MaxxForce DT, 9, 10 Diesel Engine Workshop Repair & Service Manual - SAMPLE.pdf

ENGINE SERVICE MANUAL

I

Table of Contents

Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. S e r v i c e D i a g n o s i s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .2. Safety I nf nformation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. E n g i n e S y s t e m s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .5. Mounting Engine on Engine Stand...................................................................................55 55 Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 . Variable Geom Geome etry Turbocharger ger (VGT) GT)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...107 107 Exhaust Gas Recirculati latio on (EG (EGR) System...... tem...... ... .... ... ... .... .... ... ... .... ... ... ... ... .... ... ... ... .... ... ... 119 1 . 19 Inta ntake, Inle Inlett, and and Exh Exhaust Man Manifo ifolds.... ds.... ... .... ... ... .... ... ... .... ... ... .... ... .... ... ... ... .... ... .... ... ... .... ..141 141 Fuel an and Hi High-pr -pressure Oil Oil Systems ems... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 155 1 . 55 Diamond Logic® Engine Brake.................................................................................... ..185 185 Air Co Compr mpressor and and Power Ste Steering Pump... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..201 201 Oil System Module Assembly..................................................................................... ..213 ..213 Oil Pan and Oil Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231 2 . 31 Fron Frontt Cove Coverr, Cool Coolin ing g Syste System, m, and and Rela Relate ted d Compo Compone nent nts.... s.... .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... ... .. ... ... ..243 ..243 Cylinder Head and Valve Train..................................................................................... ..291 291 Flywheel and Flywheel Housing.....................................................................................337 337 Power Cy Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 . Crankcase, Cra Crankshaft, ft, and Cam Camshaft...... ... ... ... ... ... .... .... ... ... ... ... ... .... .... ... ... ... ... ... ... ... ... 403 4 . 03 Abbreviations and Acronyms..................................................................................... ...443 443 T e r m i n o l o g y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .449 449 Appendix A - Speci fications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457 . Appendix B - To Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475 4 . 75

EGES-335-2 Read all safety instructions instructions in the "Safety Information" Information" section of this Manual before doing any procedures. procedures. warnings, cautions, cautions, and notes. Follow all warnings, © April 2011 2011 Navistar, Navistar, Inc. All rights reserved

II

ENGINE SERVICE SERVICE MANUAL

Appendix C - Sp Special Se Service ice Too Toolls... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..487 487

EGES-335-2 Read all safety instructions instructions in the "Safety Information" Information" section of this Manual before doing any procedures. procedures. warnings, cautions, cautions, and notes. Follow all warnings, © April 2011 2011 Navistar, Navistar, Inc. All rights reserved


Foreword Navista Navistar, r, Inc. is committed committed to continu continuous ous research research and development to improve products and introduce technological technological advances. advances. Procedures, Procedures, speci fications, and and part parts s defined ned in publ publish ished ed techn technic ical al serv service ice literature may be altered. This Service Service Manual provides provides a genera generall sequen sequence ce of procedu procedures res for out-ofout-of-cha chassi ssis s engine engine overha overhaul ul (removal, (removal, inspection, inspection, and installation). installation). For in-chassis in-chassis service of parts and assemblies, the sequence may vary. NOTE: Photo Photo illustrations illustrations identify specific part parts s or assemblies assemblies that support text and procedures; procedures; other areas in photo illustrations may not be exact. See See vehi vehicl cle e manu manual als s and and Techn echnic ical al Serv Servic ice e Information Information (TSI) bulletins bulletins for additional additional information. information.

1

Technical Service Literature 1171939R3

MaxxForce ®DT, 9, and 10 Engine Operation and Maintenance Manual

EGES EGES-33 -3355-1 1

Maxx MaxxFo Force rce®DT, 9, and 10 Engine Service Manual

EGES EGES-37 -3700-1 1

Maxx MaxxFo Force rce®DT, 9, and 10 Engine Diagnostic Manual

EGED EGED-3 -375 75

Maxx MaxxFo Forc rce e ® DT, 9, and 10 Hard Start/ No Start Diagnostic Form

EGED EGED-3 -380 80

Maxx MaxxFo Forc rce e ® DT, 9, and 10 Performance Diagnostic Form

EGED EGED-3 -385 85

Maxx MaxxFo Forc rce e ® DT, 9, and 10 Electronic Control Systems Form

Technical echnical Service Literature is revised periodically periodically and and maile mailed d auto automat matic icall ally y to “Rev “Revis ision ion Servi Service ce”” subscribers. subscribers. If a technical technical publication publication is ordered, ordered, the latest revision will be supplied. NOTE: To To order technical service literature, contact contact your Navistar dealer.

EGES-335-2 Read all safety instructions instructions in the "Safety Information" Information" section of this Manual before doing any procedures. procedures. Follow all warnings, warnings, cautions, cautions, and notes. © April 2011 2011 Navistar, Navistar, Inc. All rights reserved

2


Service Diagnosis Diagnosis

•

Service diagnosis is an investigative procedure that must must be foll follow owed ed to find and and corr correc ectt an engi engine ne application problem or an engine problem.

Know Knowle ledg dge e of the the prin princi cipl ples es of oper operat atio ion n for for engine application application and engine systems

•

Knowle Knowledge dge to unde understa rstand nd and and do do proce procedure dures s in diagnostic and service publications

If the the probl problem em is engine engine appl applic icati ation on,, see see spec specii fic vehicle manuals for further diagnostic information. information.

Technical Service Literature required for Effective Diagnosis

If the proble problem m is the engine engine,, see see spec specii fic Engine Diagnostic Manual for further diagnostic information.

•

Engine Service Service Manual

•

Engine Diagnostic Diagnostic Manual

•

Diag Diagno nosti stics cs Forms Forms

•

Electro Electronic nic Control Control Systems Systems Diagnos Diagnostics tics Forms Forms

•

Servi Service ce Bull Bulleti etins ns

Prerequisites for Effective Diagnosis •

Avail vailab abil ilit ity y equipment

of

gaug gauges es

and and

diag diagno nos stic tic

tes test

•

Avai Availa labi bili lity ty of curr curren entt info inform rmat atio ion n for for engi engine ne application application and engine systems

EGES-335-2 Read all safety instructions instructions in the "Safety Information" Information" section of this Manual before doing any procedures. procedures. Follow all warnings, warnings, cautions, and notes. © April 2011 2011 Navistar, Navistar, Inc. All rights reserved


Safety Information Information

Protective measures

This This manual manual provide provides s genera generall and speci speci fic servic service e procedures procedures essential for reliable engine operation operation and your your safety safety.. Since Since many variations variations in proced procedures ures,, tools, tools, and service service parts parts are involved, involved, advice advice for all possib possible le safety safety conditi conditions ons and hazards hazards cannot cannot be stated.

•

Wear Wear protec protective tive safety safety glasse glasses s and and shoes. shoes.

•

Wear Wear correct correct hearin hearing g protec protection tion..

•

Wear Wear cotto cotton n work work clot clothin hing. g.

•

Wear Wear sleeve sleeved d heat heat protect protective ive gloves. gloves.

•

Do not not wear wear rings, rings, watc watches hes or other other jewelry jewelry..

Read safety instructions before doing any service and test procedures procedures for the engine or vehicle. See related application application manuals for more information.

•

Restr Restrain ain long long hair hair..

Disregard Disregard for Safety Instructions, Instructions, Warnings, Warnings, Cautions, Cautions, and Notes in this manual can lead to injury, death or damage to the engine or vehicle. SAFETY TERMINOLOGY

Fire prevention •

Caution: Caution: A cauti caution on desc describ ribes es actio actions ns neces necessa sary ry cause to prev preven entt or elimi elimina nate te cond conditi ition ons s that that can cause damage to the engine or vehicle.

Make Make sure sure char charge ged d fire extinguishers are in the work area.

NOTE: Chec Check k the the clas classi sification ion of each fire exting extinguish uisher er to ensure ensure that the followi following ng fire types types can be extinguished. extinguished.

Three terms are used to stress your safety and saf e saf e operation of the engine: Warning, Caution, and Note Warning: Warning: A warning describes describes actions necessar necessar y to prevent or eliminate conditions, hazards, and unsafe practices practices that can cause personal personal injury or death.

3

1.

Type Type A — Wood, Wood, paper paper,, textiles, textiles, and rubbish rubbish

2.

Type B — Flamma Flammable ble liquids liquids

3.

Type Type C — Elect Electrica ricall equipme equipment nt

Batteries Batteries Batteries produce produce highly flammable gas during and after charging. charging. •

Alwa Always ys disc discon onne nect ct the the main main nega negati tive ve batt batter ery y cable first.

•

Always Always conn connect ect the the main main nega negative tive battery battery cable cable last.

Vehicle

•

Avoid Avoid leaning leaning over over batteri batteries. es.

•

•

Prot Protec ectt your your eyes eyes..

•

Do not expose expose batterie batteries s to open open fl ames or sparks.

•

Do not not smok smoke e in workp workpla lace ce..

correct, Note: Note: A note describes actions necessar necessar y for correct, ef ficient engine operation. operation. SAFETY INSTRUCTIONS

Make Make sure sure the the veh vehic icle le is is in neut neutra ral, l, the the parking brake is set, and the wheels are blocked block ed before doing any work or diagnostic procedures on the engine or vehicle.

Work area

Compressed Compressed air

•

Keep work area clean, clean, dry, dry, and organized. organized.

•

Keep Keep tools tools and and parts parts off off the the fl oor.

• •

•

Limit Limit sho shop p air air press pressur ure e for blow blow gun gun to 207 207 kPa kPa (30 psi).

Make sure the work area area is ventila ventilated ted and well well lit. lit.

•

Use Use appro approve ved d equip equipmen ment. t.

Mak Make sure a fi rst aid kit is available. availa ble.

•

Do not not dire direct ct air air at at body body or clot clothin hing. g.

Safety equipment equipment

•

Wear Wear safety safety glasse glasses s or goggle goggles. s.

•

Use Use corre correct ct liftin lifting g devi device ces. s.

•

Wear Wear hear hearing ing prote protecti ction on..

•

Use Use saf safety ety bloc blocks ks and and sta stand nds. s.

•

Use shield shielding ing to prote protect ct othe others rs in the work area. area.


4


Tools

Fuel

•

Make Make sure sure all tools tools are are in in good good conditi condition. on.

•

•

Make Make sure ure all all stan standa dard rd elec electr tric ical al tool tools s are grounded.

Do not over fi tank. Over fi fi ll the fuel tank. fi ll creates a fi re hazard.

•

Do not smok smoke e in in the the work work area area..

•

Do not not refu refuel el the the tank tank when when the the engine engine is runn running ing..

•

Check Check for for fraye frayed d power power cords cords befor before e usin using g power power tools.

Fluids under pressure pressure • •

Use Use extre extreme me cauti caution on when when work workin ing g on system systems s under pressure. Follow Follow approv approved ed procedu procedures res only only.

Removal of tools, parts, and equipment •

Rein Reinsta stall ll all safe safety ty guards guards,, shie shield lds, s, and cover covers s after servicing the engine.

•

Make Make sure sure all all tools, tools, parts, parts, and and servic service e equip equipmen mentt are removed from the engine and vehicle after all work is done.


ENGINE SYSTEMS

5

Table of Contents

Engine Identi fication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. Engine S er erial N um umber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 . Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. Engine Accessory Labels......................................................................................7 Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Standard Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1 .0 Chassis Mounted Features.........................................................................10 10 Engine Component Locations...............................................................................11 11 Air Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 . Air Management Components...............................................................................17 17 Charge Air Cooler (CAC)............................................................................17 17 Exhaust Gas Recirculation (EGR) System.......................................................18 System.......................................................18 Variable Geometry Turbocharger (VGT)..........................................................20 (VGT)..........................................................20 Afte Afterrtre treatme atmen nt (A (AFT) Sy System tem... ... ... ... ... ... ... ... .... ... ... ... ... ... ... ... ... .... ... ... ... ... ...22 22 Fuel Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2 .3 I C P S y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .24 . High-Pressure Oil Flow..............................................................................24 24 ICP Closed Loop System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 25 ICP Control S ys ystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2 .6 F u e l I n j e c t o r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..27 . Fuel S up upply Sy System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 . Fuel Supply System Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3 .0 Engine Lubrication System................................................................................... .........33 33 Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 . Engine C oo ooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . Cooling System Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 . Cooling System Components...............................................................................37 37 Coolant Heater (optional)...........................................................................37 37 Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3 .8 Electronic Control System................................................................................... ..........39 Electronic Con Contro trol System Compo mponents..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .39 39 Operation and Function.............................................................................39 39 Reference Voltage (VREF)..........................................................................40 40 Signal Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4 .0 M i c r o p r o c e s s o r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 . Microprocessor Memory............................................................................40 40 Actuator Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 4 .1 A c t u a t o r s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .41 . 41 EGES-335-2 Read all safety instructions instructions in the "Safety Information" Information" section of this Manual before doing any procedures. procedures. Follow all warnings, warnings, cautions, cautions, and notes. © April 2011 2011 Navistar, Navistar, Inc. All rights reserved

6

ENGINE SYSTEMS

E G R V a l v e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..41 I A H R e l a y s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..41 Inta Intak ke Throt Throttl tle e Actua Actuato torr and Pos Posit itio ion n Sens Sensor.. or.. .. .. ... .. .. .. .. ... .. ... .. .. .. .. ... ... .. .. .. .. ... .41 Engine and Vehicle Sensors.................................................................................42 42 Thermistor Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 42 Varia ariab ble Cap Capacita itance Sen Sensors... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...44 44 Magnetic Pickup Sensors...........................................................................45 45 Mic Micro Str Strain Gau Gauge (MS (MSG) Se Sensors... ... .... ... ... .... ... .... ... ... .... ... ... .... ... ... .... ... ...46 46 P o t e n t i o m e t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 . S w i t c h e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 48 Intake Throttle Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 4. 9 Diamond Logic® Brake System..................................................................................... ..50 50 Brake Operation Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5 .1 Exhaust Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5 .1 Engine B ra rake S ys ystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5 .2


ENGINE SYSTEMS

Engine Identification

7

Engine Emission Label

Engine Serial Number

Figure 2 U.S. Environ Environmental mental Protection Protection Agency (EPA) exhaust emission label (example) Figure Figure 1

Engine Engine serial serial numb number er

The engine serial number is in two loc ations:

The U.S. Enviro Environmen nmental tal Protect Protection ion Agency Agency (EPA) (EPA) exhaust exhaust emission label is attached attached on top of the valve cover. The EPA label typically includes the following:

•

Stamped Stamped on a crankc crankcase ase pad on the the right right side side of of the crankcase below the cylinder head. hea d.

•

Mod Model year

•

On the the engi engine ne emiss emission ion label label on on the the valve valve cover cover..

•

Engine Engine family family,, mode model, l, and and displa displaceme cement nt

•

Adverti Advertised sed brake brake horse horsepow power er and and torqu torque e ratin rating g

Engine Serial Number Examples Examples

•

Emissio Emission n family family and control control systems systems

International® MaxxForce® DT: 466HM2U3000001 46 6HM2U3000001

•

Valve alve lash lash spec specii fications

International® MaxxForce® 570HM2U3000001

•

Engin Engine e seria seriall numb number er

•

EPA, EPA, EURO EURO,, and and res reserve erved d applications

9

and

10:

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 digi digitt suf suf fix – Engine sequence ce Engine serial serial number number sequen beginning beginning with 3000001 3000001

elds fields

for spec speciific

Engine Accessory Labels The The foll follow owin ing g eng engine ine acce access ssor orie ies s may may manufacturer’s manufacturer’s labels or identification plates: •

Air Air comp compre ress ssor or

•

Air conditi conditioni oning ng compres compressor sor

•

Alte Altern rnat ator or

•

Cool Coolin ing g fan fan clut clutch ch

•

Power Power steer steerin ing g pump pump

•

Star Starte terr moto motor r


have have

8

ENGINE SYSTEMS

Engine Description International® International® MaxxForce® MaxxForce® DT, DT, 9, and 10 Diesel Engines Engine con figuration

4 stroke, inline six cylinder diesel

MaxxForce® DT displacement

7.6 L (466 in 3)

MaxxForce® 9 and 10 displacement

9.3 L (570 in 3)

Bore (sleeve diameter)

116.6 mm (4.59 in)

Stroke •

Maxx MaxxFo Forc rce® e® DT

119 mm (4.68 in)

•

Maxx MaxxFo Forc rce® e® 9 and and 10

146 mm (5.75 in)

Compression ratio •


16.9 : 1

•


17.2 : 1

Aspiration

VGT turbocharged turbocharged and Charge Air Cooled (CAC)

Rated power @ rpm

1

•


245 bhp @ 2600 2600 rpm

•

Maxx MaxxFo Forc rce® e® 9

310 bhp @ 2200 2200 rpm

•


310 bhp @ 2200 2200 rpm

Peak torque @ rpm

1

•


620 lbf·ft @ 1400 rpm

•


950 lbf·ft @ 1200 rpm

•


1050 lbf·ft @ 1200 rpm

Engine rotation (facing flywheel)

Counterclockwise

Combustion system

Direct injection injection turbocharged turbocharged

Fuel system

Electro-hydraulic injection

Total engine weight (oil and accessories)

1

•


881 kg (1,943 lbs)

•


905 kg (1,995 lbs)

Cooling ing system tem capacity (engine only only))

12.8 L (13 (13.5 qts US)

Lube system capacity (including filter)

28 L (30 qts US)

Lube system capacity (overhaul only, with fi lter)

33 L (35 qts US)

Firing order

1-5-3-6-2-4

Example Example ratings shown. shown. See Performance Performance Speci fications appendix in Diagnostic Manual for additional ratings.


ENGINE SYSTEMS

Standard Features Maxx MaxxFo Forc rce® e® DT, DT, 9, and and 10 dies diesel el engi engine nes s are are designed for increased durability, reliability, and ease of maintenance. maintenance. The cylinder head has four valves per cylinder with central centrally ly located located fuel fuel injecto injectors rs directi directing ng fuel fuel over over the pist piston ons. s. This This con configuration provides improved improved performance and reduces emissions. The camsha camshaft ft is support supported ed by four four insert insert bushin bushings gs pressed pressed into the crankcas crankcase. e. The camshaf camshaftt gear gear is driven driven from the front of the engine. engine. A thrust flange is located between the camshaft and the drive gear. The overhead valve train includes mechanical roller lifters, push rods, rocker arms, and dual valves that open using a valve bridge. MaxxForce® DT engine engines s use one piece piece aluminum aluminum alloy alloy pistons pistons.. MaxxFo MaxxForce rce® 9 and 10 engines use one one piec piece e steel steel piston pistons. s. All All pisto pistons ns use an offset offset piston axis axis and centered combustio combustion n bowls. Crown marki marking ngs s show show corre correct ct pisto piston n orien orienta tatio tion n in the the crankcase. The The one one piec piece e crank crankca case se uses uses repla replace ceab able le wet wet cylinder sleeves that are sealed by a single crevice seal. Some applications applications include include a crankcase crankcase ladder whic which h is desig designe ned d to supp support ort heav heavier ier load loads s and and reduce engine noise. The crankshaf crankshaftt has seven main bearings bearings with fore and and aft aft thrus thrustt cont control rolled led at the rear rear bear bearin ing. g. One One fract fracture ured d cap cap conn connec ectin ting g rod is attac attache hed d at each each crankshaft crankshaft journal. journal. A piston pin moves freely freely inside the connecti connecting ng rod and piston. piston. Piston Piston pin retainin retaining g rings secure secure the piston pin in the piston. The rear oil seal carrier is part of the fl ywheel housing. A gerotor lube oil pump is mounted on the t he front cover and is driven driven by the cranksh crankshaft. aft. Pressur Pressurize ized d oil is supplied supplied to engine components components and the high-pressure high-pressure injecti injection on syste system. m. All MaxxF MaxxForc orce e ® DT, DT, 9, and and 10 engines use an engine oil cooler and spin-on engine oil filter. The water supply supply housing housing serves serves as the mounting mounting brac bracke kett for for the the Freo Freon® n® comp compre ress ssor or.. Moun Mounti ting ng capa capabi bili liti ties es for for a dual dual Freo Freon® n® comp compre ress ssor or are are

9

avai availa lable ble as an option option.. The The pad pad moun mountin ting g desig design n of the alterna alternator tor and Freon® Freon® compres compressor sor bracke brackets ts provide easy removal and improved durability. The low-pressure fuel supply pump draws fuel from the the fuel fuel tank tank throu through gh the the fuel fuel filter lter hou housi sing ng.. The The housing housing includes includes a strainer, strainer, filter, primer pump, drain valve, Water in Fuel (WIF) sensor, and Engine Fuel Pressure Pressure (EFP) sensor. sensor. If equipped, an optional fuel heater element is located in the fuel filter housing. Cond Condit itio ione ned d fuel fuel is pump pumped ed thro throug ugh h the the inta intake ke manifold and cylinder head to the fuel injectors. The WIF sensor sensor detects detects water in the fuel fuel system. system. When a programmed value of water is collected in the fuel fi lter housing, the instrument panel’s amber FUEL FILTER lamp will illuminate. The collected water must be removed removed immediate immediately ly.. The water water is drained drained by using the drain valve located on the fuel fi lter housing. The fuel injectio injection n system system is electro electro-hyd -hydraul raulic. ic. The system includes an under-valve-cover high-pressure oil manifol manifold, d, fuel injectors injectors,, and a high-p high-press ressure ure oil pump. The injectors are installed installed in the cylinder head, under the high-pressure oil manifold. The Variable ariable Geometry Geometry Turboc Turbochar harger ger (VGT) (VGT) has actuated actuated vanes in the turbine housing. housing. These vanes vanes modify exhaust gas flow through the VGT. The ECM commands the VGT in response to boost and exhaust back back pressu pressure re for various various engine engine speeds speeds and load conditions. The Inlet Air Heater (IAH) system warms the incoming air supply prior to cranking to aid cold engine starting and reduce reduce white smoke smoke during warm-up. warm-up. The IAH system system will initiall initially y illumina illuminate te the WAIT WAIT TO START START lamp located on the instrument instrument panel. When the lamp turns off, the engine can be started. The The Exha Exhaus ustt Gas Gas Reci Recirc rcul ulat atio ion n (EGR (EGR)) syst system em circulates cooled exhaust into the intake air stream in the intake intake manifold. manifold. This This cools the combust combustion ion process process and reduce reduces s the formation formation of NOX engine emissions. A closed crankcase breather system uses an engine mounted oil separator to return oil to the crankcase and vent crankcase crankcase pressure into the intake system. system.


10

ENGINE SYSTEMS

Optional Optional Features Features

Chassis Chassis Mounted Features

Optional Optional features features available available include the following: following:

A Charge Air Cooler (CAC) is an air-to-air heat exch exchan ange gerr whic which h incre increas ases es the the dens density ity of the air air charge.

•

Air Air comp compre ress ssor or

•

Power Power Takeo akeoff ff (PTO) (PTO)

•

Engi Engine ne or exha exhaust ust brake brake

An air compressor is available for applications that requ require ire air brakes brakes or air suspe suspensi nsion on.. A hydr hydrau aulic lic power steering pump can be used with or without the air compressor. The front cover has a mounting flange available for PTO accessories. The air compressor drive gear train is used with a spline adapter and provides power for front mounted PTO accessories. accessories.

The Aftertreatment Aftertreatment System, part of the larger Exhaust System, processes engine exhaust to meet tailpipe emission requirements. •

The The Dies Diesel el Ox Oxid idat atio ion n Cata Cataly lyst st (DOC (DOC)) burn burns s oxygen and hydrocarbons hydrocarbons in the exhaust stream.

•

The Diesel Diesel Parti Particula culate te Filte Filterr (DPF) (DPF) captur captures es and and burns particulates in the exhaust stream.

The Diamond Diamond Logic® Logic® engine engine brake brake is availab available le for all all engi engine ne displa displace cemen ments. ts. The The engi engine ne brake brake is a compre compressio ssion n release release brake brake system system that provid provides es additio additional nal braking braking performan performance. ce. The operator operator can contr control ol the engi engine ne brake brake for diff differe erent nt opera operati ting ng conditions. The Diamond Logic® exhaust brake system is also available available for all engine displacements. displacements. The exhaust brake uses the turbocharger to restrict exhaust flow for additiona additionall braking braking.. The operator operator can contro controll the exhaust brake for different operating conditions. Optional Cold Climate Features Optional Optional cold climate features available include the following: •

Oil Oil pan pan heat heater er

•

Cool Coolan antt heat heater er

•

Fuel Fuel hea heater ter

All three heaters use an electric element to warm engine fluids in cold weather conditions. The The oil oil pan pan heat heater er warm warms s engi engine ne oil oil to ensu ensure re optimum oil flow. The coolant coolant heater heater warms warms engine engine coolant coolant surroun surrounding ding the the cyli cylind nder ers. s. Warme armed d engi engine ne coola coolant nt aids aids in performance performance and fuel economy during start-up. The fuel heater is installed in the fuel filter header assembly assembly and warms the supply fuel. Warmed Warmed supply fuel prevents waxing, and improves improves performance performance and fuel economy during cold weather start-up.


ENGINE SYSTEMS

11

Engine Component Locations

Figure Figure 3 1. 2. 3. 4. 5.

Compon Component ent loca location tion – top

Valve alve cover cover EGR and inlet inlet air air mixe mixerr duct duct Intake Intake throttl throttle e assembl assembly y Intake Intake side side EGR cooler cooler EGR valve valve manifol manifold d asse assembl mbly y

6. 7. 8. 9.

EGR tube tube asse assemb mbly ly Alterna Alternator tor bracke brackett Variabl ariable e Geomet Geometry ry Turbo Turbocha charge rger r (VGT) assembly assembly Exhaust Exhaust side side EGR cooler cooler

10. Flywheel Flywheel housing housing


12

ENGINE SYSTEMS

Figure Figure 4 1. 2. 3.

Componen Componentt locatio location n – front front

Water Water outlet outlet tube assembl assembly y Coolan Coolantt cros crossove soverr tube tube assembly (EGR) Tube Tube supp suppor ortt

4. 5. 6. 7.

Front Front cove cover r Fan driv drive e pull pulley ey Front Front engi engine ne moun mountin ting g brack bracket et Vibrat Vibration ion damper damper assemb assembly ly

8. Water Water inlet inlet elbow elbow 9. Water Water pump pump pulley pulley 10. Automatic Automatic belt tensione tensioner r


ENGINE SYSTEMS

Figure Figure 5 1. 2. 3. 4. 5.

13

Compone Component nt locati location on – right right

Turbo Turbocha charge rgerr oil oil suppl supply y tube tube assembly Exhaust Exhaust manifo manifold ld Exhaust Exhaust side side EGR cooler cooler Variabl ariable e Geomet Geometry ry Turbo Turbocha charge rger r (VGT) assembly assembly Breath Breather er inle inlett tube tube assem assembly bly

6. 7.

Lift Liftin ing g eye eye Water Water supply supply housin housing g (Freo (Freon n® compressor mount) 8. Alterna Alternator tor bracke brackett 9. EGR coolan coolantt supp supply ly tube tube 10. Crankcase Crankcase breather breather assembly assembly with turbine turbine

11. 12. 13. 14.

VGT actuator actuator Coolan Coolantt tube (oil (oil system system module module)) Cooler Cooler heat exchange exchanger r M18 plug assembly assembly (coolant (coolant drain) 15. 15. Oil Oil filter 16. Oil system system module assembl assembly y


14

ENGINE SYSTEMS

Figure Figure 6 Compone Component nt locati location on – left 1. 2. 3. 4. 5.

Low-pr Low-press essure ure fuel fuel pump pump Priming Priming pump pump (fuel) (fuel) EGR valve valve manifo manifold ld assemb assembly ly Fuel Fuel strai straine nerr cap cap Fuel fi lter cap

6. 7. 8. 9.

Water Water drain drain valve valve Intake Intake Air Air Heat Heater er (IAH) (IAH) relay relay assembly Lifti Lifting ng eye eye Intak Intake e mani manifo fold ld

10. 10. 11. 12. 13. 14.

ECM ECM Oil pan Power steering steering pump pump assembly assembly Air compresso compressorr assembly assembly High-pressu High-pressure re oil pump pump


ENGINE SYSTEMS

Figure Figure 7 1. 2. 3.

15

Compon Component ent locati location on – rear rear

Valve alve cover cover Cylin Cylinde derr head head VGT asse assemb mbly ly

4. 5.

Cran Crankc kcase ase Rear Rear engin engine e mount mounting ing bracke brackett (2)

6. 7. 8.

Flywhe Flywheel el housin housing g Flyw Flywhe heel el Oil fi ller tube


16

ENGINE SYSTEMS

Air Management System

Figure Figure 8

Air managem management ent system system

The Air Management Management System includes the following: following:

•

Inlet Inlet Air Heat Heater er Contro Controll (IA (IAHC) HC)

•

Air filter assembly assembly

•

Exha Exhaus ustt and and intak intake e valve valves s

•

Variable ariable Geometry Geometry Turboc Turbochar harger ger (VGT) (VGT)

•

Exha Exhaus ustt syst system em

•

Charg Charge e Air Coole Coolerr (CAC) (CAC)

•

Diamond Diamond Logic® Logic® exhaus exhaustt and and engine engine brake brake

•

Intak Intake e thrott throttle le valv valve e

•

•

Exhaus Exhaustt Gas Recircu Recirculati lation on (EGR) (EGR)

Diese Diesell Parti Particu cula late te Filter Filter (DPF – After Aftertre treat atme ment nt System)

•

Intak Intake e manifo manifold ld and and EGR mixer mixer


ENGINE SYSTEMS

17

Air Flow

Air Management Management Components Components

Air fl fl ows through the air fi fi lter assembly and enters the VGT. The VGT compressor increases the pressure, temperat temperature ure,, and density density of the intake air before before it enters enters the CAC. CAC. Cooled Cooled compres compressed sed air flows ows from from the the CAC into the inlet throttle valve and EGR mixer duct.

Charge Air Cooler (CAC)

If the EGR contr control ol valv valve e is open open,, exha exhaus ustt gas gas will will pass pass thro throug ugh h the the EGR EGR syst system em and and mix mix with with the the filtered intak intake e air. air. This This mixture mixture flows through through the inlet air heater and into the intake manifold. If the EGR control valve is closed, only filtered intake air will flow through the inlet air heater and into the intake manifold. manifold. After combustion gases exit through the exhaust valv valves es and and port ports, s, the the gas gas is forc forced ed thro throug ugh h the the exhaust manifold to the EGR system and VGT. Some gas flows through the EGR system, which is controlled by the EGR valve. The remaining gas fl ows to the VGT turbine. The turbo vanes control fl ow and pressure pressure of exhaust exhaust gas. gas. This This cont control rols s the the speed speed of the the comp compre ress ssor or whee wheel, l, which is connected to the turbine wheel by a shaft. The VGT compressor wheel compresses the filtered air. Exhaus Exhaustt gases gases exit the turboch turbocharg arger er,, flow into the exhaust piping to the aftertreatment system, and are released from the exhaust tail pipe.

Figu Figure re 9 1. 2. 3. 4.

CAC CAC

Air Air outl outlet et CAC Air Air inle inlett Radi Radiat ator or

The chassis mounted CAC is mounted on top of the radiator. radiator. Air from the turbocharger passes passes through a network of heat exchanger tubes before entering the engine engine intake intake system. system. Outsid Outside e air flowing over the heat heat exchang exchanger er tube fi ns cools the charge air. air. Cooling the charge air increases the density and improves the air to fuel ratio during combustion.


18

ENGINE SYSTEMS

Exhaust Exhaust Gas Recirculation Recirculation (EGR) System

Figur Figure e 10 10 1. 2. 3. 4.

EGR syste system m

Exhaust Exhaust side side EGR cooler cooler Intake Intake side side EGR cooler cooler EGR EGR valv valve e EGR coo coola lant nt retur return n tube tube assembly

5. 6. 7. 8.

EGR valve valve manifo manifold ld EGR tube tube asse assemb mbly ly Coolan Coolantt cross crossove overr tube tube assembly EGR mete meteri ring ng tube tube

9. EGR coolan coolantt supply supply tube tube 10. Exhaust Exhaust manifold manifold

The EGR system includes the following:

•

EGR EGR mixe mixerr duc duct

•

Exha Exhaus ustt mani manifo fold ld

•

Inta Intake ke mani manifo fold ld

•

EGR EGR exhau exhaust st side side cool cooler er

•

Exha Exhaus ustt gas gas cross crossov over er tube tube

•

Electric Electrical al control control system system

•

EGR EGR cont contro roll valv valve e

The The EGR EGR syste system m reduc reduces es Nitro Nitroge gen n Oxid Oxide e (NO (NO X) engi engine ne emi emiss ssio ions ns.. NOX forms forms durin during g a reacti reaction on between nitrogen and oxygen at high temperatures during during combustio combustion. n. Combus Combustion tion starts starts when when fuel is injected into the compressed combustion chamber.

•

EGR intak intake e side side coole cooler r EGES-335-2 Read all safety instructions instructions in the "Safety Information" Information" section of this Manual before doing any procedures. procedures. Follow all warnings, warnings, cautions, and notes. © April 2011 2011 Navistar, Navistar, Inc. All rights reserved

MaxxForce DT, 9, 10 Diesel Engine Workshop Repair & Service Manual - SAMPLE.pdf

Recommend Documents