Navistar MaxxForce 7 User manual

MaxxForce®70000001802 EPA10,2013HD-OBD-US,Canada4328090R1
March2013
MaxxForce®7
EngineOperationandMaintenanceManual
Navistar,Inc.
2701NavistarDrive,Lisle,IL60532USA
©2013Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

IMPORTANT
Theinformation,specications,andillustrationscontainedinthismanualarebasedondatathatwascurrentatthetimeof
publication.Navistar,Inc.reservestherighttomakechangesand/orimprovementsatanytimewithoutnotication,liability,
orwithoutapplyingthosechangesorimprovementstovehiclespreviouslymanufacturedand/orsold.
NOTICE
Beadvisedthatthismotorvehiclemaybeequippedwith
computer/recordingdevices.Theirfunctionistoallowan
authorizedindividualtodownloaddataorinformationrelating
totheoperationorperformanceofthisvehicle.
Thestoreddataorinformationmaybeneitherdownloaded
norretrievedexceptbythevehicle’sregisteredowner,or,in
thealternative,byanotherindividualorentityauthorizedby
theregisteredowner,(e.g.,InternationalDealer)whomay
needthisdataorinformationtoproperlyserviceordiagnose
thisvehicleforrepairorfollowinganaccident.
Anyaccesstothisinformationwithouttheowner’sconsent
maybeinviolationoflawandmaysubjectthatpersonor
entitytocriminalpenalties.
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofitsconstituentsare
knowntotheStateofCaliforniatocausecancer,birth
defects,andotherreproductiveharm.
Batteryposts,terminalsandrelatedaccessoriescontain
leadandleadcompounds,chemicalsknowntotheState
ofCaliforniatocausecancerandreproductiveharm.
Washhandsafterhandling.

TABLEOFCONTENTS
FOREWORD......................................................................................1
SAFETYINFORMATION.......................................................................3
WARRANTY......................................................................................7
U.S.FederalEmissionSystemWarranty....................................................................7
WarrantyPeriod..............................................................................................7
RequiredMaintenance......................................................................................7
WarrantyRepairsandService..............................................................................7
RecommendedMaintenanceorRepairParts............................................................8
EmergencyRepairs..........................................................................................8
WhatisnotCoveredbyWarranty..........................................................................8
WarrantyRightsandResponsibilities......................................................................9
CaliforniaEmissionSystemWarranty.....................................................................10
WarrantyPeriod.............................................................................................10
RequiredMaintenance.....................................................................................10
WarrantyRepairsandService............................................................................10
RecommendedMaintenanceorRepairParts...........................................................10
EmergencyRepairs.........................................................................................11
WhatisCoveredbyWarranty.............................................................................11
WhatisnotCoveredbyWarranty.........................................................................12
WarrantyRightsandResponsibilities....................................................................12
SECTION1–ENGINESYSTEMS
EngineSerialNumber.........................................................................................15
EngineEmissionLabel.......................................................................................15
EngineAccessories...........................................................................................16
EngineSpecications.........................................................................................17
EngineDescription.........................................................................................19

TABLEOFCONTENTS
EngineFeatures............................................................................................21
EngineOptionalFeatures..................................................................................24
ComponentLocation–Top..................................................................................27
ComponentLocation–Front................................................................................28
ComponentLocation–Left..................................................................................29
ComponentLocation–Right...............................................................................30
ComponentLocation–Rear.................................................................................31
SECTION2–REQUIREMENTSFORFUEL,ENGINEOIL,ANDCOOLANT
Fuel...............................................................................................................33
UltraLowSulfurDiesel(ULSD)..........................................................................33
UnacceptableFuelandBlends............................................................................33
AcceptableFuelBlends....................................................................................34
UseofHigherBiodieselFuelBlends(B6toB20).......................................................34
UnsafePractices............................................................................................35
EngineOil.......................................................................................................35
EngineOilQualityandServiceCategories..............................................................35
APICJ-4forHighPerformanceDieselEngines.........................................................35
OilViscosity.................................................................................................36
Coolant..........................................................................................................37
CoolantMixtures............................................................................................37
ExtendedLifeCoolant(ELC)-Red.......................................................................37
ContaminationofCoolant..................................................................................38
SECTION3–INSTRUMENTS,INDICATORS,ANDSWITCHES
InstrumentPanelGaugeCluster............................................................................39
WarningLamps.................................................................................................39
WaittoStartLamp.............................................................................................39

TABLEOFCONTENTS
IdleShutDownIndicator.....................................................................................40
MaintenanceLamp.............................................................................................40
AmberWarningLamp(AWL).................................................................................41
RedStopLamp(RSL).........................................................................................41
HighExhaustSystemTemperature(HEST)Lamp.......................................................42
DieselParticulateFilter(DPF)Indicator...................................................................42
MalfunctionIndicatorLamp(MIL)...........................................................................43
TypicalWaterTemperatureGauge..........................................................................44
OilTemperatureGauge.......................................................................................45
OilPressureGauge............................................................................................45
EngineExhaustBrakeOn/OffToggleSwitch...........................................................46
AirCleanerRestrictionIndicator............................................................................47
SECTION4–ENGINEOPERATION
PreoperationChecklist........................................................................................49
PrimingtheFuelSystem.....................................................................................50
PrimingtheFuelSystemAfterServicingtheFuelFilters...............................................50
PrimingtheFuelSystemAfterRunningOutofFuel....................................................51
StartingtheEngine............................................................................................51
EmergencyStarting...........................................................................................53
Operation........................................................................................................54
SuggestedWarm-upTime.................................................................................54
IdleSpeed...................................................................................................54
ExtendedIdlingPeriods....................................................................................54
AftertreatmentSystem.....................................................................................55
EngineIdleShutdownTimer(U.S.Federal-Optional[2010and2011vehicles])....................55
EngineIdleShutdownTimer(Californiaandallstate-optional[2012andnewervehicles]).......56
ColdWeatherOperation...................................................................................57
ColdAmbientProtection(CAP)...........................................................................58
HotWeatherOperation....................................................................................59

TABLEOFCONTENTS
EngineShutdown...........................................................................................59
EngineWarningProtectionSystem(EWPS)............................................................59
HD-OBDOverview.........................................................................................60
RadiatorShuttleEnable(RSE)............................................................................61
RoadSpeedLimiting(RSL)...............................................................................61
RoadOperation.............................................................................................61
DownhillOperation.........................................................................................62
SECTION5–MAINTENANCESCHEDULEANDSERVICEPROCEDURES
MaintenanceSchedule........................................................................................63
ServiceProcedures............................................................................................67
OilLevel.....................................................................................................67
CoolantLevel...............................................................................................68
ChargeAirCooler(CAC)..................................................................................69
ExternalLeakage...........................................................................................69
AirCleanerRestriction....................................................................................70
FuelWaterSeparator......................................................................................71
EngineOilandFilter........................................................................................72
ResettingChangeEngineOilServiceIntervalMessage...............................................76
Belt,AirIntakePipingandClamps.......................................................................77
AirIntakePipingandClamps.............................................................................79
CoolantFreezePoint.......................................................................................79
PrimaryFuelFilter.........................................................................................80
SecondaryFuelFilter......................................................................................84
CrankcaseBreather........................................................................................86
ResettingChangeServiceBreatherElementMessage(ServiceableCrankcasebreatheronly)...88
ElectricalSystem...........................................................................................88
InductionSystem...........................................................................................89
ExtendedLifeCoolant(ELC)Extender...................................................................89

TABLEOFCONTENTS
CleaningDieselParticulateFilter(DPF).................................................................90
ServiceCoolingSystem...................................................................................91
SECTION6–LONGTERMSTORAGE
GeneralInformation...........................................................................................95
SECTION7–SERVICERECORDS
MaintenanceServiceRecord................................................................................97
DailyCareandReport.......................................................................................100

FOREWORD
Foreword
Navistar,Inc.iscommittedtocontinuousresearchand
developmenttoimproveproductsandintroducetechnological
advances.Procedures,specications,andpartsdenedin
publishedtechnicalserviceliteraturemaybealtered.
NOTE:Photoillustrationsidentifyspecicpartsorassemblies
thatsupporttextandprocedures;otherareasinaphoto
illustrationmaynotbeexact.
Thismanualincludesnecessaryinformationandspecications
foroperatorstoserviceNavistar®dieselengines.Contactyour
dealerformoreinformation.
TechnicalServiceLiterature
MaxxForce®7EngineOperationandMaintenanceManual
MaxxForce®7EngineServiceManual
MaxxForce®7EngineDiagnosticManual
MaxxForce®7HardStartandNoStartandPerformanceDiagnostic
Form
MaxxForce®7ElectronicControlSystemsDiagnosticForm
TechnicalServiceLiteratureisrevisedperiodically.Useonly
up-to-dateserviceinformation.
Toordertechnicalserviceliterature,contactyourdealer.
Allmarksaretrademarksoftheirrespectiveowners.
AbouttheManual
Thismanualcontainsinformationneededtocorrectlyoperate
andmaintainyourengineasrecommendedbyNavistar,Inc.
Numerousillustrations,symbolsandfeaturedescriptions
areusedtoaidinunderstandingthemeaningofthetext.
Theillustrations,symbolsorfeaturedescriptionswillnotbe
availableforallapplications;pleasereferenceyourVehicle
OperatorManualforcompleteinformation.Bothmetricand
U.S.customaryvaluesarelistedinthismanual.TheU.S.
customaryvalueislistedrst,followedbythemetricvaluein
brackets.Foradditionalinformationrefertoserviceliterature
notedinthismanual.Thismanualdoesnotcovervehicle
orequipmentmaintenanceprocedures.Consulttheoriginal
vehicleorequipmentmanufacturerforspecicmaintenance
recommendations.
Page1

FOREWORD
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