Navistar MaxxForce 15 User manual

ENGINESERVICEMANUAL0000001746 MaxxForce®15LDieselEngineRevision1 EPA10-US,Canada,MexicoJanuary2013
ENGINESERVICEMANUAL
MaxxForce®15LDieselEngine
Navistar,Inc.
2701NavistarDrive,Lisle,IL60532USA
©2013Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

ENGINESERVICEMANUALI
TABLEOFCONTENTS
Foreword...................................................................................................................1
ServiceDiagnosis........................................................................................................2
SafetyInformation........................................................................................................3
EngineSystems...........................................................................................................5
MountingEngineonEngineStand...................................................................................53
EngineElectrical.........................................................................................................63
ColdStartAssist.......................................................................................................111
AftertreatmentSystem................................................................................................123
Turbochargers..........................................................................................................139
AirCompressorandPowerSteering...............................................................................171
FuelSystem.............................................................................................................183
ExhaustGasRecirculation(EGR)System.........................................................................205
OilCooler,FilterHousingandCrankcaseVentilation...........................................................257
AirInletandExhaustManifold......................................................................................281
FrontCover,HighMountFanDrive,CoolingSystem,andRelatedComponents..........................295
EngineBrake...........................................................................................................351
CylinderHead,CamshaftandValveTrain.........................................................................369
OilPan,OilPickupTubeandOilPump............................................................................429
FlywheelandFlywheelHousing.....................................................................................453
PowerCylinders........................................................................................................477
CrankcaseandCrankshaft...........................................................................................499
AbbreviationsandAcronyms........................................................................................529
Terminology.............................................................................................................537
AppendixA–Specications.........................................................................................549
AppendixB–Torques.................................................................................................557

IIENGINESERVICEMANUAL
AppendixC–SpecialServiceTools................................................................................573

ENGINESERVICEMANUAL1
Foreword
Navistar,Inc.iscommittedtocontinuousresearch
anddevelopmenttoimproveproductsandintroduce
technologicaladvances.Procedures,specications,
andpartsdenedinpublishedtechnicalservice
literaturemaybealtered.
ThisEngineServiceManualprovidesageneral
sequenceofproceduresforout-of-chassisengine
overhaul(removal,inspection,andinstallation).For
in-chassisserviceofpartsandassemblies,the
sequencemayvary.
NOTE:Photoillustrationsidentifyspecicpartsor
assembliesthatsupporttextandprocedures;other
areasinaphotoillustrationmaynotbeexact.
SeevehiclemanualsandTechnicalService
Information(TSI)bulletinsforadditionalinformation.
TechnicalServiceLiterature
1172042MaxxForce®15EngineOperation
andMaintenanceManual
0000001746MaxxForce®15EngineService
Manual
EGES-515MaxxForce®15EngineDiagnostic
Manual
EGED-520MaxxForce®15HardStartand
NoStartForm
EGED-525MaxxForce®15EngineWiring
SchematicForm
EGED-535MaxxForce®15Performance
DiagnosticForm
TechnicalServiceLiteratureisrevisedperiodically
andmailedautomaticallyto“RevisionService”
subscribers.Ifatechnicalpublicationisordered,the
latestrevisionwillbesupplied.
NOTE:Toordertechnicalserviceliterature,contact
yourMaxxForce®dealer.
Allmarksaretrademarksoftheirrespectiveowners.

2ENGINESERVICEMANUAL
ServiceDiagnosis
Servicediagnosisisaninvestigativeprocedurethat
mustbefollowedtondandcorrectanengine
applicationproblemoranengineproblem.
Iftheproblemisengineapplication,seespecic
vehiclemanualsforfurtherdiagnosticinformation.
Iftheproblemistheengine,seespecicEngine
DiagnosticManualforfurtherdiagnosticinformation.
PrerequisitesforEffectiveDiagnosis
•Availabilityofgauges,diagnostictestequipment,
anddiagnosticsoftware.
•Availabilityofcurrentinformationforengine
applicationandenginesystems.
•Knowledgeoftheprinciplesofoperationfor
engineapplicationandenginesystems.
•Knowledgetounderstandanddoproceduresin
diagnosticandservicepublications.
TechnicalServiceLiteraturerequiredforEffective
Diagnosis
•EngineServiceManual
•EngineDiagnosticManual
•DiagnosticsForms
•ElectronicControlSystemsDiagnosticsForms
•ServiceBulletins

ENGINESERVICEMANUAL3
SafetyInformation
Thismanualprovidesgeneralandspecic
maintenanceproceduresessentialforreliableengine
operationandyoursafety.Sincemanyvariationsin
procedures,tools,andservicepartsareinvolved,
adviceforallpossiblesafetyconditionsandhazards
cannotbestated.
Readsafetyinstructionsbeforedoinganyserviceand
testproceduresfortheengineorvehicle.Seerelated
applicationmanualsformoreinformation.
ObeySafetyInstructions,Warnings,Cautions,and
Notesinthismanual.Notfollowingwarnings,
cautions,andnotescanleadtoinjury,deathor
damagetotheengineorvehicle.
SafetyTerminology
Threetermsareusedtostressyoursafetyandsafe
operationoftheengine:Warning,Caution,andNote
Warning:Awarningdescribesactionsnecessaryto
preventoreliminateconditions,hazards,andunsafe
practicesthatcancausepersonalinjuryordeath.
Caution:Acautiondescribesactionsnecessary
topreventoreliminateconditionsthatcancause
damagetotheengineorvehicle.
Note:Anotedescribesactionsnecessaryforcorrect,
efcientengineoperation.
SafetyInstructions
WorkArea
•Keepworkareaclean,dry,andorganized.
•Keeptoolsandpartsofftheoor.
•Makesuretheworkareaisventilatedandwelllit.
•MakesureaFirstAidKitisavailable.
SafetyEquipment
•Usecorrectliftingdevices.
•Usesafetyblocksandstands.
ProtectiveMeasures
•Wearprotectivesafetyglassesandshoes.
•Wearcorrecthearingprotection.
•Wearcottonworkclothing.
•Wearsleevedheatprotectivegloves.
•Donotwearrings,watchesorotherjewelry.
•Restrainlonghair.
Vehicle
•Shifttransmissiontoparkorneutral,setparking
brake,andblockwheelsbeforedoingdiagnostic
orserviceprocedures.
•Cleartheareabeforestartingtheengine.
Engine
•Theengineshouldbeoperatedorservicedonly
byqualiedindividuals.
•Providenecessaryventilationwhenoperating
engineinaclosedarea.
•Keepcombustiblematerialawayfromengine
exhaustsystemandexhaustmanifolds.
•Installallshields,guards,andaccesscovers
beforeoperatingengine.
•Donotrunenginewithunprotectedairinletsor
exhaustopenings.Ifunavoidableforservice
reasons,putprotectivescreensoverallopenings
beforeservicingengine.
•Shutengineoffandrelieveallpressureinthe
systembeforeremovingpanels,housingcovers,
andcaps.
•Ifanengineisnotsafetooperate,tagtheengine
andignitionkey.
FirePrevention
•Makesurechargedreextinguishersareinthe
workarea.
NOTE:Checktheclassicationofeachre
extinguishertoensurethatthefollowingretypes
canbeextinguished.
1.TypeA—Wood,paper,textiles,andrubbish
2.TypeB—Flammableliquids
3.TypeC—Electricalequipment
Batteries
•Alwaysdisconnectthemainnegativebattery
cablerst.
•Alwaysconnectthemainnegativebatterycable
last.
•Avoidleaningoverbatteries.

4ENGINESERVICEMANUAL
•Protectyoureyes.
•Donotexposebatteriestoamesorsparks.
•Donotsmokeinworkplace.
CompressedAir
•UseanOSHAapprovedblowgunratedat207
kPa(30psi).
•Limitairpressureto207kPa(30psi).
•Wearsafetyglassesorgoggles.
•Wearhearingprotection.
•Useshieldingtoprotectothersintheworkarea.
•Donotdirectcompressedairatbodyorclothing.
Tools
•Makesurealltoolsareingoodcondition.
•Makesureallstandardelectricaltoolsare
grounded.
•Checkforfrayedordamagedpowercordsbefore
usingpowertools.
FluidsUnderPressure
•Useextremecautionwhenworkingonsystems
underpressure.
•Followapprovedproceduresonly.
Fuel
•Donotoverllthefueltank.Overllcreatesare
hazard.
•Donotsmokeintheworkarea.
•Donotrefuelthetankwhentheengineisrunning.
RemovalofTools,Parts,andEquipment
•Reinstallallsafetyguards,shields,andcovers
afterservicingtheengine.
•Makesurealltools,parts,andserviceequipment
areremovedfromtheengineandvehicleafterall
workisdone.

ENGINESYSTEMS5
TableofContents
EngineIdentication.....................................................................................................7
EngineSerialNumber..........................................................................................7
EngineEmissionLabel.........................................................................................7
EngineAccessoryLabelsandIdenticationPlates.......................................................8
EngineSpecications..........................................................................................9
EngineDescription....................................................................................9
OptionalFeatures....................................................................................10
ChassisMountedFeatures.........................................................................10
EngineComponentLocations...............................................................................11
AirManagementSystem(AMS).......................................................................................16
AirFlow..........................................................................................................16
AirManagementComponents...............................................................................17
Turbochargers........................................................................................17
InterstageCooler(ISC)..............................................................................18
High-PressureChargeAirCooler(HPCAC).....................................................19
AirControlValve.....................................................................................19
ExhaustGasRecirculation(EGR)System.......................................................20
Aftertreatment(AFT)System..........................................................................................22
AftertreatmentFuelInjectionComponents......................................................24
FuelManagementSystem.............................................................................................26
ChassisMountedComponents..............................................................................27
EngineMountedComponents...............................................................................29
EngineLubricationSystem............................................................................................31
OilFlowandComponents....................................................................................32
EngineCoolingSystem................................................................................................35
CoolingSystemComponents...............................................................................35
CoolingSystemFlow..........................................................................................36
ThermostatOperation.........................................................................................38
CoolantControlValve(CCV)AssemblyOperation......................................................38
MaxxForce®EngineBrakeSystem..................................................................................40
EngineBrakeSystemComponents........................................................................40
EngineBrakeOperation......................................................................................41
OpenCrankcaseBreatherSystem...................................................................................42
OpenCrankcaseBreatherSystemComponents.........................................................42
OpenCrankcaseBreatherSystemOperation............................................................43
ColdStartAssistSystem..............................................................................................44
ColdStartAssistSystemOperation........................................................................45

6ENGINESYSTEMS
ElectronicControlSystem.............................................................................................46
ElectronicControlSystemComponents..................................................................46
OperationandFunction.............................................................................46
ReferenceVoltage(VREF)..........................................................................46
SignalConditioner...................................................................................46
Microprocessor.......................................................................................46
DiagnosticTroubleCodes..........................................................................46
MicroprocessorMemory............................................................................46
ActuatorControl......................................................................................47
Actuators........................................................................................................47
CoolantFlowValveandCoolantMixerValve...................................................47
ExhaustGasRecirculation(EGR)ValveAssembly............................................47
AirControlValve.....................................................................................47
ColdStartRelay(CSR)..............................................................................47
ColdStartFuelSolenoid(CSFS)..................................................................47
EngineThrottleValve(ETV)........................................................................48
FuelPressureControlValve(FPCV)..............................................................48
EngineandVehicleSensors.................................................................................48
ThermistorSensor...................................................................................48
VariableResistanceSensor........................................................................49
MagneticPickupSensor............................................................................50
Potentiometer.........................................................................................51
Switches...............................................................................................51
OxygenSensor(O2S)...............................................................................52
Turbocharger2CompressorInletSensor(TC2CIS)...........................................52

ENGINESYSTEMS7
EngineIdentication
EngineSerialNumber
Figure1Engineserialnumberlocation
Theengineserialnumberislocatedonthelowerleft
sideofthecrankcaseabovetheoilpanange.
EngineSerialNumberExample
152HM2YXXXXXXX
EngineSerialNumberCodes
15.2–Enginedisplacement
H–Diesel,turbocharged,ChargeAirCooler(CAC)
andelectronicallycontrolled
M2–Motortruck
Y–UnitedStates,Huntsville
7digitsufx–Engineserialnumbersequence
EngineEmissionLabel
Figure2U.S.EnvironmentalProtectionAgency
(EPA)exhaustemissionlabel(example)
TheU.S.EnvironmentalProtectionAgency(EPA)
exhaustemissionlabelisontopofthevalvecover
(frontleftside).TheEPAlabeltypicallyincludesthe
following:
•Modelyear
•Enginefamily,model,anddisplacement
•Advertisedbrakehorsepowerandtorquerating
•Emissionfamilyandcontrolsystems
•Valvelashspecications
•Engineserialnumber
•EPA,EURO,OBDandreservedeldsforspecic
applications

8ENGINESYSTEMS
EngineAccessoryLabelsandIdentication
Plates
Thefollowingengineaccessoriesmayhave
manufacturer'slabelsoridenticationplates:
•Aircompressor
•Airconditioningcompressor
•Alternator
•EngineControlModule(ECM)
•Coolingfanclutch
•High-pressurefuelpump
•Powersteeringpump
•Startermotor
•Turbochargers

ENGINESYSTEMS9
EngineSpecications
MaxxForce®15DieselEngine
EngineConguration4stroke,inlinesixcylinderdiesel
Advertisedbrakehorsepower@rpmSeeEPAexhaustemissionlabel
Peaktorque@rpmSeeEPAexhaustemissionlabel
Displacement15.2L(928in3)
Compressionratio16.0:1
Stroke171.5mm(6.75in)
Bore(sleevediameter)137.2mm(5.40in)
Engineweight(dry,withouttrimoraccessories)1429kg(3,150lbs)
Firingorder1-5-3-6-2-4
Enginerotation(facingywheel)Counterclockwise
AspirationDualturbochargedandChargeAir
Cooled(CAC)
CombustionsystemDirectinjectionturbocharged
FuelsystemHigh-pressurecommonrail
Lubesystemrellcapacity(includinglter)
•Gravitydrainfromrightrearandbottomfrontsumpplugs38L(40qts)
•Suctionoilrecoveryoption34.5L(36.5qts)
Enginelubricationoilpressureat99°C(210°F)
•600rpm
•1,600rpm
Minimum83kPa(12psi)
275-550kPa(40-80psi)
Idlespeed(noload)600rpm,nominal
Thermostattransitionrange(startopen—fullopen)88°C-103°C(190°F-217°F)
EngineDescription
TheMaxxForce®15dieselenginehasbeendesigned
forincreaseddurabilityandreliability.
Thecylinderheadhasfourvalvespercylinderwith
centrallylocatedfuelinjectorsdirectingfuelover
thepistons.Thiscongurationprovidesimproved
performanceandreducesemissions.
Theoverheadcamshaftissupportedbyseven
bearingsinthecylinderhead.Thecamshaftgearis
drivenfromthefrontoftheengine.Theoverhead
valvetrainincludesrollerrockerarmsanddualvalves
thatopenusingavalvebridge.
TheMaxxForce®15engineusesonepieceforged
steelpistons.Coolingjetcutoutsandfeedholesare
placedonbothsidesofthepistons.Pistonsmay
beinstalledineitherdirectionhoweverpistonsare
originallyinstalledwithcastingbumponbottomofpin
bosstowardrearofengine.
Theonepiececrankcasecanwithstandhigh-pressure
loadsduringoperation.Thecrankcaseuses
replaceablewetcylindersleevesthataresealedbya
systemofthreeO-rings.
Soundshieldsarestrategicallyplacedontheengine
toreducenoise.

10ENGINESYSTEMS
Thecrankshafthassevenmainbearingswithfore
andaftthrustcontrolledattheforthbearing.One
connectingrodisattachedateachcrankshaftjournal.
Thepistonpinmovesfreelyinsidetheconnectingrod
andpiston.Pistonpinretainingringssecurethepiston
pininthepiston.Therearoilsealcarrierispartofthe
ywheelhousing,andthefrontoilsealcarrierispart
ofthefrontcover.
Anoilpumpismountedwithintheoilpantothe
bottomofthecrankcasebehindthefrontcoverandis
drivenbythecrankshaft.Pressurizedoilissupplied
tointernalenginecomponents,aircompressor,power
steeringpumpandturbochargers.AllMaxxForce®
15enginesuseanengineoilcoolerandaspin-on
canstyleengineoillterelement.
Fuelisdrawnfromthefueltankthroughthe
frame-mountedfuel/waterlterseparator.Ahand
operatedprimerpumpislocatedeitherontopof
ornexttotheframe-mountedfuel/waterseparator.
Thefuelisthenroutedintothefuelpumpandtothe
engine-mountedfuellter.Conditionedfuelisthen
pumpedtothefuelinjectors.
Thefuelinjectionsystemisdirectcommonrail.The
systemincludesahigh-pressurefuelpump,fuelrail
andfuelinjectors.Theinjectorsareinstalledinthe
cylinderheadunderthevalvecover.
TheMaxxForce®15engineusesdualturbochargers
withanair-to-liquidInterstageCooler(ISC)between
turbochargers,andachassis-mountedair-to-air
ChargeAirCooler(CAC)toreduceairtemperature
beforeenteringtheintake.
Thecoldstartassistsystemwarmstheincoming
airsupplybefore,during,andashortperiodafter
crankingtoaidcoldenginestartingandreducewhite
smokeduringwarm-up.
TheExhaustGasRecirculation(EGR)system
circulatescooledexhaustintotheintakeairstreamin
themixingduct.Thiscoolsthecombustionprocess
andreducestheformationofNitrogenOxides(NOX)
engineemissions.TheEGRcoolerassemblycools
theexhaustgasintwostages.
Anopencrankcasebreathersystemusesanoil
separatortoreturnoiltothecrankcaseandvent
thecrankcasegassestotheatmosphere.Theoil
separatorismountedonthecylinderhead.
TheenginebrakeisstandardontheMaxxForce®15.
Theenginebrakeisacompressionreleasesystem
thatprovidesadditionalvehiclebrakingperformance.
Theoperatorcancontroltheenginebrakefordifferent
operatingconditions.
OptionalFeatures
Anoilpanheaterandacoolantheaterareavailable
asoptionalcoldclimatefeatures.Bothheatersusean
electricelementtowarmengineuidsincoldweather
conditions.
Theoilpanheaterwarmsengineoiltoensure
optimumoilowtoenginecomponents.
Thecoolantheaterwarmstheenginecoolant
surroundingthecylinders.Warmedenginecoolant
increasesfueleconomyandaidsstart-upincold
weatherconditions.
ChassisMountedFeatures
Theaftertreatmentsystem,partofthelarger
exhaustsystem,processesengineexhaustsothat
itmeetstailpipeemissionrequirements.Mostofthe
aftertreatmentsystemismountedonthechassis.
•ThePre-DieselOxidationCatalyst(PDOC)
andDieselOxidationCatalyst(DOC)whichis
mountedonthechassis,oxidizeshydrocarbons
andcarbonmonoxide,providesheatforexhaust
systemwarm-up,andaidsintemperature
managementfortheDieselParticulateFilter
(DPF)forpassiveDPFregeneration.
•TheDPFtemporarilystorescarbon-based
particulatesthenoxidizestheparticulatesand
storesthenoncombustibleash.
TheHigh-PressureChargeAirCooler(HPCAC)
mountedonthevehiclecoolingmodule,isconnected
betweentheoutletofthehigh-pressureturbocharger
andtheinlettotheenginethrottlevalveassembly.
TheHPCACisanair-to-aircoolerthatusesambient
airtocoolpressurizedairbeforeitenterstheengine.

ENGINESYSTEMS11
EngineComponentLocations
Figure3Componentlocation–top
1.Turbochargerinterstagecooler
assembly
2.Flywheelhousingassembly
3.Valvecoverassembly
4.Exhaustgastemperaturesensor
5.ColdStartFuelIgniter(CSFI)
6.ChargeAirCoolerOutlet
Temperature(CACOT)sensor
7.Breatherlterassembly

12ENGINESYSTEMS
Figure4Componentlocation–front
1.Waterpumppulley
2.Airinletduct(turbocharger)
3.Frontliftingeye
4.EGRcrossovertubeassembly
5.Enginethrottlevalveassembly
6.Oilllerpipeassembly
7.Camshaftgearcover
8.Lowmountfandrive
9.Damper(crankshaft)

ENGINESYSTEMS13
Figure5Componentlocation–right
1.Pre-DieselOxidationCatalyst
(PDOC)assembly
2.Fueldoser
3.ExhaustGasRecirculation
(EGR)coolerassembly
4.High-Pressure(HP)
turbochargerassembly
5.Thermostathousing
6.Interstagecoolerassembly
7.High-pressureturbocharger
compressoroutlet
8.Oilsupplytubeforsecondary
ltration(tosootlter)
9.Coolantinlet(fromradiator)
10.CoolantControlValve(CCV)
assembly
11.Oillter
12.Low-Pressure(LP)turbocharger
assembly
13.High-pressureturbocharger
wastegateactuator
14.Engineoilcoolerassembly

14ENGINESYSTEMS
Figure6Componentlocation–left
1.Aircompressor
2.Oillevelgaugeassembly
3.Crankcasebreather
4.EngineControlModule(ECM)
5.DownStreamInjection(DSI)
assembly
6.12Vrelay(forcoldstartassist
solenoid)
7.FuelDeliveryPressure(FDP)
sensor
8.Fuellter
9.Oilpandrainplug(rearsump)
10.CrankcasePressure(CPS)
sensor
11.EngineOilPressure(EOP)
sensor
12.Oilpandrainplug(frontsump)
13.ColdStartFuelSolenoid(CSFS)
14.5mm60degreespeedsensor
(crankshaftpositionsensor)
15.High-pressurefuelpump
16.Powersteeringpump

ENGINESYSTEMS15
Figure7Componentlocation–rear
1.Rearliftingeye
2.ExhaustGasRecirculation
(EGR)valveassembly
3.Fuelreturntubeassembly
4.EGRcoolersupplytube
5.Flywheel
6.Oilpan
7.Flywheelhousing

16ENGINESYSTEMS
AirManagementSystem(AMS)
Figure8AirManagementSystem(AMS)
AirFlow
Airowsthroughtheaircleanerassemblyandenters
thelow-pressureturbocharger.Thelow-pressure
turbochargerincreasesthepressure,temperature,
anddensityoftheintakeairbeforeitentersthe
InterstageCooler(ISC).Cooledcompressedairows
fromtheISCintothehigh-pressureturbocharger.The
high-pressureturbochargerincreasestheintakeair
pressureupto345kPa(50psi).Thehotcompressed
airowsintotheChargeAirCooler(CAC)whereit
iscooled,andthendirectedtotheEngineThrottle
Valve(ETV)andmixingductareaofthethrottlevalve
assembly.
IftheEGRcontrolvalveisopen,exhaustgaspasses
throughtheEGRsystemintothemixingductwhereit
ismixedwiththelteredintakeair.Thismixtureows
throughthemixingductintotheintakemanifoldand