Navistar MaxxForce 9

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SAFETYINFORMATION

Tools

•Makesurealltoolsareingoodcondition.

•Makesureallstandardelectricaltoolsaregrounded.

•Checkforfrayedpowercordsbeforeusingpowertools.

FluidsUnderPressure

•Useextremecautionwhenworkingonsystemsunder

pressure.

•Followapprovedproceduresonly.

Fuel

•Donotoverllthefueltank.Overllcreatesarehazard.

•Donotsmokeintheworkarea.

•Donotrefuelthetankwhentheengineisrunning.

RemovalofTools,Parts,andEquipment

•Reinstallallsafetyguards,shields,andcoversafter

servicingtheengine.

•Makesurealltools,parts,andserviceequipmentare

removedfromtheengineandvehicleafterallworkis

done.

Page5

Main Page

Table of Contents3
Foreword9
Safety Information11
Warranty15
Federal Emission System Warranty15
- Warranty Period15
- Required Maintenance15
- Warranty Repairs and Service15
- Recommended Maintenance or Repair Parts16
- Emergency Repairs16
- What Is Not Covered by Warranty16
- Warranty Rights and Responsibilities17
California Emission System Warranty17
- Warranty Period17
- Required Maintenance18
- Warranty Repairs and Service18
- Recommended Maintenance or Repair Parts18
- Emergency Repairs18
- What Is Covered by Warranty19
- What Is Not Covered by Warranty19
- Warranty Rights and Responsibilities20
Section 1 - Engine Systems21
Engine Serial Number21
Engine Emission Label22
Engine Accessory Labels and Identification Plates22
Engine Specifications23
- Engine Description25
- Engine Features27
- Engine Optional Features29
Engine Component Locations32
- Component Location - Top32
- Component Location - Front33
- Component Location - Intake Side34
- Component Location - Exhaust Side35
- Component Location - Rear36
Section 2 - Requirements for Fuel, Engine Oil, and Coolant37
Fuel37
- Ultra Low Sulfur Diesel (ULSD)37
- Unacceptable Fuel and Blends37
- Acceptable Fuel Blends38
- Use of Higher Biodiesel Fuel Blends (B6 to B20)38
- Unsafe Practices39
Engine Oil39
- Engine Oil Quality and Service Categories39
- API CJ-4 for High Performance Diesel Engines39
- SAE Oil Viscosity Grades and Temperature Ranges40
Coolant41
- Coolant Mixtures41
- Extended Life Coolant (ELC) - Red41
- Contamination of Coolant42
Wait to Start Lamp43
Section 3 - Instruments, Indicators, and Switches43
Instrument Panel Gauge Cluster43
Warning Lights43
Idle Shutdown Indicator44
Maintenance Lamp44
Amber Warning Lamp (AWL)45
RED Stop Lamp (RSL)45
High Exhaust System Temperature (HEST) Lamp46
Diesel Particulate Filter (DPF) Indicator46
Malfunction Indicator Lamp (MIL)47
Typical Water Temperature Gauge48
Oil Pressure Gauge49
Oil Temperature Gauge50
Switches51
- Engine Brake ON/OFF Switch51
- Engine Exhaust Brake ON/OFF Toggle Switch51
Air Cleaner Restriction Indicator52
Section 4 - Engine Operation53
Preoperation Checklist53
Priming the Fuel System54
Starting the Engine54
Emergency Starting56
Operation57
- Suggested Warm-Up Time57
- Idle Speed57
- Extended Idling Periods58
- Exhaust Aftertreatment System58
- Aftertreatment (AFT) High-Soot Auto Engine Shut down59
- Engine Idle Shutdown Timer (Federal-Optional)59
- Engine Idle Shutdown Timer (California-Standard)60
- Cold Weather Operation61
- Cold Ambient Protection (CAP)62
- Hot Weather Operation62
- Engine Shutdown63
- HD-OBD Overview63
- Radiator Shuttle Enable (RSE)63
- Road Speed Limiting (RSL)63
- Road Operation63
- Downhill Operation64
Section 5 - Maintenance Schedule and Service Procedures65
Maintenance Schedule65
Service Procedures68
- Oil Level68
- Coolant Level69
- Water Separator70
- Charge Air Cooler (CAC)72
- External Leakage72
- Air Cleaner Restriction72
- Engine Oil and Filter73
- Centrifuge Filter (if Equipped)77
- Resetting Change Engine Oil Service Interval Message80
- Belt, Air Intake Piping and Clamps81
- Coolant Freeze Point83
- Fuel Filter83
- Fuel Strainer87
- Electrical System89
- Vibration Damper89
- Engine Valve Lash89
- Engine Brake Lash89
- Induction System89
- Extended Life Coolant (ELC) Extender90
- Crankcase Pressure91
- Turbochargers91
- Cleaning Diesel Particulate Filter91
- Service Cooling System91
Section 6 - Long Term Storage95
General Information95
Section 7 - Service Records97
Maintenance Service Record97
Daily Care and Report100

Navistar MaxxForce 9 - Page 13

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