecting for external leakage.
1. Check for the following:
• Cracked hoses
• Loose clamps Figure 29 Air cleaner restriction indicator
• Coolant stains

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 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.
If the yellow position indicator has locked in the red zone, a To prevent personal injury or death, wear safety
new air filter should be installed to prevent low engine power glasses and avoid moving components such as
or engine damage. fans, pulleys, and belts when taking an engine oil
sample.
1. Remove restricted air filter element and discard.
Engine oil sampling can be utilized for the following:
CAUTION Engine Oil Sampling - Optional
To prevent engine damage, do not use 1. Determine oil change interval based upon fuel
compressed air to clean filter housing. consumption and specific engine application.
2. Use a clean water-dampened cloth to clean inside of air filter 2. Catch contaminates which, if left unattended, may result
housing. in engine failure.
3. Inspect air filter housing for damage or distortion. Install new Service Interval (based upon fuel consumption and specific
housing if necessary. engine application):
4. Install a new air filter element. See charts for specific engine family and service interval.
5. Push reset button on air restriction indicator. The yellow
indicator will return to zero. CAUTION
To prevent engine damage, do not extend
recommended oil change intervals.

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 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 Less than or equal More than 30 mph Fuel Economy Less than or equal More than 30 mph
(mpg) to 30 mph (48 kmpl) (48 kmpl) (mpg) to 30 mph (48 kmpl) (48 kmpl)
20,000 miles (32,187
More than 8.5 650 hours
25,000 miles km)
More than 8.5 825 hours
(40,234 km) 4.5 to 8.5 575 hours See Figure 33
4.5 to 8.5 700 hours See Figure 33 6,000 miles (9,656
Less than 4.5 500 hours
10,000 miles km)
Less than 4.5 600 hours
(16,093 km)
MaxxForce® DT, 9, and 10 Diesel Engine With Greater Than
MaxxForce® DT Diesel Engine With Less Than or Equal to 230 Horsepower (With Centrifuge Filter)
230 Horsepower (With Centrifuge Filter) Average Vehicle Speed
Average Vehicle Speed Fuel Economy Less than or equal More than 30 mph
Fuel Economy Less than or equal More than 30 mph (mpg) to 30 mph (48 kmpl) (48 kmpl)
(mpg) to 30 mph (48 kmpl) (48 kmpl) 25,000 miles (40,234
More than 8.5 825 hours
30,000 miles (48,300 km)
More than 8.5 1,000 hours
km) 4.5 to 8.5 650 hours See Figure 33
4.5 to 8.5 800 hours See Figure 33 7,500 miles (12,070
Less than 4.5 500 hours
12,500 miles (20,117 km)
Less than 4.5 600 hours
km)

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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.

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
Figure 30 Drain intervals for MaxxForce® DT, 9, and 10 nails using hand cleaner and wash with soap
applications. and water. Wash or discard clothing and rags
contaminated with engine fluids.
3. Place a drain pan under the oil pan drain plug, remove oil
1. Park vehicle on level ground. Set parking brake and shift pan drain plug, and drain oil.
transmission to park or neutral.
2. Run engine until operating temperature is reached, then shut
down engine.

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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. Remove old oil filter and recycle or dispose of according to
necessary.
applicable regulations.
5. Using clean engine oil, lubricate a new oil pan drain plug
10. Lubricate new oil filter gasket with clean engine oil.
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). CAUTION
7. Recycle or dispose of oil according to applicable regulations. To prevent engine damage, install the correct oil
filter for the engine application.
11. Install new oil filter.
• Standard oil filter (long)
• Front drive/steering axle oil filter (shorter)

CAUTION
To prevent engine damage, do not overtighten
filter.
12. Hand tighten filter 2/3 to 1 full turn after gasket first contacts
oil filter header.

CAUTION
To prevent engine damage, do not overfill with oil.
Figure 31 Oil cooler module assembly
13. Add engine oil with the correct oil viscosity and formulation.
1. Oil cooler housing API CJ-4 oil is recommended but CI-4 is allowable. Use of
2. Oil cooler CI-4 oils will reduce DPF cleaning interval, see Maintenance
3. Oil filter Schedule (page 57). Add oil through the engine oil fill tube.

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 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. Check oil level gauge. Oil level must be within the • On the right side of the engine compartment. It is
crosshatched operating range. recommended to change the centrifuge filter every time
15. Start engine and run at low idle. the engine oil filter is changed. For safety information,
refer to the your Engine Operation and Maintenance
16. Check reading on oil pressure gauge. Manual and Vehicle Operator Manual.
• Minimum lube oil pressure is 15 psi (103 kPa) • In the engine compartment. It is recommended to change
minimum @ 700 rpm. the centrifuge filter every time the engine oil and filter is
• If there is no gauge reading, shut engine down changed. See Engine Oil and Filter (page 65) for specific
immediately. Check for oil filter leaks. service intervals. For safety information, refer to the your
Engine Operation and Maintenance Manual and Vehicle
• Let engine run until operating temperature is reached. Operator Manual.
Check for leaks.
17. Shut down engine for 15 minutes.

CAUTION
To prevent engine damage, do not overfill with oil.
18. Recheck oil level and add oil to bring oil level within the upper
half of the crosshatched operating range on oil level gauge.

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 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
(oil, fuel, and coolant) may be a hazard to human 2. Before attempting to open the centrifuge oil filter, wait 2
health and the environment. Handle all fluids and minutes to assure the rotor has stopped spinning.
other contaminated materials (e.g. filters, rags) in
accordance with applicable regulations. Recycle NOTE: When separating the cover assembly from the body
or dispose of engine fluids, filters, and other assembly, it may be necessary to insert a coin or flat blade
contaminated materials according to applicable screwdriver in to the gap to start the separation.
regulations. 3. Turn the band clamp handle counter clockwise until the tee
bolt head can be disengaged. Remove band clamp.
4. Remove the cover and rotor assembly from the body
WARNING assembly.
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 with soap
and water. Wash or discard clothing and rags
contaminated with engine fluids.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Figure 33 Centrifuge filter assembly

1. Cover assembly
2. Band clamp handle
3. Body assembly Figure 34 Centrifuge rotor
4. Band clamp 1. O-ring
2. Rotor
3. Body assembly

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 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. following procedure:
7. Clean and inspect the cover assembly. Clean the O-ring 1. If not already done, set the parking brake.
groove in the cover assembly and mating surface.
2. Turn ignition switch to ON.
8. Inspect the bearings in the cover and body assemblies.
Make sure both assemblies are free of debris. 3. Turn cruise ON.

9. Lubricate a new O-ring with clean engine oil and insert in to 4. Turn cruise OFF.
the groove of the cover assembly. 5. Turn cruise ON.
10. Insert a new rotor assembly into the cover assembly and 6. Very rapidly push the resume switch four times and then hold
firmly press until it seats. down on the fifth time for four seconds.
11. Insert the rotor inlet with the bearing in the body assembly. 7. The Change Oil message should clear.
Press the cover and body assemblies together.
8. The operation from the time the cruise is turned ON for
12. Position the band clamp over the cover and body flanges. the second time to the fifth activation of the resume switch
Engage the tee bolt and turn the band clamp handle and must take place within six seconds. If you fail to reset the
tighten securely. message, repeat the process.
13. Start the engine and check all connections for leaks.
• If no leaks are observed, shut down engine.
• If leaks are observed, shut down engine and correct
leaks. Start engine again and observe for leaks. If no
leaks are observed, shut down engine.

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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
hours • 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 tensioner
Figure 35 Cracks in belt ribs automatically adjusts.

1. Belt in good condition 4. Remove the breaker bar.

2. Belt ready for replacement
3. Belt ribs
4. Cracks in belt

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 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. 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
Figure 36 Square hole in auto tensioner

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 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. Mixtures having more than 67% Concentrate
ELC 50/50 Premix provides freeze protection to -36 °C (-34 °F) are not recommended due to the risk of additive fallout.
and maximum corrosion protection. If a customer wishes to use Check freeze point with a refractometer.
a conventional (non-OAT ELC) coolant, it should minimally meet
ASTM D6210, Standard Specification for fully - Formulated 1. Put drop of coolant on refractometer window.
Glycol Base Engine Coolant for Heavy Duty Engines. ELC 2. Look through eyepiece and focus.
50/50 Premix is used to replenish coolant loss and ensure that
glycol/water concentrations stay in balance. 3. Record freeze point.

ELC 50/50 Extender is added at the designated service interval. 4. Adjust coolant concentration as necessary to achieve
desired freeze point protection.
Freeze Point Protection Levels Concentrate (ethylene
glycol) and Water Mixtures FUEL FILTER

Concentrate and Water Freeze Point Protection Service Interval: 30,000 miles (43,300 km), 12 months, 1,100
Mixtures hours or 4,200 gallons (15,898 liters) of fuel
40% Concentrate and 60% -12 °F (-24.4 °C)
water
NOTE: Change fuel filter, if optional fuel filter lamp is
illuminated.
50% Concentrate and 50% -34 °F (-36.7 °C)
water NOTE: If fuel used has more than average impurities,
60% Concentrate and 40% -62 °F (-52.0 °C) shorter service intervals may be required.
water
67% Concentrate and 33% -95 °F (-70.6 °C)
water

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 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
regulations.

WARNING

To prevent personal injury or death, store diesel Figure 37 Fuel filter header assembly
fuel properly in an approved container designed 1. Electric fuel pump
for and clearly marked DIESEL FUEL. 2. Fuel filter cover
3. Exhaust Gas Recirculation (EGR) valve
CAUTION 4. Oil fill tube
To prevent engine damage, do not add fuel to the 5. Water drain valve
fuel filter housing; this can add contaminants to
the fuel.

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 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.
To prevent personal injury or death, make sure Contaminants may cause engine failure.
that the engine has cooled before removing 4. Using a 23 mm wrench, loosen the fuel filter cover
components. counterclockwise three and one-half turns to expose the
2. Turn ignition switch to OFF and allow engine to cool before vent hole below O-ring.
removing components. 5. If necessary, attach a hose to the end of the water drain
valve.
WARNING 6. Put a suitable container under the water drain valve.
To prevent personal injury or death, wear safety 7. Open water drain valve and drain the fuel filter assembly.
glasses with side shields. Limit compressed air
8. Close water drain valve.
pressure to 207 kPa (30 psi).
9. Recycle or dispose of fuel according to applicable
CAUTION regulations.
To prevent engine damage, clean area around fuel
filter housing before removing fuel filter cover.
This will protect the open fuel filter housing
from contaminants falling into the housing. If
contaminants do fall in, remove them 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.

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 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. 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 element.
15. Coat threads of fuel filter cover with clean diesel fuel.
16. Install a fuel filter element with cover into the fuel filter
housing. Slowly lower the fuel filter element into the fuel
filter housing, until fuel filter cover is ready to be secured to
the fuel filter housing.
Figure 38 Fuel filter removal and installation 17. Secure the fuel filter cover and element to the fuel filter
housing by turning the fuel filter cover clockwise until
1. Fuel filter cover
finger-tight.
2. Exhaust Gas Recirculation (EGR) valve
3. Water drain valve
CAUTION
4. Fuel pump (fuel strainer location)
5. Fuel filter element To prevent engine damage, tighten fuel cover on
6. Fuel filter cover O-ring fuel filter assembly.
18. Using a 23 mm wrench tighten fuel filter cover to 30 N·m (22
10. Continue turning the fuel filter cover until loose. Remove the lbf·ft).
fuel filter cover and element from the fuel filter housing. 19. Depress clutch pedal if equipped.
11. Remove the fuel filter cover from the fuel filter element by 20. Turn the ignition switch to ON for approximately 60 seconds,
holding the element vertically and pushing up on the cover. allowing the fuel pump to prime the fuel system. See Priming
The cover will snap off the fuel filter element. Dispose of the the Fuel System (page 46).
fuel filter element according to applicable regulations.

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 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.
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: 30,000 miles (43,300 km), 12 months, 1,100

hours or 15898 liters (4200 gallons) of fuel

NOTE: If fuel used has more than average impurities,

shorter service intervals may be required.

NOTE: The fuel strainer is located under the electric fuel

pump. The pump must be disconnected from the engine
Figure 39 Electric fuel pump and fuel strainer location
wiring harness and removed from the fuel filter housing for
the fuel strainer to be cleaned or replaced. See following 1. Electrical fuel pump wiring harness connector
procedure. 2. Fuel filter cap
3. Fuel filter housing

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 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. Using a flat blade screw driver gently pry up the fuel pump
and pulling away from the electric fuel pump. from the fuel filter housing.
5. Once the fuel pump is loose, pull the fuel pump out of the
fuel filter housing.
6. Remove the fuel strainer and O-rings from the fuel pump.
Discard the O-rings.
7. Do 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 in the fuel pump cover
Figure 40 Fuel strainer with the bolt threads of the fuel filter housing. Place palm
of hand on top of fuel pump and push down firmly. This will
1. Pump cover bolt (3)
seat the fuel pump into the fuel filter housing.
2. Electric fuel pump
3. Fuel pump O-ring (2) 9. Secure the fuel pump to the fuel filter housing by installing
4. Fuel strainer and tightening the three pump cover bolts to 5 N·m (44 lbf·in).
5. Fuel filter housing
10. Depress clutch pedal if equipped.
11. Turn ignition switch to ON for approximately 60 seconds
allowing fuel pump to prime the fuel system.

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 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
and correct the problem. Have the vibration damper inspected by an authorized service
provider for deterioration of rubber, dents, and runout.
14. Once leaks are fixed or no leaks are found, shut down the
engine. ENGINE VALVE LASH

ELECTRICAL SYSTEM Service Interval: 120,000 miles (193,000 km) or 5,000 hours

Service Interval: Annually • For inspection procedures, see the applicable Engine
Service Manual.
1. Check wiring harness for cracks, rubbing, and loose
connections. • Have an authorized service provider adjust the valve lash
at the correct service interval.
2. Check sensors for loose connections, corrosion or cracks.
3. Check battery cables for the following conditions: ENGINE BRAKE LASH

• Broken insulation. Service Interval: 120,000 miles (193,000 km) or 5,000 hours
• Rubbing or chaffing. • For inspection procedures, see the applicable Engine
• Corroded or loose connections. Service Manual.

4. Repair items identified. • Have an authorized service provider adjust the valve lash
at the correct service interval.
Electronics
Check for diagnostic fault codes and repair as required. After INDUCTION SYSTEM
repairs are made, clear fault codes and verify they do not
Service Interval: 24 months
reappear. For correct procedures, see the applicable Engine
Diagnostic Manual or contact an authorized service provider.

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 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.
• Have an authorized service provider pressure test the air
induction system.
ELC Extender
EXTENDED LIFE COOLANT (ELC) EXTENDER Cooling System Drain ELC Coolant Add ELC Extender
Capacity
Service Interval: 150,000 miles (240,000 km), 30 months or
22-30 liters (6-8 0.2 liter (0.5 quart 0.2 liter (0.5 quart
6,000 hours
gallons) US) US)
30-49 liters (8-13 0.5 liter (1.0 quart 0.5 liter (1.0 quart
WARNING
gallons) US) US)
To prevent personal injury or death, do the 49-83 liters (13-22 0.7 liter (1.5 quart 0.7 liter (1.5 quart
following when removing the radiator cap or gallons) US) US)
coolant tank cap:
• Allow the engine to cool for 15 minutes or more. NOTE: ELC 50/50 Premix is the standard factory fill for the
cooling system. ELC 50/50 Premix is used to replenish
• Wrap a thick cloth around the radiator cap or
coolant loss and ensure that glycol/water concentrations
coolant tank cap.
stay in balance. If a customer wishes to use a conventional
• Loosen cap slowly a quarter to half turn to vent (non OAT ELC) coolant, it should minimally meet ASTM
pressure. D6210, Standard Specification for fully Formulated Glycol
Base Engine Coolant for Heavy Duty Engines. Coolant
• Pause for a moment to avoid being scalded by
service intervals are more frequent with conventional
steam.
coolants.
• Continue to turn cap counterclockwise to
4. Add the same volume of Extender to the cooling system.
remove.
1. Remove coolant tank cap.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

5. Install and tighten the coolant tank cap until the plastic cap CLEANING DIESEL PARTICULATE FILTER
clicks or the metal cap runs up against the detent.
For Engine Using CJ-4 Engine Oil
CRANKCASE PRESSURE Service Interval: 200,000 miles (322,000 km) 30 months or
6,000 hours
Service Interval: 180,000 - 200,000 miles (290,000 - 322,000
km) or 6,700 - 7,500 hours Clean DPF at designated service interval. The ECM will
illuminate the MIL and generate an Ash Servicing Required
• 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.
For Engines Using CI-4 Engine Oil
TURBOCHARGERS Service Interval: 150,000 miles (241,000 km) 22 months or
4,500 hours
Service Interval: 180,000 - 200,000 miles (290,000 - 322,000
km) or 6,700 - 7,500 hours Clean DPF at designated service interval. Take vehicle to an
authorized service provider for cleaning.
1. Clean, then remove the turbocharger compressor inlet
connections for both turbochargers. SERVICE COOLING SYSTEM
2. Inspect the compressor wheels for the following:
Service Interval for Extended Life Coolant: 300,000 miles
• Dirt or corrosion (500,000 km) or 12,000 hours
• Wheel rub damage
WARNING
• Wheel blade damage (bent or broken tips)
3. Check condition of turbochargers. (Consult with an To prevent personal injury or death, shift
authorized service provide if questionable.) transmission to park or neutral, set parking
brake, and install wheel chocks before doing
diagnostic or service procedures.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

WARNING 3. Remove coolant tank cap.

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. Clean skin and
nails using hand cleaner and wash with soap 5. After radiator has drained, close the drain valve and move
and water. Wash or discard clothing and rags the drain pan beneath the oil system module.
contaminated with engine fluids.

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 thick cloth around the radiator cap or
coolant tank cap.
• Loosen cap slowly a quarter to half turn to vent
pressure. Figure 41 EGR coolant drain plug
• Pause for a moment to avoid being scalded by
steam.
6. If the Exhaust Gas Recirculation (EGR) cooler must be
• Continue to turn cap counterclockwise to removed from the engine the coolant should be drained
remove. before removal. See Engine Service Manual for the removal
1. Park vehicle on level ground. Set parking brake and shift and installation procedure.
transmission to park or neutral.
2. Place a drain pan under the radiator.

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 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. Install and tighten the coolant tank cap until the plastic cap
clicks or the metal cap runs up against the detent.

CAUTION
To prevent engine damage, disconnect electrical
connector at the EGR valve before running engine
to purge air from cooling system. Failure to do so
Figure 42 Coolant drain plug for oil system module could cause failure of EGR cooler.
11. Disconnect electrical connector at the EGR valve.
7. Remove coolant drain plug from bottom of oil system 12. Start the engine.
module.
13. Allow the engine to operate at a fast idle until the engine
8. After coolant has drained, install the coolant drain plug and reaches normal operating temperature.
tighten to 28 N·m (18 lb·ft).
14. As the engine warms up, make sure coolant is flowing
through coolant line – the coolant line will feel warm to the
NOTE: ELC 50/50 Premix is the standard factory fill for the
touch.
cooling system. ELC 50/50 Premix is used to replenish
coolant loss and ensure that glycol/water concentrations
stay in balance. If a customer wishes to use a conventional
(non-OAT ELC) coolant, it should minimally meet ASTM
D6210, Standard Specification for fully Formulated Glycol
Base Engine Coolant for Heavy Duty Engines.

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 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 at the Exhaust Gas
recirculation (EGR) valve. Clear any Diagnostic Trouble
Codes (DTC) that may have occurred. See the Engine
Diagnostic Manual for further information.

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 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.
17. If necessary, add coolant to the coolant tank to bring the level
up to the COLD MAX mark.

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 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
procedures. these procedures are also recommended for • Cover air intake ducts to prevent moisture and debris
engines outside of warranty to assure maximum engine life: intrusion during storage.

• Maintain a “Full” fuel tank with the addition of diesel • Cover vertical exhaust stack.
fuel stabilizer to minimize microbial growth within the • Check the battery charge and recharge if needed.
fuel system. Run engine long enough to allow the fuel Disconnect the battery cables between batteries
stabilizer to enter the entire fuel system. If the engine is and between the batteries and vehicle. If freezing
utilized in a mobile application drive vehicle to mix the temperatures are expected, remove batteries and store
stabilizer in the fuel tank. in an area with temperature above freezing. If battery
• Before storage replace engine fuel filter(s) and drain all removal is not required (warm climate), maintain the
water separators of any water. battery charge every 30 days.

• Every 30 days or less, run engine until full operating • Test the cooling system, additive levels and coolant
temperature has been maintained. freeze protection. Coolant freeze protection must be
set below the coldest anticipated temperature during
storage.

Page 87
 SECTION 6 – LONG TERM STORAGE

Page 88
 SECTION 7 – SERVICE RECORDS

Maintenance Service Record WARNING

WARNING To prevent personal injury or death, shift

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.
section of this manual.
Save scheduled maintenance work orders and receipts for proof
of correct maintenance. Failure to maintain work orders and
receipts may affect your warranty coverage.

Page 89
 SECTION 7 – SERVICE RECORDS

Maintenance Service Record

Date Service Month Service Hours Miles (km) Item Serviced

Page 90
 SECTION 7 – SERVICE RECORDS

Maintenance Service Record

Date Service Month Service Hours Miles (km) Item Serviced

Page 91
 SECTION 7 – SERVICE RECORDS

Daily Care and Report • Excessive use of crankcase lubricating oil, coolant,
battery fluid or fuel
WARNING • Unusual engine noise

To prevent personal injury or death, read all • Correct amount of electrolyte, if not a maintenance free
safety instructions in the “Safety Information” battery
section of this manual. • Condition of electrical equipment
Do the following before engine operation to prevent engine
WARNING
failure
To prevent personal injury or death, shift • Add coolant if necessary. Make sure filler cap seal is in
transmission to park or neutral, set parking good condition and the cap is installed tightly
brake, and install wheel chocks before doing
diagnostic or service procedures. • Check air cleaner indicator with engine running. When
the yellow position indicator reaches and locks in the red
Check the following before engine operation to prevent engine zone, a new air filter should be installed
failure. Report all problems for immediate service.
• Fill the fuel tank with correct fuel
• Oil level
• Drain water from the fuel filter housing
• Oil, air, fuel or coolant leaks
• Clean external surfaces of the engine, radiator, and
• Cooling system hoses for leaks accessories
• Coolant system level

Page 92
 SECTION 7 – SERVICE RECORDS

Daily Care and Report

Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost

Page 93
 SECTION 7 – SERVICE RECORDS

Daily Care and Report

Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost

Page 94