Navistar MaxxForce DT 9 User manual

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

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

TABLE OF CONTENTS
FOREWORD......................................................................................1
SAFETYINFORMATION.......................................................................3
WARRANTY......................................................................................7
Federal Emission System Warranty..........................................................................7
WarrantyPeriod..............................................................................................7
RequiredMaintenance......................................................................................7
WarrantyRepairsandService..............................................................................7
RecommendedMaintenanceorRepairParts.............................................................7
EmergencyRepairs..........................................................................................8
WhatisnotCoveredbyWarranty..........................................................................8
Warranty Rights and Responsibilities......................................................................8
California Emission System Warranty.....................................................................10
WarrantyPeriod.............................................................................................10
RequiredMaintenance.....................................................................................10
WarrantyRepairsandService............................................................................10
RecommendedMaintenanceorRepairParts...........................................................10
EmergencyRepairs........................................................................................10
WhatisCoveredbyWarranty.............................................................................11
WhatisnotCoveredbyWarranty.........................................................................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
Form No. 1172040R1
Printed in the United States of America

TABLE OF CONTENTS
EngineDescription.........................................................................................17
EngineFeatures............................................................................................19
EngineOptionalFeatures..................................................................................21
Engine Component Locations...............................................................................24
ComponentLocation-Top.................................................................................24
ComponentLocation-Front...............................................................................25
ComponentLocation-IntakeSide........................................................................26
ComponentLocation-ExhaustSide.....................................................................27
ComponentLocation-Rear...............................................................................28
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT
Fuel...............................................................................................................29
UltraLowSulfurDiesel(ULSD)..........................................................................29
UnacceptableFuelandBlends............................................................................29
AcceptableFuelBlends....................................................................................30
UseofHigherBiodieselFuelBlends(B6toB20).......................................................30
UnsafePractices............................................................................................31
Engine Oil.......................................................................................................32
EngineOilQualityandServiceCategories..............................................................32
APICJ-4forHighPerformanceDieselEngines.........................................................32
SAEOilViscosityGradesAndTemperatureRanges...................................................33
Coolant..........................................................................................................34
CoolantMixtures............................................................................................34
ExtendedLifeCoolant(ELC)–Red......................................................................34
ContaminationofCoolant..................................................................................35
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES
Instrument Panel Gauge Cluster............................................................................37
Form No. 1172040R1
Printed in the United States of America

TABLE OF CONTENTS
Warning Lights.................................................................................................37
Wait to Start Lamp.............................................................................................37
Idle Shut Down Indicator.....................................................................................38
Maintenance Lamp.............................................................................................38
Warn Engine Lamp............................................................................................39
Stop Engine Lamp.............................................................................................39
High Exhaust System Temperature (HEST) Lamp.......................................................40
Diesel Particulate Filter (DPF) Indicator...................................................................40
Malfunction Indicator Lamp..................................................................................41
Typical Water Temperature Gauge..........................................................................42
Oil Pressure Gauge............................................................................................43
Oil Temperature Gauge.......................................................................................44
Switches.........................................................................................................45
EngineBrakeON/OFFSwitch............................................................................45
EngineExhaustBrakeON/OFFToggleSwitch..........................................................45
Air Cleaner Restriction Indicator............................................................................46
SECTION 4 – ENGINE OPERATION
Preoperation Checklist....................................................................................... 47
Priming the Fuel System.....................................................................................48
Starting the Engine............................................................................................48
Emergency Starting...........................................................................................50
Operation........................................................................................................51
SuggestedWarmupTime.................................................................................51
IdleSpeed...................................................................................................51
ExtendedIdlingPeriods....................................................................................51
AftertreatmentSystem.....................................................................................52
EngineIdleShutdownTimer(Federal-Optional)........................................................52
EngineIdleShutdownTimer(California-Standard).....................................................53
Form No. 1172040R1
Printed in the United States of America

TABLE OF CONTENTS
ColdWeatherOperation...................................................................................54
ColdAmbientProtection(CAP)...........................................................................55
HotWeatherOperation....................................................................................56
EngineShutdown...........................................................................................56
EngineWarningProtectionSystem(EWPS)............................................................56
RadiatorShuttleEnable(RSE)............................................................................57
RoadSpeedLimiting(RSL)...............................................................................58
RoadOperation.............................................................................................58
DownhillOperation.........................................................................................58
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Maintenance Schedule........................................................................................59
Service Procedures............................................................................................62
OilLevel.....................................................................................................62
CoolantLevel...............................................................................................63
WaterSeparator...........................................................................................65
ChargeAirCooler(CAC)..................................................................................66
ExternalLeakage...........................................................................................67
AirCleanerRestriction....................................................................................68
EngineOilandFilter........................................................................................69
CentrifugeFilter(IfEquipped).............................................................................73
Resetting Change Engine Oil Service Interval Message...............................................76
Belt,AirIntakePipingandClamps.......................................................................77
CoolantFreezePoint.......................................................................................79
FuelFilter....................................................................................................79
FuelStrainer................................................................................................83
ElectricalSystem...........................................................................................86
VibrationDamper...........................................................................................87
EngineValveLash..........................................................................................87
Form No. 1172040R1
Printed in the United States of America

TABLE OF CONTENTS
EngineBrakeLash.........................................................................................87
InductionSystem...........................................................................................87
ExtendedLifeCoolant(ELC)Extender...................................................................88
CrankcasePressure........................................................................................89
Turbochargers..............................................................................................89
CleaningDieselParticulateFilter.........................................................................89
ServiceCoolingSystem...................................................................................90
SECTION 6 – LONG TERM STORAGE
General Information...........................................................................................93
SECTION 7 – SERVICE RECORDS
Maintenance Service Record................................................................................95
Daily Care and Report.........................................................................................98
Form No. 1172040R1
Printed in the United States of America

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

FOREWORD
Foreword
Navistar, Inc. is committed to continuous research and
development to improve products and introduce technological
advances. Procedures, specifications, and parts defined in
published technical service literature may be altered.
NOTE: Photo illustrations identify specific parts or assemblies
that support text and procedures; other areas in a photo
illustration may not be exact.
This manual includes necessary information and specifications
for operators to operate and maintain Navistar diesel engines.
Contact your dealer for more information.
Technical Service Literature
1172040R1 MaxxForce® DT, 9, and 10 Engine Operation
and Maintenance Manual
EGES-450 MaxxForce® DT, 9, and 10 Engine Service
Manual
EGES-455 MaxxForce® DT, 9, and 10 Engine Diagnostic
Manual
EGED-460 MaxxForce® DT, 9, and 10 Diagnostic Form
EGED-495 MaxxForce® DT, 9, and 10 Electronic Control
System Diagnostics Form
Technical Service Literature is revised periodically. Use only up
to date service information.
To order technical service literature, contact your dealer.
All marks are trademarks of their respective owners.
About the Manual
This manual contains information needed to correctly operate
and maintain your engine as recommended by Navistar, Inc.
Numerous illustrations, symbols and feature descriptions
are used to aid in understanding the meaning of the text.
The illustrations, symbols or feature descriptions will not be
available for all applications, please reference your vehicle
operations manuals for complete information. Both metric and
U.S. customary values are listed in this manual. The metric
value is listed first, followed by the U.S. customary in brackets.
For additional service literature refer to Service Literature
noted in this manual. This manual does not cover vehicle
or equipment maintenance procedures. Consult the original
vehicle or equipment manufacturer for specific maintenance
recommendations.
Form No. 1172040R1
Printed in the United States of America Page 1

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

SAFETY INFORMATION
Safety Information
This manual provides general and specific maintenance
procedures essential for reliable engine operation and your
safety. Since many variations in procedures, tools, and service
parts are involved, advice for all possible safety conditions and
hazards cannot be stated.
Read safety instructions before doing any service and test
procedures for the engine or vehicle. See related application
manuals for more information.
Obey Safety Instructions, Warnings, Cautions, and Notes in this
manual. Not following warnings, cautions, and notes can lead to
injury, death or damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe operation of
the engine: Warning, Caution, and Note
Warning: A warning describes actions necessary to prevent
or eliminate conditions, hazards, and unsafe practices that can
cause personal injury or death.
Caution: A caution describes actions necessary to prevent or
eliminate conditions that can cause damage to the engine or
vehicle.
Note: A note describes actions necessary for correct, efficient
engine operation.
Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
• Use safety blocks and stands.
Protective Measures
• Wear protective safety glasses and shoes.
• Wear correct hearing protection.
• Wear cotton work clothing.
• Wear sleeved heat protective gloves.
• Do not wear rings, watches or other jewelry.
• Restrain long hair.
Vehicle
• Shift transmission to park or neutral, set parking brake, and
block wheels before doing diagnostic or service procedures.
Form No. 1172040R1
Printed in the United States of America Page 3

SAFETY INFORMATION
• Clear the area before starting the engine.
Engine
• The engine should be operated or serviced only by qualified
individuals.
• Provide necessary ventilation when operating engine in a
closed area.
• Keep combustible material away from engine exhaust
system and exhaust manifolds.
• Install all shields, guards, and access covers before
operating engine.
• Do not run engine with unprotected air inlets or exhaust
openings. If unavoidable for service reasons, put protective
screens over all openings before servicing engine.
• Shut engine off and relieve all pressure in the system before
removing panels, housing covers, and caps.
• Ifanengineisnot safeto operate,tag theengineand ignition
key.
Fire Prevention
• Makesurechargedfire extinguishers are in the work area.
NOTE: Check the classification of each fire extinguisher to
ensure that the following fire types can be extinguished.
1. Type A — Wood, paper, textiles, and rubbish
2. Type B — Flammable liquids
3. Type C — Electrical equipment
Batteries
• Always disconnect the main negative battery cable first.
• Always connect the main negative battery cable last.
• Avoid leaning over batteries.
• Protect your eyes.
• Do not expose batteries to flames or sparks.
• Donotsmokeinworkplace.
Compressed Air
• Use an OSHA approved blow gun rated at 207 kPa (30 psi).
• Limit shop air pressure to 207 kPa (30 psi).
• Wear safety glasses or goggles.
• Wear hearing protection.
• Use shielding to protect others in the work area.
• Do not direct compressed air at body or clothing.
Tools
• Make sure all tools are in good condition.
• Make sure all standard electrical tools are grounded.
Form No. 1172040R1
Page 4 Printed in the United States of America

SAFETY INFORMATION
• Check for frayed power cords before using power tools.
Fluids Under Pressure
• Use extreme caution when working on systems under
pressure.
• Follow approved procedures only.
Fuel
• Do not over fill the fuel tank. Over fill creates a fire hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
• Reinstall all safety guards, shields, and covers after
servicing the engine.
• Make sure all tools, parts, and service equipment are
removed from the engine and vehicle after all work is done.
Form No. 1172040R1
Printed in the United States of America Page 5

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

WARRANTY
Warranty
Federal Emission System Warranty
WARRANTY PERIOD
Navistar, Inc. warrants your medium-heavy duty diesel engine
for the following warranty period (whichever comes first):
•5years
• 160,000 km (100,000 miles)
• Or if covered by any basic or extended warranty (if greater
than above)
Your medium-heavy duty diesel engine conforms to U.S.
Environmental Protection Agency regulations for emission
systems.
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.
REQUIRED MAINTENANCE
As the vehicle owner, you are responsible for all required
maintenance described in this manual. Navistar recommends
that you retain all maintenance receipts. Navistar will not deny
an emission warranty claim solely because you have no record
of maintenance. However, a claim may be denied if your failure
to perform proper maintenance resulted in the failure of a
warranted part and you cannot provide appropriate evidence
of maintenance. Take your vehicle to an authorized service
provider when a problem occurs.
WARRANTY REPAIRS AND SERVICE
All emission controlsystem parts proven defective during normal
use will be repaired or replaced during the warranty period.
Warranty repairs and service will be done by an authorized
service provider with no charge for parts, labor and diagnostics.
Warranty repairs should be completed in a reasonable time, not
to exceed 30 days. Navistar may deny warranty coverage if
your vehicle or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
RECOMMENDED MAINTENANCE OR REPAIR PARTS
MaxxForce® service parts or MaxxForce® ReNEWed® parts
are recommended for maintenance or repairs to maintain the
original quality of your emission certified engine. If parts not
recommended by Navistar cause damage to the engine or
vehicle, the warranty is invalid and maintenance and repair
costs will not be covered.
Form No. 1172040R1
Printed in the United States of America Page 7

WARRANTY
Federal Emission System Warranty (cont.)
EMERGENCY REPAIRS
Emergency repairs are recognized, if parts are not available
within 30 days or repairs are not completed within 30 days.
If an authorized service provider is not reasonably available,
the vehicle owner or any service establishment can install any
replacement part.
Navistar will reimburse you for emergency repairs (including
diagnostics) for the following:
• Replacement parts that do not exceed manufacturer’s
suggested retail price.
• Labor charges based on manufacturer’s recommended time
allowance and geographic hourly rate.
Replaced parts and paid invoices must be given to your dealer
for reimbursement of emergency repairs.
WHAT IS NOT COVERED BY WARRANTY
Unauthorized parts or expendable parts
• Parts other than MaxxForce® service parts or ReNEWed®
parts.
• Aftermarket parts or service kits
• Non-defective parts replaced by an unauthorized service
provider.
• Parts requiring replacement at inspection or adjustment
maintenance intervals for reasons other than being
defective.
• Replacement of expendable items made in connection with
scheduled maintenance.
Vehicle, engine, and part malfunctions caused by the
following:
• Use of incorrect fuel, engine oil, or coolant
• Failure to maintain correct maintenance schedule
• Incorrect adjustments, modifications, alterations, tampering
or disconnection of vehicle components.
• Abuse or misuse of engine
• Accidents, acts of nature or other events beyond control of
Navistar.
Conditions not covered by Warranty
• Loss of time, inconvenience, use of vehicle/engine or
commercial loss.
• Vehicles with an altered or disconnected odometer or
hourmeter when mileage or hours cannot be determined.
WARRANTY RIGHTS AND RESPONSIBILITIES
Navistar assures that the emission warranty is being properly
administered. If you have not received satisfactory service
Form No. 1172040R1
Page 8 Printed in the United States of America

WARRANTY
Federal Emission System Warranty (cont.)
WARRANTY RIGHTS AND RESPONSIBILITIES (cont.)
or have questions regarding your warranty rights and
responsibilities, contact the regional office for assistance.
The address and phone number of each regional office is listed
in your Vehicle Operator Manual. If additional assistance is
required, contact the Manager of Customer Relations.
Manager, Customer Relations
Navistar, Inc.
4201 Winfield Road
Warrenville, Illinois 60555
(Telephone [phone])
Form No. 1172040R1
Printed in the United States of America Page 9

WARRANTY
California Emission System Warranty
WARRANTY PERIOD
Navistar, Inc. warrants your medium-heavy duty diesel engine
for the following warranty period (whichever comes first):
• 5 years
• 160,000 km (100,000 miles)
• Or if covered by any basic or extended warranty (if greater
than above)
Your medium-heavy duty diesel engine conforms to applicable
California Air Resources Board regulations. This vehicle is
registered and certified for sale in California.
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.
REQUIRED MAINTENANCE
As the vehicle owner, you are responsible for all required
maintenance described in this manual. Navistar recommends
that you retain all receipts covering maintenance on your truck,
but Navistar cannot deny warranty solely for the lack of receipts
or your failure to ensure the performance of all scheduled
maintenance. However, a claim may be denied if Navistar
demonstrates that the (engine/vehicle) has been abused,
neglected, or improperly maintained, and that such abuse,
neglect, or improper maintenance was the direct cause of the
need for the repair or replacement of the part. Take your vehicle
to an authorized service provider when a problem occurs.
WARRANTY REPAIRS AND SERVICE
All emission control system parts proven defective during normal
use will be repaired or replaced during the warranty period.
Warranty repairs and service will be done by an authorized
service provider with no charge for parts, labor and diagnostics.
Warranty repairs should be completed in a reasonable time, not
to exceed 30 days. Navistar may deny you warranty coverage if
your vehicle or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
RECOMMENDED MAINTENANCE OR REPAIR PARTS
MaxxForce® service parts or MaxxForce® ReNEWed® parts
are recommended for maintenance or repairs to maintain the
original quality of your emission certified engine. If parts not
recommended by Navistar cause damage to the engine or
vehicle, the warranty is invalid and maintenance and repair
costs will not be covered.
EMERGENCY REPAIRS
Emergency repairs are recognized, if parts are not available
within 30 days or repairs are not completed within 30 days.
If an authorized service provider is not reasonably available,
Form No. 1172040R1
Page 10 Printed in the United States of America

WARRANTY
California Emission System Warranty (cont.)
EMERGENCY REPAIRS (cont.)
the vehicle owner or any service establishment can install
replacement part.
Navistar will reimburse you for emergency repairs (including
diagnostics) for the following:
• Replacement parts that do not exceed manufacturer’s
suggested retail price.
• Labor charges based on manufacturer’s recommended time
allowance and geographic hourly rate.
Replaced parts and paid invoices must be given to a
MaxxForce® dealer for reimbursement of emergency repairs.
WHAT IS COVERED BY WARRANTY
New vehicles and engines, registered and certified for sale in
California, have the following items covered by the emission
warranty when first installed on the engine as original equipment
by Navistar:
• Fuel injection system
• Air induction system (includes turbocharger, exhaust
manifold, and intake manifold)
• Diesel Particulate Filter (DPF)
• Hoses, clamps, fittings and tubing
• Pulleys, belts and idlers
• Vacuum, temperature and time sensitive valves and
switches
WHAT IS NOT COVERED BY WARRANTY
Unauthorized parts or expendable parts
• Parts other than MaxxForce® service parts or ReNEWed®
parts.
• Aftermarket parts or service kits
• Nondefective parts replaced by other an unauthorized
service provider.
• Parts requiring replacement at inspection or adjustment
maintenance intervals for reasons other than being
defective.
• Replacement of expendable items made in connection with
scheduled maintenance.
Vehicle, engine, and part malfunctions caused by the
following:
• Use of incorrect fuel, engine oil, or coolant
• Failure to maintain correct maintenance schedule
Form No. 1172040R1
Printed in the United States of America Page 11

WARRANTY
California Emission System Warranty (cont.)
WHAT IS NOT COVERED BY WARRANTY (cont.)
• Incorrect adjustments, modifications, alterations, tampering
or disconnection of vehicle components.
• Abuse or misuse of engine
• Accidents, acts of nature or other events beyond control of
Navistar.
Conditions not Covered by Warranty
• Vehicles registered and normally operated outside the
United States.
• Loss of time, inconvenience, use of vehicle/engine or
commercial loss.
• Vehicles with an altered or disconnected odometer or
hourmeter when mileage or hours cannot be determined.
WARRANTY RIGHTS AND RESPONSIBILITIES
Navistar assures that the emission warranty is being properly
administered. If you have not received satisfactory service
or have questions regarding your warranty rights and
responsibilities, contact the regional office for assistance.
The address and phone number of each regional office is listed
in your Vehicle Operator Manual. If additional assistance is
required, contact the Manager of Customer Relations.
Manager, Customer Relations
Navistar, Inc.
4201 Winfield Road
Warrenville, Illinois 60555
(Telephone [phone])
Iffurtherquestions ofwarranty rightsand responsibilities remain,
contact:
The Air Resources Board
9528 Telstar Avenue
El Monte, California 91731
Form No. 1172040R1
Page 12 Printed in the United States of America