International Navistar MaxxForce 5 7 DT 9 10 Diesel Engine Service Diagnostic Troubleshooting Repair Manual PDF - MINTMF5MF10OPES.zip
Full workshop service and repair documentation, complete with electrical wiring diagrams, covering the International MaxxForce 5, MaxxForce 7, MaxxForce DT, MaxxForce 9, and MaxxForce 10 diesel engines — containing every technical detail needed to service, troubleshoot, fix, and rebuild these engines the way professional technicians do.
The International / Navistar MF5, MF7, MF DT, MF 9, and MF 10 diesel engine workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 14,891 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
0000001624 - 2010 MaxxForce DT, 9, and 10 Engines Diagnostic Manual..4
toc..6
Table of Contents..6
Safety Terminology..10
Safety Instructions..10
Work Area..10
Safety Equipment..10
Protective Measures..10
Vehicle..10
Engine..11
Fire Prevention..11
Batteries..11
Compressed Air..11
Tools..11
Fluids Under Pressure..12
Fuel..12
Removal of Tools, Parts, and Equipment..12
Table of Contents..14
Engine Identification..16
Engine Serial Number..16
Engine Serial Number Examples..16
Engine Serial Number Codes..16
Engine Emission Label..17
Engine Accessory Labels..18
Engine Description..18
Standard Features..19
Optional Features..20
Optional Cold Climate Features..20
Chassis Mounted Features..20
Engine Component Locations (245 hp and above)..22
Air Management System (AMS)..27
Air Flow ? Pre Combustion..28
Air Flow ? Post Combustion..28
Air Management Components..28
Turbochargers..28
Interstage Cooler (ISC)..29
High-pressure Charge Air Cooler (HPCAC)..30
Turbocharger 2 Wastegate Control (TC2WC) Valve..30
Exhaust Gas Recirculation (EGR) System..31
EGR Flow..32
EGR Valve..32
EGR Closed Loop System..32
Crankcase Ventilation System..34
Aftertreatment (AFT) System..36
AFT Control System..37
Sensors..37
Exhaust Back Pressure Valve..37
Pre-Diesel Oxidation Catalyst (PDOC)..37
Diesel Oxidation Catalyst (DOC)..37
Diesel Particulate Filter (DPF)..37
AFT Conditions and Responses..38
Downstream Injection System..38
Fuel Management System..39
ICP System..41
High-Pressure Oil Flow..42
ICP Closed Loop System..42
ICP Control System..43
Fuel Injector..44
Fuel Injector Features..44
Injector Coils and Spool Valve..44
Intensifier Piston and Plunger..44
Plunger and Barrel..45
Injector Needle..45
Fuel Injector Operation..45
Fill Stage..45
Injection..46
End of Injection..46
Fuel Supply System..47
Fuel Supply System Flow..48
Engine Lubrication System..51
Oil Flow..52
Engine Cooling System..53
Cooling System Description..53
Cooling System Components..55
Coolant Heater (optional)..55
Thermostat Operation..55
Low Temperature Radiator (LTR) Thermostat Operation..58
Electronic Control System..59
Electronic Control System Components..59
Operation and Function..60
Reference Voltage (VREF)..60
Microprocessor..60
Actuator Control..60
Actuators..60
Exhaust Gas Recirculation (EGR) Valve..61
Intake Air Heater (IAH) Relay..61
Engine Throttle Valve (ETV) and Position Sensor..61
Turbocharger 2 Wastegate Control (TC2WC) valve (turbocharger wastegate actuator)..61
Exhaust Back Pressure Valve (EBPV)..61
Engine Compression Brake (ECB) valve..61
Injection Pressure Regulator (IPR) valve..61
Engine and Vehicle Sensors..62
Temperature Sensors..62
Thermistor Sensors..62
ECT Sensor..62
EOT Sensor..63
AIT Sensor..63
IMT Sensor..63
CACOT Sensor..63
TC2CIT Sensor..63
Exhaust Gas Temperature (EGT) sensors..63
Variable Capacitance Sensors..64
FDP Sensor..64
EOP Sensor..64
EBP Sensor..64
MAF Sensor..65
IMP Sensor..65
Magnetic Pickup Sensors..65
CKP Sensor..65
CMP Sensor..65
VSS..66
High-pressure Sensors..66
DPFDP Sensor..66
ECBP..66
ICP..67
Potentiometer..67
APP..67
Switches..68
DDS..68
ECL..68
WIF..68
Engine Throttle Valve Control System..69
Exhaust and Engine Brake System..70
Exhaust Brake..70
Engine Brake..71
ECBP..71
ECB..71
Brake Pressure Relief Valve..71
EBP..72
High-pressure Oil Manifold..72
Operation..72
Operation Modes..74
Coast Mode..74
Latched Mode..74
Cruise Mode..74
Table of Contents..76
Standard Features..78
Electronic Governor Control..78
SAE J1939 Communication Datalink..78
American Trucking Association (ATA) Datalink..78
Service Diagnostics..78
Event Logging System..79
Electronic Speedometer and Tachometer..79
Aftertreatment System..79
Engine Fuel Pressure (EFP) Monitor..79
Intake Air Heater (IAH)..79
Fast Idle Advance..79
Cold Ambient Protection (CAP)..79
Coolant Temperature Compensation..80
Engine Crank Inhibit (ECI)..80
Optional Features..80
Road Speed Limiting (RSL)..80
Cruise Control..81
Traction Control..81
Exhaust Brake..81
Engine Brake..81
Engine Warning Protection System (EWPS)..81
Idle Shutdown Timer (IST)..81
IST for California ESS Compliant Engines..82
Engine Idle Shutdown Timer (IST for Federal ? Optional)..82
Electronic Fan (EFAN)..82
Radiator Shutter Enable (RSE)..82
In Cab Power Take Off (PTO) Control..82
Remote Accelerator Pedal Position (RAPP)..83
Change Engine Oil Interval Message..83
Fuel Heater..83
Table of Contents..84
Session Files..86
Diagnostic Trouble Codes (DTCs)..86
Suspect Parameter Number (SPN) ..86
Failure Mode Indicator (FMI)..86
Active..86
Previously Active..86
Intermittent or Inactive Fault Diagnostic Procedure..86
Overview..86
Tools Required..87
Equipment Condition..87
Test Setup..87
Test Procedure..87
Expected Outcome..87
Follow-On Procedure..87
ECM Programmable Parameters..87
Connecting EST with ServiceMaxx? Software to Engine..88
Obtain Vehicle Health Report..88
Overview..88
Tools Required..88
Equipment Condition..88
Test Setup..88
Test Procedure..88
Expected Outcome..88
Follow-On Procedure..88
Record Snapshot of KOEO Data..89
Overview..89
Tools Required..89
Equipment Condition..89
Test Setup..89
Test Procedure..89
Expected Outcome..89
Follow-On Procedure..89
Record Snapshot of Engine Running Data..89
Overview..89
Tools Required..89
Equipment Condition..90
Test Setup..90
Test Procedure..90
Expected Outcome..92
Follow-On Procedure..92
Service Bay Tests..92
Key On, Engine Off (KOEO) Tests..92
KOEO Standard Test..94
KOEO Injector Test..94
KOEO Output State Low Test..94
KOEO Output State High Test..94
KOEO Output State Intake Air Heater Test..94
KOEO Continuous Monitor Test..94
KOEO Aftertreatment Tests ? Doser Actuator Test..95
Tools..95
KOEO Aftertreatment Test Pin-point Diagnostics..96
KOEO Engine Cranking Test..97
Overview..97
Tools Required..97
Equipment Condition..97
Test Setup..97
Procedure..98
Expected Outcome..99
Follow-on Procedure..99
Relative Compression Test..99
Fuel Pressure Adaptation Reset..99
Overview..99
Tools Required..99
Equipment Condition..99
Test Setup..100
Test Procedure..100
Follow-On Procedure..101
Key On, Engine Running (KOER) Tests..101
Overview..101
Tools Required..102
KOER Standard Test..102
Test Setup..102
Test Procedure..102
Air Management Test..102
Overview..102
Tools Required..102
Equipment Conditions..103
Test Setup..103