Documente Academic
Documente Profesional
Documente Cultură
Table of Contents
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449
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Follow all warnings, cautions, and notes.
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II ENGINE SERVICE MANUAL
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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ENGINE SERVICE MANUAL 1
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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2 ENGINE SERVICE MANUAL
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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ENGINE SERVICE MANUAL 3
This manual provides general and specific service Wear protective safety glasses and shoes.
procedures essential for reliable engine operation and Wear correct hearing protection.
your safety. Since many variations in procedures,
tools, and service parts are involved, advice for all Wear cotton work clothing.
possible safety conditions and hazards cannot be Wear sleeved heat protective gloves.
stated.
Do not wear rings, watches or other jewelry.
Read safety instructions before doing any service and
test procedures for the engine or vehicle. See related Restrain long hair.
application manuals for more information. Fire prevention
Disregard for Safety Instructions, Warnings, Cautions, Make sure charged fire extinguishers are in the
and Notes in this manual can lead to injury, death or work area.
damage to the engine or vehicle.
NOTE: Check the classification of each fire
SAFETY TERMINOLOGY extinguisher to ensure that the following fire types
can be extinguished.
Three terms are used to stress your safety and safe
operation of the engine: Warning, Caution, and Note 1. Type A Wood, paper, textiles, and rubbish
Note: A note describes actions necessary for correct, Always disconnect the main negative battery
efficient engine operation. cable first.
Always connect the main negative battery cable
SAFETY INSTRUCTIONS last.
Vehicle Avoid leaning over batteries.
Make sure the vehicle is in neutral, the parking Protect your eyes.
brake is set, and the wheels are blocked before
doing any work or diagnostic procedures on the Do not expose batteries to open flames or sparks.
engine or vehicle. Do not smoke in workplace.
Work area Compressed air
Keep work area clean, dry, and organized. Limit shop air pressure for blow gun to 207 kPa
Keep tools and parts off the floor. (30 psi).
Make sure the work area is ventilated and well lit. Use approved equipment.
Make sure a first aid kit is available. Do not direct air at body or clothing.
Use safety blocks and stands. Use shielding to protect others in the work area.
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Follow all warnings, cautions, and notes.
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4 ENGINE SERVICE MANUAL
Tools Fuel
Make sure all tools are in good condition. Do not over fill the fuel tank. Over fill creates a fire
hazard.
Make sure all standard electrical tools are
grounded. Do not smoke in the work area.
Check for frayed power cords before using power Do not refuel the tank when the engine is running.
tools.
Removal of tools, parts, and equipment
Fluids under pressure
Reinstall all safety guards, shields, and covers
Use extreme caution when working on systems after servicing the engine.
under pressure.
Make sure all tools, parts, and service equipment
Follow approved procedures only. are removed from the engine and vehicle after all
work is done.
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Follow all warnings, cautions, and notes.
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ENGINE SYSTEMS 5
Table of Contents
Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Accessory Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Standard Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Chassis Mounted Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
EGES-335-2
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
April 2011 Navistar, Inc. All rights reserved
6 ENGINE SYSTEMS
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Follow all warnings, cautions, and notes.
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ENGINE SYSTEMS 7
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Follow all warnings, cautions, and notes.
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8 ENGINE SYSTEMS
Engine Description
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ENGINE SYSTEMS 9
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Follow all warnings, cautions, and notes.
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10 ENGINE SYSTEMS
EGES-335-2
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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ENGINE SYSTEMS 11
EGES-335-2
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Follow all warnings, cautions, and notes.
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12 ENGINE SYSTEMS
EGES-335-2
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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ENGINE SYSTEMS 13
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
April 2011 Navistar, Inc. All rights reserved
14 ENGINE SYSTEMS
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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ENGINE SYSTEMS 15
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Follow all warnings, cautions, and notes.
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16 ENGINE SYSTEMS
The Air Management System includes the following: Inlet Air Heater Control (IAHC)
Air filter assembly Exhaust and intake valves
Variable Geometry Turbocharger (VGT) Exhaust system
Charge Air Cooler (CAC) Diamond Logic exhaust and engine brake
Intake throttle valve Diesel Particulate Filter (DPF Aftertreatment
System)
Exhaust Gas Recirculation (EGR)
Intake manifold and EGR mixer
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Follow all warnings, cautions, and notes.
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ENGINE SYSTEMS 17
EGES-335-2
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
April 2011 Navistar, Inc. All rights reserved
18 ENGINE SYSTEMS
EGES-335-2
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
April 2011 Navistar, Inc. All rights reserved