International® MaxxForce® 7 Diesel Engine · This manual includes necessary information and speciﬁcations for operators to service Navistar diesel engines. Contact an International

International® MaxxForce® 7 Diesel Engine

For2008 Through 2009 Model Year

Truck and Derivative Vehicle Applications

Engine Operation and Maintenance Manual

© 2009 Navistar, Inc. All rights reserved.

Form No. 1171941R4Printed in the United States of America


TABLE OF CONTENTS

FOREWORD.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY INFORMATION.... . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . 3

WARRANTY..... . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . 7

Federal Emission System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Required Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Warranty Repairs and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Recommended Maintenance or Repair Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Emergency Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8What is not Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Warranty Rights and Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

California Emission System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Required Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Warranty Repairs and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Recommended Maintenance or Repair Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Emergency Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10What is Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11What is not Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Warranty Rights and Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

SECTION 1 – ENGINE SYSTEMS

Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Engine Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Engine Specifications and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15


TABLE OF CONTENTS

Component Location – Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Component Location – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Component Location – Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Component Location – Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Ultra Low Sulfur Diesel (ULSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Unacceptable Fuel and Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Acceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Use of Higher Biodiesel Fuel Blends (B6 to B20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Engine Oil Quality and Service Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26API CJ-4 for High Performance Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Coolant Mixtures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Shell ROTELLA® Extended Life Coolant (ELC) – red). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Contamination of Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Water Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Warning Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Odometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34


TABLE OF CONTENTS

Air Cleaner Restriction Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

SECTION 4 – ENGINE OPERATION

Preoperation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Priming the Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Emergency Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Suggested Warm up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Idle Speed.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Extended Idling Periods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Engine Idle Shutdown Timer (Federal-Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Engine Idle Shutdown Timer (California-Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Cold Ambient Protection (CAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Engine Shutdown.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Engine Warning Protection System (EWPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Road Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Water Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53


TABLE OF CONTENTS

Charge Air Cooler (CAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55External Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Air Cleaner Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Resetting Change Engine Oil Service Interval Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Belt, Air Intake Piping and Clamps.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Coolant Freeze Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Secondary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Electrical System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Induction System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Extended Life Coolant (ELC) Extender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Cleaning Diesel Particulate Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Service Cooling System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

SECTION 6 – SERVICE RECORDS

Maintenance Service Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73Daily Care and Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76


FOREWORD

ForewordNavistar, Inc. is committed to continuous research anddevelopment to improve products and introduce technologicaladvances. Procedures, specifications, and parts defined inpublished technical service literature may be altered.

NOTE: Photo illustrations identify specific parts or assembliesthat support text and procedures; other areas in a photoillustration may not be exact.

This manual includes necessary information and specificationsfor operators to service Navistar diesel engines. Contact anInternational dealer for more information.

Technical Service Literature

1171941R4 International® MaxxForce® 7 EngineOperation and Maintenance Manual

EGES-345 International® MaxxForce® 7 Service Manual

EGES-350–1 International® MaxxForce® 7 DiagnosticManual

EGED-355–1 International® MaxxForce® 7 DiagnosticForm

EGED-365 International® MaxxForce® 7 ElectronicControl Systems Diagnostic Form

Technical Service Literature is revised periodically and mailedautomatically to “Revision Service” subscribers. If a technicalpublication is ordered, the latest revision will be supplied.

To order technical service literature, contact your International®dealer.

All marks are trademarks of their respective owners.

Form No. 1171941R4Printed in the United States of America Page 1

FOREWORD

Form No. 1171941R4Page 2 Printed in the United States of America

SAFETY INFORMATION

Safety InformationThis manual provides general and specific maintenanceprocedures essential for reliable engine operation and yoursafety. Since many variations in procedures, tools, and serviceparts are involved, advice for all possible safety conditions andhazards cannot be stated.

Read safety instructions before doing any service and testprocedures for the engine or vehicle. See related applicationmanuals for more information.

Disregard for Safety Instructions, Warnings, Cautions, andNotes in this manual can lead to injury, death or damage to theengine or vehicle.

Safety Terminology

Three terms are used to stress your safety and safe operation ofthe engine: Warning, Caution, and Note

Warning: A warning describes actions necessary to preventor eliminate conditions, hazards, and unsafe practices that cancause personal injury or death.

Caution: A caution describes actions necessary to prevent oreliminate conditions that can cause damage to the engine orvehicle.

Note: A note describes actions necessary for correct, efficientengine operation.

Safety Instructions

Work Area

• Keep work area clean, dry, and organized.

• Keep tools and parts off the floor.

• Make sure the work area is ventilated and well lit.

• Make sure a First Aid Kit is available.

Safety Equipment

• Use correct lifting devices.

• Use safety blocks and stands.

Protective Measures

• Wear protective safety glasses and shoes.

• Wear correct hearing protection.

• Wear cotton work clothing.

• Wear sleeved heat protective gloves.

• Do not wear rings, watches or other jewelry.

• Restrain long hair.

Vehicle

• Make sure the vehicle is in neutral, the parking brake is set,and the wheels are blocked before servicing engine.


SAFETY INFORMATION

• Clear the area before starting the engine.

Engine

• The engine should be operated or serviced only by qualifiedindividuals.

• Provide necessary ventilation when operating engine in aclosed area.

• Keep combustible material away from engine exhaustsystem and exhaust manifolds.

• Install all shields, guards, and access covers beforeoperating engine.

• Do not run engine with unprotected air inlets or exhaustopenings. If unavoidable for service reasons, put protectivescreens over all openings before servicing engine.

• Shut engine off and relieve all pressure in the system beforeremoving panels, housing covers, and caps.

• If an engine is not safe to operate, tag the engine and ignitionkey.

Fire Prevention

• Make sure charged fire extinguishers are in the work area.

NOTE: Check the classification of each fire extinguisher toensure that the following fire types can be extinguished.

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

2. Type B — Flammable liquids

3. Type C — Electrical equipment

Batteries

• Always disconnect the main negative battery cable first.

• Always connect the main negative battery cable last.

• Avoid leaning over batteries.

• Protect your eyes.

• Do not expose batteries to open flames or sparks.

• Do not smoke in workplace.

Compressed Air

• Use an OSHA approved blow gun rated at 207 kPa (30 psi).

• Limit shop air pressure to 207 kPa (30 psi).

• Wear safety glasses or goggles.

• Wear hearing protection.

• Use shielding to protect others in the work area.

• Do not direct compressed air at body or clothing.

Tools

• Make sure all tools are in good condition.

• Make sure all standard electrical tools are grounded.


SAFETY INFORMATION

• Check for frayed power cords before using power tools.

Fluids Under Pressure

• Use extreme caution when working on systems underpressure.

• Follow approved procedures only.

Fuel

• Do not over fill the fuel tank. Over fill creates a fire hazard.

• Do not smoke in the work area.

• Do not refuel the tank when the engine is running.

Removal of Tools, Parts, and Equipment

• Reinstall all safety guards, shields, and covers afterservicing the engine.

• Make sure all tools, parts, and service equipment areremoved from the engine and vehicle after all work is done.


SAFETY INFORMATION


WARRANTY

Warranty

Federal Emission System Warranty

WARRANTY PERIOD

Navistar, Inc. warrants your light heavy-duty diesel engine forthe following warranty period (whichever comes first):

• 5 years

• 80,000 km (50,000 miles)

• Or if covered by any basic or extended warranty (if greaterthan above)

Your light heavy-duty diesel engine conforms to U.S.Environmental Protection Agency regulations for emissionsystems.

The engine model year, service class, and required emissioninformation is on the emission label on top of the valve cover.This warranty is based on the engine model year, not the modelyear of the vehicle. The warranty period begins on the date thenew vehicle is delivered to the first retail purchaser.

REQUIRED MAINTENANCE

As the vehicle owner, you are responsible for all requiredmaintenance described in this manual. Navistar Engine Grouprecommends that you retain all maintenance receipts. Navistarwill not deny an emission warranty claim solely because you

have no record of maintenance. However, a claim may bedenied if your failure to perform proper maintenance resultedin the failure of a warranted part and you cannot provideappropriate evidence of maintenance. Take your vehicle to anInternational dealer when a problem occurs.

WARRANTY REPAIRS AND SERVICE

All emission control system parts proven defective duringnormal use will be repaired or replaced during the warrantyperiod. Warranty repairs and service will be done by anyauthorized International dealer with no charge for parts, laborand diagnostics. Warranty repairs should be completed in areasonable time, not to exceed 30 days. Navistar may denyyou warranty coverage if your vehicle or a part has faileddue to abuse, neglect, improper maintenance or unapprovedmodifications.

RECOMMENDED MAINTENANCE OR REPAIR PARTS.

International® service parts or International ReNEWed™ partsare recommended for maintenance or repairs to maintain theoriginal quality of your emission certified engine. If parts notrecommended by Navistar cause damage to the engine orvehicle, the warranty is invalid and maintenance and repaircosts will not be covered.


WARRANTY

Federal Emission System Warranty (cont.)EMERGENCY REPAIRS

Emergency repairs are recognized, if parts are not availablewithin 30 days or repairs are not completed within 30 days. Ifan International dealer is not reasonably available, the vehicleowner or any service establishment can install any replacementpart.

Navistar will reimburse you for emergency repairs (includingdiagnostics) for the following:

• Replacement parts that do not exceed manufacturer’ssuggested retail price.

• Labor charges based on manufacturer’s recommended timeallowance and geographic hourly rate.

Replaced parts and paid invoices must be given to anInternational dealer for reimbursement of emergency repairs.

WHAT IS NOT COVERED BY WARRANTY

Unauthorized parts or expendable parts

• Parts other than International® service parts or ReNEWed™parts.

• Aftermarket parts or service kits

• Nondefective parts replaced by other than Internationaldealer.

• Parts requiring replacement at inspection or adjustmentmaintenance intervals for reasons other than beingdefective.

• Replacement of expendable items made in connection withscheduled maintenance.

Vehicle, engine, and part malfunctions caused by thefollowing:

• Use of incorrect fuel, engine oil, or coolant

• Failure to maintain correct maintenance schedule

• Incorrect adjustments, modifications, alterations, tamperingor disconnection of vehicle components.

• Abuse or misuse of engine

• Accidents, acts of nature or other events beyond control ofNavistar.

Conditions not covered by warranty

• Vehicles registered and normally operated outside theUnited States.

• Loss of time, inconvenience, use of vehicle/engine orcommercial loss.

• Vehicles with an altered or disconnected odometer orhourmeter when mileage or hours cannot be determined.


WARRANTY

Federal Emission System Warranty (cont.)WARRANTY RIGHTS AND RESPONSIBILITIES

Navistar assures that the emission warranty is being properlyadministered. If you have not received satisfactory serviceor have questions regarding your warranty rights andresponsibilities, contact the Navistar regional office forassistance. The address and phone number of each regionaloffice is listed in your vehicle Operator’s Manual. If additionalassistance is required, contact the Manager of CustomerRelations.

Manager, Customer RelationsNavistar, Inc.4201 Winfield RoadWarrenville, Illinois 60555(Telephone 1-800-448-7825)


WARRANTY

California Emission System Warranty

WARRANTY PERIOD

Navistar, Inc. warrants your light heavy-duty diesel engine forthe following warranty period (whichever comes first):

• 5 years

• 160,000 km (100,000 miles)

• Or if covered by any basic or extended warranty (if greaterthan above)

Your light heavy-duty diesel engine conforms to applicableCalifornia Air Resources Board regulations. This vehicle isregistered and certified for sale in California.

The engine model year, service class, and required emissioninformation is on the emission label on top of the valve cover.This warranty is based on the engine model year, not the modelyear of the vehicle. The warranty period begins on the date thenew vehicle is delivered to the first retail purchaser.

REQUIRED MAINTENANCE

As the vehicle owner, you are responsible for all requiredmaintenance described in this manual. Navistar recommendsthat you retain all receipts covering maintenance on yourtruck, but Navistar cannot deny warranty solely for the lackof receipts or your failure to ensure the performance of allscheduled maintenance. However, a claim may be deniedif Navistar demonstrates that the (engine/vehicle) has been

abused, neglected, or improperly maintained, and that suchabuse, neglect, or improper maintenance was the direct causeof the need for the repair or replacement of the part. Take yourvehicle to an International® dealer when a problem occurs.

WARRANTY REPAIRS AND SERVICE

All emission control system parts proven defective duringnormal use will be repaired or replaced during the warrantyperiod. Warranty repairs and service will be done by anyauthorized International dealer with no charge for parts, laborand diagnostics. Warranty repairs should be completed in areasonable time, not to exceed 30 days. Navistar may denyyou warranty coverage if your vehicle or a part has faileddue to abuse, neglect, improper maintenance or unapprovedmodifications.

RECOMMENDED MAINTENANCE OR REPAIR PARTS

International® service parts or International ReNEWed™ partsare recommended for maintenance or repairs to maintain theoriginal quality of your emission certified engine. If parts notrecommended by Navistar cause damage to the engine orvehicle, the warranty is invalid and maintenance and repaircosts will not be covered.

EMERGENCY REPAIRS

Emergency repairs are recognized, if parts are not availablewithin 30 days or repairs are not completed within 30 days. If


WARRANTY

California Emission System Warranty (cont.)

EMERGENCY REPAIRS (cont.)

an International dealer is not reasonably available, the vehicleowner or any service establishment can install any replacementpart.

Navistar will reimburse you for emergency repairs (includingdiagnostics) for the following:

• Replacement parts that do not exceed manufacturer’ssuggested retail price.

• Labor charges based on manufacturer’s recommended timeallowance and geographic hourly rate.

Replaced parts and paid invoices must be given to anInternational dealer for reimbursement of emergency repairs.

WHAT IS COVERED BY WARRANTY

New vehicles and engines, registered and certified for sale inCalifornia, have the following items covered by the emissionwarranty when first installed on the engine as original equipmentby Navistar:

• Fuel injection system

• Air induction system (includes turbocharger, exhaustmanifold, and intake manifold)

• Positive Crankcase Ventilation (PCV) system – if applicable(includes PCV valve and oil fill cap)

• Diesel Particulate Filter (DPF)

• Hoses, clamps, fittings and tubing

• Pulleys, belts and idlers

• Vacuum, temperature and time sensitive valves andswitches

WHAT IS NOT COVERED BY WARRANTY

Unauthorized parts or expendable parts

• Parts other than International® service parts or ReNEWed™parts.

• Aftermarket parts or service kits

• Nondefective parts replaced by other than Internationaldealer.

• Parts requiring replacement at inspection or adjustmentmaintenance intervals for reasons other than beingdefective.


WARRANTY

California Emission System Warranty (cont.)

WHAT IS NOT COVERED BY WARRANTY (cont.)

• Replacement of expendable items made in connection withscheduled maintenance.

Vehicle, engine, and part malfunctions caused by thefollowing:

• Use of incorrect fuel, engine oil, or coolant

• Failure to maintain correct maintenance schedule

• Incorrect adjustments, modifications, alterations, tamperingor disconnection of vehicle components.

• Abuse or misuse of engine

• Accidents, acts of nature or other events beyond control ofNavistar.

Conditions not Covered by Warranty

• Vehicles registered and normally operated outside theUnited States.

• Loss of time, inconvenience, use of vehicle/engine orcommercial loss.

• Vehicles with an altered or disconnected odometer orhourmeter when mileage or hours cannot be determined.

WARRANTY RIGHTS AND RESPONSIBILITIES

Navistar assures that the emission warranty is being properlyadministered. If you have not received satisfactory serviceor have questions regarding your warranty rights andresponsibilities, contact the Navistar regional office forassistance. The address and phone number of each regionaloffice is listed in your vehicle Operator’s Manual. If additionalassistance is required, contact the Manager of CustomerRelations.

Manager, Customer RelationsNavistar, Inc.4201 Winfield RoadWarrenville, Illinois 60555(Telephone 1-800-448-7825)

If further questions of warranty rights and responsibilities remain,contact:

The Air Resources Board9528 Telstar AvenueEl Monte, California 91731



Engine Serial Number

Figure 1 Engine serial number

The engine serial number is stamped on the crankcase pad, onthe rear left side below the cylinder head.

Engine Serial Number Example

6.4HM2YXXXXXXX

6.4 – Engine displacement (liters)H – Diesel, turbocharged, air intercooled and electronicallycontrolled

M2 – Motor truck or U2 power unit and OEM (sold to originalequipment manufacturer)Y – United States, Huntsville7 digit suffix – Sequence number

Engine Emission Label

Figure 2 The U.S. Environmental Protection Agency (EPA)exhaust emission label (Example)

The U.S. Environmental Protection Agency (EPA) exhaustemission label is on top of the rear of the right valve cover,under the EBP sensor mounting bracket. The label includes thefollowing:

• Advertised brake horsepower ratings

• Engine model code

• Service applications



Engine Emission Label (cont.)• Emission family and control systems

• Year the engine was certified to meet EPA emissionstandards

Engine Accessories

The following engine accessories may have manufacturers’labels or identification plates:

• Air compressor

• Air conditioning compressor

• Alternator

• Cooling fan clutch

• Power steering pump

• Starter motor

Labels or identification plates include information andspecifications helpful to vehicle operators and technicians.



Engine Specifications and Features

International® MaxxForce® 7 Features and Specifications

Engine Configuration 4 stroke, V8 diesel

Rated power @ rpm 230 bhp @ 2300 rpm 1

Peak torque @ rpm 620 lbf•ft @ 1500 rpm 1

Displacement 6.4 L (389 in3)

Compression ratio 17.5 : 1

Stroke 105 mm (4.134 in)

Bore (sleeve diameter) 98.2 mm (3.87 in)

Firing order 1-2-7-3-4-5-6-8

Aspiration Variable Geometry Turbocharger (VGT) and Charge Air Cooled (CAC)

Combustion system Direct injection, turbocharged

Fuel system Direct injection common rail

Lube system capacity (including filter) 17.9 L (19 qts US)

Lube system capacity (overhaul only, with filter) 18.9 L (20 qts US)

Engine lubrication oil pressure at operating temperature

• Low idle

• High idle

83 kPa (12 psi) minimum

276 kPa (40 psi) minimum

Idle speed (no load) 700 rpm ± 50 (nonadjustable)

Thermostat operating temperature 88 °C - 96 °C (190 °F - 205 °F)

1Example. See EPA emission label for other ratings.



Engine Specifications and Features (cont.)STANDARD FEATURES

The International® MaxxForce® 7 is a V8 engine with adisplacement of 6.4 liters (389 cubic inches).

The electronic governor controls the engine’s rpm within a safeand stable operating range for ideal performance. Low idlegovernor prevents the engine rpm from dropping below a stablespeed to prevent stalling when various loads are demanded onthe engine. High idle governor prevents the engine rpm fromgoing above a safe speed that would cause internal damage tothe engine.

The cylinder heads have four valves per cylinder. Each fuelinjector is centrally located between the four valves and directsfuel over the piston bowl for improved performance and reducedemissions.

The camshaft is supported by four bushings pressed into thecrankcase. The camshaft is crankshaft driven and thrust iscontrolled by a plate mounted behind the fourth cam journal.

The overhead valve train includes hydraulic roller cam followers,push rods, rocker arms, and valve bridges to open the dualintake and exhaust valves.

The crankcase is comprised of two major matching components.The upper crankcase half houses the cylinders, main bearingsaddles, with oil and coolant passages either cast or machined.The lower crankcase consists of a structural plate with the main

bearing caps machined into it for improved load retention andalignment.

The crankshaft is supported by five main bearings with fore andaft thrust controlled at the upper half of the second main bearing.Two connecting rods are attached to each crankshaft rod journaland are offset to minimize vibration. Piston pins are free floating,allowing the pins free lateral movement within the connecting rodas well as the piston. Piston pins are held in place with retainingrings.

One piece aluminum-alloy pistons are fitted with one keystonering, one rectangular intermediate compression ring, and a twopiece oil control ring. The combustion bowl is located in thepiston crown to reduce emissions. All pistons are mated tofractured cap joint connecting rods.

The Crankshaft Position (CKP) sensor and Camshaft Position(CMP) sensor are used by the Electronic Control Module (ECM)to calculate rpm, fuel timing, fuel quantity, and duration of fuelinjection.

The Exhaust Gas Recirculating (EGR) system includes an EGRvalve and an intake throttle valve. The EGR valve is mounted inan EGRmixer elbow that is part of the EGR valve elbow housing.The intake throttle valve is mounted on the other side of the EGRvalve elbow housing in the air stream from the CAC.

A gerotor lube oil pump is mounted in the front cover and isdriven by the crankshaft. Pressurized oil is supplied to engine



STANDARD FEATURES (cont.)

components. All MaxxForce® 7 engines use an engine oil coolerand engine oil filter.

A closed crankcase breather system draws crankcase vaporsthrough a breather element. The breather element removes oilfrom the vapor and sends the vapor to the air intake and returnsthe oil to the crankcase.

The low-pressure fuel pump draws fuel from the fuel tank(s)through the primary fuel filter. The primary fuel filter assemblyincludes a Water in Fuel (WIF) sensor and an optional fuelheater. Water and solids are separated from the fuel and thewater is collected in the water separator bowl. The instrumentpanel WIF lamp is illuminated when water needs to be drained.A drain valve in the water separator bowl drains water out. Fuelis discharged to the secondary fuel filter. The secondary fuelfilter assembly is pressure regulated and incorporates an airbleed orifice allowing air to be automatically purged if it hasbeen introduced to the system.

The high-pressure fuel system includes a High-Pressure FuelPump (HPFP), high-pressure common rails, and fuel injectors.The ECM electronically controls the injectors allowing multipleinjections and more precise fuel delivery to improve combustion,emissions, and cold start performance.

A hand operated primer pump is mounted on the right valvecover. The manual priming pump draws fuel from the fuel tank(s)through the primary filter after filter replacement or when system

has run out of fuel. This primes the fuel system to minimize theamount of air injected into the system on initial startup.

The Variable Geometry Turbocharger (VGT) has actuated vanesin the turbine housing. These vanes modify exhaust gas flowthrough the VGT. The ECM commands the VGT to control boostpressure for various engine speeds and load conditions.

The Exhaust Gas Recirculating (EGR) system circulates cooledexhaust into the intake air stream in the intake manifold. Thiscools the combustion process and reduces the formation of NOXengine emissions.

Diamond Logic® engine control is a single electronic control unitthat monitors and controls the engine and chassis components.

The glow plug relay controls the eight glow plugs, one for eachcylinder. The glow plugs warm the cylinders during start-up.

OPTIONAL FEATURES

An air compressor is available for applications that require airbrakes or air suspension.

A coolant heater is available to raise the temperature of thecoolant surrounding the cylinders for improved performanceduring cold weather startups.

A fuel heater is available to warm the supply fuel in the primaryfuel filter. Warmed supply fuel prevents waxing, and improvesperformance and fuel economy during cold weather start-up.



CHASSIS MOUNTED FEATURES

A Charge Air Cooler (CAC) is an air-to-air heat exchanger whichincreases the density of the air charge.

The Aftertreatment System part of the larger exhaust system,processes engine exhaust so that it meets tailpipe emissionrequirements.

• The Diesel Oxidation Catalyst (DOC) oxidizes hydrocarbonsand carbon monoxide, provides heat for exhaust systemwarmup, aids in temperature management for the DPF, andoxidizes NO into NO2 for passive DPF regeneration.

• The Diesel particulate Filter (DPF) temporarily storescarbon-based particulates, oxidizes stored particulates,stores non-combustible ash, and provides required exhaustback pressure drop for engine performance.



Component Location – Front

Figure 3 Front

1. Fan drive pulley2. Air compressor belt tensioner

3. Water pump4. Vibration damper

5. Water drain valve6. Belt tensioner



Component Location – Left

Figure 4 Left

1. Oil level gauge 2. Electronic Control Module (ECM) 3. Oil level gauge and tube assembly



Component Location – Right

Figure 5 Right

1. Exhaust Back Pressure (EBP) sensor2. Fuel priming pump

3. Fuel priming pump operating handle4. Primary fuel filter

5. Low-pressure fuel pump



Component Location – Top

Figure 6 Top

1. Exhaust Gas Recirculation (EGR) cooler2. Turbocharger

3. Oil fill cap4. Secondary fuel filter

5. Exhaust Gas Recirculation (EGR) valve6. Engine oil filter



Fuel

ULTRA LOW SULFUR DIESEL (ULSD)

Figure 7 American Petroleum Institute (API) Diesel PumpLabel

The API Diesel Pump Label is compliant with EPA CFR 80.570.

GOVERNMENTREGULATION: Diesel fuel sold foruse in 2007 and later highway vehicles must be limitedto a sulfur content of 15 parts per million (ppm).

Ultra Low Sulfur Diesel (ULSD) fuel is required forInternational® MaxxForce® 7 Diesel Engines used withadvanced aftertreatment systems. The fuel should meet all thespecifications of ASTM D975 standard (current year revision),including the EPA specification for sulfur content (0.0015 %mass or 15 ppm maximum). These specifications are includedin the standard under the designation No. 2-D S15 fuel and No.1-D S15 fuel. Grade No. 1-D fuel is a lighter fuel with highervolatility than grade No. 2-D; it may be blended with gradeNo. 2-D in wintertime to provide engine operability under lowambient temperature.

UNACCEPTABLE FUEL AND BLENDS

• Off road diesel fuel

• Low Sulfur Diesel (LSD) fuel 0.05% (500 ppm)

• Commercial Jet A or JP8 aviation fuel

• Heating or furnace oil

• Biodiesel B100 (neat biodiesel)

• Biodiesel blends higher than 20%



Fuel (cont.)

UNACCEPTABLE FUEL AND BLENDS (cont.)

Biodiesel fuels are methyl or ethyl esters derived from a broadvariety of renewable sources such as vegetable oils, animal fats,and waste cooking oils. These oxygenated organic compoundshave key properties that are comparable to those in diesel fuel.

ACCEPTABLE FUEL BLENDS

• Ultra low sulfur kerosene (No. 1-D S15 diesel fuel) blendedwith No. 2-D S15 fuel to improve cold weather performance.Blend rate would depend upon regional low temperatures.

• Lower biodiesel blends up to B5 (a blend of 5% neatbiodiesel with 95% diesel fuel).

Such blends have characteristics indistinguishable fromdiesel fuel, if the two components meet the requirements oftheir respective standards: ASTM D6751 current revision,for neat biodiesel and ASTM D975 current revision, for ultralow sulfur diesel fuel.

As of October 1, 2008 blends of up to 5% biodiesel areincluded in the diesel fuel standard ASTM D975-08a.(D975-08a designates the 2008 revision of the standard.)

Navistar, Inc. approves of blends up to B5, provided that thetwo components satisfy current specifications. Quality biodieselblends up to B5 should not cause engine or fuel systemproblems.

USE OF HIGHER BIODIESEL FUEL BLENDS (B6 TO B20)

A new standard ASTM D7467-08 covers the specifications forblends between 6% and 20% (B6 to B20). These blends may beused in vehicles that operate in populated areas or in fleets whichare required to use alternative fuels to reduce urban pollution.

Use of B6 to B20 blends is at the discretion of thecustomer/operator and will not automatically void an enginewarranty. However, if engine component failure can be directlyattributable to use of a B6 to B20 blend not provided bya BQ9000 certified fuel supplier or not meeting the ASTMD7467-08 Standard, Navistar may, at its option, deny warrantyon the affected engine or engine component.

Navistar recommends that users of B20 select a BQ9000certified fuel supplier and request proof from the supplierthat the fuel meets the ASTM D7467-08 Standard. Fuels notmeeting the specification may cause fuel system deposits,plugged filters, contaminated engine oil, and fuel degradation.

If providers and customers follow correct storage andmaintenance procedures for fuel and equipment, blendsof B6 to B20 that meet the ASTM D7467-08 Standardshould perform satisfactorily in diesel engines. Contact yourInternational® dealer for further information on ASTM standardsand recommendations for correct storage and maintenanceprocedures.



Fuel (cont.)

USE OF HIGHER BIODIESEL FUEL BLENDS (B6 TO B20)(cont.)

Navistar, Inc. follows the official position of the EngineManufacturers Association (EMA) on biodiesel fuel. Seewww.enginemanufacturers.org for more information.

UNSAFE PRACTICES

WARNING: To prevent personal injury or death, donot mix gasoline, gasohol, or alcohol with diesel fuel. Anopen heat source, spark, cell phone or electronic devicecan ignite these fuel mixtures. This creates a fire hazardand possible explosion.

CAUTION: To prevent engine damage, do not mix propanewith diesel fuel. Navistar will not honor warranty claims againstengines that have used propane.



Engine Oil

ENGINE OIL QUALITY AND SERVICE CATEGORIES

The American Petroleum Institute (API) defines engine oil qualityby service categories that define oil performance measured instandardized engine tests.

API CJ-4 FOR HIGH PERFORMANCE DIESEL ENGINES

Figure 8 API Identification Symbol

API CJ-4 oils are recommended for high speed diesel engineswith advanced, exhaust aftertreatment systems that meet 2007on-highway exhaust emission standards.

API CJ-4 oils provide protection against the following:

• Catalyst poisoning and particulate blockage

• Engine wear

• Piston deposits

• Soot related viscosity increase, deposits, and wear

• Viscosity loss due to shear

• Oxidative thickening

• Oil foaming and aeration

API CJ-4 oil, in combination with Ultra Low Sulfur Diesel(ULSD) fuel [0.0015% (15 ppm) maximum sulfur content],is recommended to maintain performance and durabilityof aftertreatment systems meeting 2007 diesel emissionregulations.

API CI-4 oils are allowed in diesel engines that meet theseregulations. Use of the CI-4 engine oil shortens DieselParticulate Filter (DPF) cleaning service intervals.



Engine Oil (cont.)OIL VISCOSITY

Figure 9 SAE viscosity grades and temperature ranges

The Society of Automotive Engineers (SAE) defines oil viscosity(thickness) by grade. Colder temperatures require lower grade

oils for correct flow during starting. Higher temperatures requirehigher grade oils for satisfactory lubrication.

• A block heater is required, if temperatures are below -23 °C(-10 °F).

• For heavy duty driving or trailer towing, higher oil grades15W-40 and 5W-40 oils are required, if temperatures areover 10 °C (50 °F).

For oil system capacity and service, see Section 5 - MaintenanceSchedule and Service Procedures.



Coolant

COOLANT MIXTURES

Engine coolant mixtures include water, glycol (ethylene orpropylene), and inhibitors. Conventional and fully formulatedcoolants require regular testing of inhibitor levels to maintainsafe levels of protection. Testing of conventional coolantdetermines levels of nitrite, nitrite/molybdate, and freeze pointprotection. If necessary, Supplemental Coolant Additives(SCAs) are added to replenish inhibitors.

Extended life coolant mixtures (water and ethylene glycol) do notrequire regular testing of inhibitor levels or addition of SCAs.

SHELL ROTELLA® EXTENDED LIFE COOLANT (ELC) –RED)

Part Numbers for ROTELLA® Extended Life Coolant(premix, concentrate, and extender)

2000 gal (50/50 Premix)ROTELLA® 9404200001

55 gal (Concentrate) ROTELLA®940410055

55 gal (50/50 Premix)ROTELLA® 94042000055

1 gal (Concentrate)ROTELLA® 9404106021

1 gal (6/pack 50/50 Premix)ROTELLA® 9404206021

1 qt. US (6/pack 50/50 Extender)ROTELLA® 9404306031

Shell ROTELLA® Extended Life Coolant (ELC) 50/50 Premix isthe standard factory fill for the cooling system. If a customer

wishes to use a different coolant, it should minimally meet ASTMD6210, Standard Specification for fully - Formulated Glycol BaseEngine Coolant for Heavy Duty Engines.

ROTELLA® ELC 50/50 Premix provides freeze protection to -36°C (-34 °F) and maximum corrosion protection. ROTELLA® ELC50/50 Premix is used to replenish coolant loss and ensure thatglycol/water concentrations stay in balance.

ROTELLA® ELC 50/50 Extender is added at the designatedservice interval. See Section 5 - Maintenance Schedule andService Procedures.

Freeze Point Protection Levels Provided by ROTELLA®Concentrate and Water Mixtures

Concentrate and WaterMixtures

Freeze Point Protection

40% ROTELLA® Concentrateand 60% water

-24.4 °C (-12 °F)


-36.7 °C (-34 °F)


-52.0 °C (-62 °F)


-70.6 °C (-95 °F)

For vehicles operating in extremely cold climates, a coolantmixture of 60% ROTELLA® Concentrate and 40% water or 67%ROTELLA® Concentrate and 33% water provide additional



Coolant (cont.)

SHELL ROTELLA® EXTENDED LIFE COOLANT (ELC) –RED) (cont.)

freeze protection as shown in the table above. Mixtures havingmore than 67% ROTELLA® Concentrate are not recommended.

For cooling system service, see Section 5 - MaintenanceSchedule and Service Procedures.

CONTAMINATION OF COOLANT

The coolant color should indicate the condition of the coolant.

• Coolant color should be a reddish orange (clear – notcloudy).

• Coolant must not have floating debris or visible oil.

Contamination of ROTELLA® ELC with other coolant productswill not be obvious.

To verify coolant quality, contact an International® service partsdealer and request coolant test kit ZSH297400001KIT.





Instrument Panel Gauge Cluster

Figure 10 Typical instrument panel gauge cluster

Gauges may vary with vehicle applications. Warning andindicator lamps show conditions not indicated by the gauges.



Water Temperature Gauge

Figure 11 Water temperature gauge

The water temperature gauge indicates the temperature ofcoolant in the cooling system. The gauge operates only whenthe ignition switch is turned to ON. Normal engine operatingtemperature is 89 °C to 104 °C (192 °F to 219 °F).

CAUTION: To prevent engine damage – do not operate engineabove 109 °C (228 °F); this may cause internal damage.

The amber indicator lamp will be activated at engine coolanttemperatures above 109 °C (228 °F). If engine temperaturesuddenly rises, shut down engine and determine the cause ofoverheating.

Oil Pressure Gauge

Figure 12 Oil pressure gauge

The engine oil pressure gauge indicates operating oil pressure.The engine oil pressure indicator lamp will be activated atpressure less than 35 kPa (5 psi) when engine is over 325 rpm.

CAUTION: To prevent engine damage, shut down engineimmediately, if the gauge fluctuates or drops to 241 kPa (35 psi)or less under load. Correct the problem.



Oil Pressure Gauge (cont.)Lubrication Oil Pressure

Lube Oil PressureAt normal operating temperature

Low idle 83 kPa (12 psi) min.

High idle 276 kPa (40 psi)

Oil Temperature Gauge

Figure 13 Oil temperature gauge

The engine oil temperature gauge indicates the operating oiltemperature of the engine.



Warning Lights

Warning lights signal when a gauge reading is outside presetlimits.

• Red warning lamps indicate situations that must beinspected before operating the vehicle.

• Amber warning lamps indicate situations that should bereviewed by the operator.

• An audible alarm is activated when a warning lamp is lit. Thisalerts the operator that an active fault exists.

Odometer

Figure 14 Odometer and Change engine oil message

1. Odometer2. Illuminated change oil message

The change oil indicator can be programmed for kilometers,miles, hours or calculated fuel consumption. These serviceinterval limits may be adjusted at the owners discretion. Consultyour International dealer.

The change engine oil message below the odometer illuminatesafter a preselected parameter is reached. This feature remainsinactive until ordered active.

NOTE: If this feature is active, the system must be resetafter each oil change. See Resetting Change Engine OilService Interval in Section 5 “MAINTENANCE SCHEDULEAND SERVICE PROCEDURES”.



Air Cleaner Restriction Indicators

Air restriction is resistance of airflow through the air cleaner.Accurate air restriction is measured at maximum airflow.

Figure 15 Air cleaner restriction indicators

1. Mounted on air cleaner2. Mounted on instrument panel

Air cleaner restriction is measured by an air restriction indicator,mounted on the air cleaner or instrument panel.

Air Restriction Indicator Calibration

• Both indicators are calibrated in inches of water.

• Both should be tested periodically (using a master vacuumgauge) to ensure a correct calibration.

Air Restriction Indicator Operation

• The yellow position indicator progressively fills the windowas air filter restriction increases, locking at the highestrestriction at full load.

• When the yellow position indicator reaches and locks in thered zone, a new air filter should be installed.

NOTE: If the yellow indicator locks in the red zone, it is notnecessary to shut down the engine immediately, but a new airfilter should be installed as soon as possible.

Air Restriction Indicator Reset

• The air restriction indicator should be reset, when theindicator is checked to determine air filter restriction.

If the air filter was not changed, the yellow indicator willmaintain the same reading when the vehicle is driven undernormal driving conditions.

• If a new air filter is installed, the air restriction indicatorshould be reset.





Preoperation Checklist

WARNING: To prevent personal injury or death,provide ventilation when operating an engine in a closedarea. Inhalation of exhaust gas can be fatal.

This engine has been given predelivery and delivery service byyour International dealer and is ready for operation. The operatorshould fully understand the use and function of all controls andinstruments.

NOTE: See Service Procedures in Section 5 for the followingsteps.

1. Check cooling system level.

Figure 16 Oil level gauge

2. Check for correct oil level.

CAUTION: To prevent engine damage, do not overfill withoil.

3. Inspect for coolant, fuel or oil leaks.

4. Inspect air cleaner and piping for tightness and correctinstallation of filter element.

5. Check for loose or hanging electrical connections.

6. Check belt condition and alignment.

7. Fill the tank with recommended fuel.

8. Inspect exhaust system for obstruction or damage.

9. Drain water from fuel system.



Priming the Fuel System

WARNING: To prevent personal injury or death, shifttransmission to park or neutral, set parking brake, and blockwheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, makesure that the engine has cooled before priming the fuelsystem.

WARNING: To prevent personal injury or death, do notsmoke and keep fuel away from open flames and sparks.

CAUTION: To prevent engine damage, do not add fuel to thefuel filter header. This can contaminate the fuel.

Figure 17 Fuel priming pump

1. Fuel priming pump2. Fuel priming pump knob

If engine runs out of fuel or the fuel filter header has beendrained, do the following:

1. Set parking brake and shift transmission to Park or Neutral.

2. Fill fuel filter header with fuel by pumping the fuel primerpump.



Starting the Engine

WARNING: To prevent personal injury or death, do notuse ether, propane, gasoline or gasohol as starting aids.

WARNING: To prevent personal injury or death, do notinstall ether start equipment, if an engine has an intake airheater or other cold climate starting aid.

WARNING: To prevent personal injury or death, do notuse ether starting fluid to start engine.

Figure 18 Ignition key positions


CAUTION: To prevent damage to the engine, do not depress theaccelerator pedal.

2. Depress clutch pedal if equipped.

3. Turn ignition key to ON to preheat glow plugs

NOTE: The ECM normally does not energize glow plugsduring hot starts. However, the ECM senses reducedatmospheric pressure at high altitude and could energizethe glow plugs during hot starts.

4. Watch for theWAIT TO START lamp on the instrument panelto go off. Do not crank engine until the lamp is off.

5. When the WAIT TO START lamp goes off, turn ignition keyto START. If the vehicle has push button starting, press andhold starter button.

6. When the engine starts, release the ignition key or starterbutton. The ignition key will return to ON and the engine willcontinue to run.

7. Release clutch pedal if equipped.



Starting the Engine (cont.)CAUTION: To prevent damage to the engine, if the engine failsto start within 20 seconds, do the following:

• Turn ignition key to OFF and wait 2-3 minutes.

• Repeat steps 1 through 5.

• If after three attempts the engine does not start, determinethe cause.

• If starting attempts are continued, the starter motor can bedamaged.

8. Low idle speed is 700 rpm (nonadjustable). Extended idlingperiods should be avoided. See Extended Idling Periods inthis section. Check all gauges during warm-up.

9. Within seconds after engine start, engine oil pressure shouldexceed 83 kPa (12 psi).

CAUTION: To prevent engine damage – do not increase enginespeed until oil pressure gauge indicates normal. If oil pressuredoes not reach the minimum limit within 20 to 30 seconds,shutdown engine.

10. If oil pressure does not meet the minimum limit 276 kPa (40psi), stop the engine and correct the problem.

11. After the engine has reached operating temperature andrated speed, the oil pressure should be 276 kPa (40 psi)minimum. If oil pressure does not meet the minimum limit,stop the engine and correct the problem.

NOTE: If engine starts and then stops, repeat engine startingprocedure. If more than three attempts are required, correctcause of no-start.

Emergency Starting

WARNING: To prevent personal injury or death, do thefollowing when jump starting an engine:

• Wear eye protection.

• Do not smoke

• Keep flames or sparks away from battery vent openings.

• Protect against inhaling hydrogen gas fumes from batteryvent openings.

• Use a 12 volt system with a negative ground.

• Do not exceed 16.0 volts, if the ignition switch is turned toOFF, ACC or ON during engine cranking.

CAUTION: To prevent engine damage, do not allow metal toolsto contact positive terminal of battery.


2. Shut off lights, heater, air conditioner, and other electricalloads in both vehicles.

3. Make sure vehicles are not touching.



Emergency Starting (cont.)

WARNING: To prevent personal injury or death,always connect jumper cable for positive battery terminalsfirst.

4. Connect one end of the first jumper cable to the positive (+)terminal of the dead battery or to the positive (+) terminal ofthe jump start stud. Connect the other end to the positive (+)terminal of the booster battery.

WARNING: To prevent personal injury or death, do notattach jumper cable to the negative (-) terminal of the deadbattery and the negative (-) terminal of the booster battery.This can cause sparks and an explosion.

5. Connect one end of the second jumper cable to thenegative (-) terminal of the booster battery and the otherend to chassis frame of the vehicle with the dead battery.

6. Start engine in vehicle that has the charged battery.

7. Start engine in vehicle that has the dead battery.

WARNING: To prevent personal injury or death,always disconnect jumper cable from negative contactsfirst.

8. Disconnect jumper cable from negative terminal and chassisframe.

9. Disconnect jumper cable from positive battery terminals orone terminal and jump start stud.

Operation

SUGGESTED WARM UP TIME

NOTE: Before applying a load or increasing speed above 1000rpm, warm up engine for a minimum of 5 minutes at or below1000 rpm. The warm up period allows lubricating oil to establisha film between moving parts.

Cold ambient engine warm up time can be reduced by operatingthe vehicle under load at reduced engine speed. Begin normaloperation when engine systems reach operating temperature.The Cold Ambient Protection (CAP) system aids in engine warmup and maintains engine heat during extended idling periods.See Extended Idling Periods, in this section.

IDLE SPEED

WARNING: To prevent personal injury or death,provide ventilation when operating an engine in a closedarea.



Operation (cont.)

IDLE SPEED (cont.)

Figure 19 Idle speed

Low idle speed for the International® MaxxForce® 7 DieselEngines is 700 rpm (nonadjustable).

EXTENDED IDLING PERIODS

CAUTION: To prevent engine damage, do not extend low idleperiods.

Extended idling periods should be avoided. Diesel engineefficiency is improved when the cylinder temperature remainshigh. Low temperature in cylinders may cause the following:

• Unburned fuel may seep from exhaust manifold gaskets andvehicle exhaust system connections. This seepage has thedark colored appearance of lubricating oil.

• Incomplete combustion and unburned fuel will washlubricating oil from cylinder sleeves. Unburned fuel will becarried into the lubricating oil, dilute the oil, and change oilviscosity.

• Carbon will form on internal components of turbocharger andEGR, reducing engine efficiency.

• Carbon will clog and damage the Diesel Particulate Filter(DPF)

ENGINE IDLE SHUTDOWN TIMER (FEDERAL-OPTIONAL)

GOVERNMENT REGULATION: State and localregulations may limit engine idle time. The vehicleowner or operator is responsible for compliance withthese regulations.



Operation (cont.)

ENGINE IDLE SHUTDOWN TIMER (FEDERAL-OPTIONAL)(cont.)

The optional Idle Shutdown Timer (IST) allows the EngineControl Module (ECM) to shutdown the engine during extendedidle. Idle time can be programmed from 5 to 120 minutes. TheECM can be programmed to deactivate the IST when the PTOis active.

Thirty seconds before engine shutdown, the amber IDLESHUTDOWN indicator in the instrument panel gauge clusterilluminates. This continues until the engine shuts down or thelow idle shutdown timer is reset. The engine must be out ofgear for the IST to work. Engine shutdown timer will deactivatefor one or more of the following conditions:

• Engine speed is not at idle speed (700 rpm).

• Vehicle movement or a Vehicle Speed Sensor (VSS) fault isdetected.

• Manual DPF Regeneration is enabled.

• Accelerator pedal movement or an Accelerator Positionsensor (APS) fault is detected.

• Engine coolant operating temperature is below 60 °C (140°F).

• Ambient temperature below 16 °C (60 °F) or above 44 °C(110 °F).

• Brake pedal movement is detected or a brake switch fault isdetected.

• Parking brake transition is detected.

• Clutch pedal is pressed or clutch pedal switch fault isdetected (manual transmissions, if equipped with a clutchswitch).

• Shift selector is moved from neutral (automatictransmissions).

• If the IST is enabled, the Cold Ambient Protection (CAP) willnot function.

ENGINE IDLE SHUTDOWN TIMER(CALIFORNIA-STANDARD)

GOVERNMENT REGULATION: State and localregulations may limit engine idle time. The vehicleowner or operator is responsible for compliance withthese regulations.



Operation (cont.)

ENGINE IDLE SHUTDOWN TIMER(CALIFORNIA-STANDARD) (cont.)

Your heavy duty diesel engine conforms to applicable CaliforniaAir Resources Board (CARB) Engine Shutdown System (ESS)regulations. This vehicle is registered and certified for sale inCalifornia.

The CARB Idle Shutdown Timer (IST) allows the Engine ControlModule (ECM) to shutdown the engine during extended idle.When parking brake is set, the idle time can be programmedup to 5 minutes. When parking brake is released, the idle timecan be programmed up to 15 minutes. No parking brake, theidle time can be programmed up to 15 minutes. During service,the idle time can be programmed up to 60 minutes. The ECMwill deactivate the IST when the PTO is active.

Thirty seconds before engine shutdown, the amber IDLESHUTDOWN indicator in the instrument panel gauge clusterilluminates. This continues until the engine shuts down or thelow idle shutdown timer is reset. The engine must be out ofgear for the IST to work. Engine shutdown timer will deactivatefor one or more of the following conditions:

• Engine speed is not at idle speed (700 rpm).

• Vehicle movement or a Vehicle Speed Sensor (VSS) fault isdetected.

• Manual DPF regeneration is enabled.

• Accelerator pedal movement or an Accelerator PedalSensor (APS) fault is detected.

• Engine coolant operating temperature is below 16°C (60°F).

• Brake pedal movement or a brake switch fault is detected.

• Parking brake transition is detected.

• Clutch pedal is pressed or clutch pedal switch fault isdetected (manual transmissions, if equipped with a clutchswitch).

• Shift selector is moved from neutral (automatictransmissions).

• If the IST is enabled, the Cold Ambient Protection (CAP) willnot function.

COLD WEATHER OPERATION

NOTE: If operating in temperatures below -29 °C (-20 °F),contact an International dealer for information about specialcold weather equipment and precautions.

NOTE: At temperatures below -20 °C (-4 °F), a crankcasemounted cup plug coolant heater is recommended to improvecold starting.



Operation (cont.)

COLD WEATHER OPERATION (cont.)

1. Before operating the engine at 0 °C (32 °F) or lower, checkor service the following:

• Correct battery size

• Correct amount of electrolyte, if not a maintenance freebattery.

• Full battery charge

• Condition of other electrical equipment

• Cooling system hoses for leaks

• Correct coolant and cooling system level

2. At the end of each daily operation do the following:

• Fill the fuel tank with correct fuel.

• Drain water from the fuel filter housing.

• Check oil level.

• Clean external surfaces of the engine, radiator, andaccessories to prevent dirt or snow build up.

COLD AMBIENT PROTECTION (CAP)

CAP safeguards the engine from damage caused by prolongedidle at no load during cold weather. CAP also improves cabwarm-up.

CAPmaintains engine coolant temperature by increasing enginerpm to a programmed value when ambient air temperature isbelow 20 °C (68 °F), coolant temperature is below 70 °C (158°F), and engine has been idling at no load for over five minutes.

CAP is standard on all trucks without an idle shutdown timer, witha clutch switch (manual transmissions) or a neutral safety switch(automatic transmission).

The engine speed will continue to increase or decrease tomaintain a coolant temperature of 80 °C (176 °F) until thefollowing occurs:

• Engine load is greater than 45%.

• Brake pedal is applied or brake switch fault is detected.

• Clutch pedal is depressed or clutch pedal switch fault isdetected (manual transmissions, if equipped with a clutchswitch).

• Shift selector is moved from neutral (automatictransmissions). Shift selector must be in neutral for CAPto work.

• Power Takeoff (PTO) switch, also used for electronic handthrottle, is turned on and actively controls engine speed.

• Accelerator pedal is depressed or accelerator pedal sensorfault is detected.



Operation (cont.)

COLD AMBIENT PROTECTION (CAP) (cont.)

• Idle Shutdown Timer (IST) is enabled.

• Engine Coolant Temperature (ECT) sensor fault is detected.

• Intake Air Temperature (IAT) ambient temperature sensorfault is detected.

HOT WEATHER OPERATION

1. Before operating the engine above 0 °C (32 °F), check orservice the following:

• Correct battery size


• Full battery charge

• Condition of other electrical equipment


• Correct coolant and cooling system level

2. At the end of each daily operation do the following:



• Check oil level

• Clean external surfaces of the engine, radiator, andaccessories to prevent dirt build up.

ENGINE SHUTDOWN

At the end of each day, idle the engine for several minutes beforeshutdown.

• Idling is recommended, if an engine has been running atmaximum horsepower.

• Idling dissipates heat.

ENGINE WARNING PROTECTION SYSTEM (EWPS)

The Engine Warning Protection System (EWPS) warns theoperator of engine conditions that can damage the engine.EWPS has two modes of operation: warning mode (standard)and protection mode (optional)

Warning mode (standard)

• The warning mode is the standard calibration for EWPS.

• The warning mode monitors engine rpm, Engine CoolantTemperature (ECT), Engine Oil Pressure (EOP), and EngineCoolant Level (ECL) optional.



Operation (cont.)

ENGINE WARNING PROTECTION SYSTEM (EWPS) (cont.)

• When a condition meets or exceeds a programmed warninglimit, the red engine lamp will illuminate and an alarm willsound.

• The engine will not shut down.

Protection mode (optional)

• The protection mode is an optional calibration that canbe added to the EWPS by the dealer, if requested by thecustomer.

• The protection mode monitors critical engine conditions:ECT, ECL, and EOP.

• When a condition meets or exceeds a programmed (warningcritical) limit, the red engine lamp will flash and an alarm willsound.

• The engine will shut down, after 30 seconds of operationpast critical threshold values for coolant temperature,coolant level or oil pressure. The operator has 30 secondsto safely pull the vehicle off the road. If the critical enginecondition remains, the ECM allows the engine to berestarted and run for 30 second periods.

NOTE: The protection mode is not offered for school buses oremergency vehicles.

PARKING

WARNING: To prevent personal injury or death, do thefollowing after parking vehicle:

• Set transmission to park or neutral.

• Set parking brake.

• Block wheels or turn wheels toward curb.

ROAD OPERATION

Figure 20 Road operation



Operation (cont.)

ROAD OPERATION (cont.)

Correct road operation of your vehicle will provide the following:

• Satisfactory engine performance

• Maximum fuel economy

• Long service life

General guidelines for correct road operation

1. Use the lowest gear to start vehicle. This allows the engineto easily start the load.

2. Accelerate smoothly and evenly to engine rated speed.Rapid acceleration causes high fuel consumption.

3. To prevent lugging, do not let engine speed drop below peaktorque rpm during full throttle.

4. When approaching a hill, depress accelerator smoothlyto start the upgrade at full power. Shift down to maintainmaximum vehicle speed.

DOWNHILL OPERATION

Figure 21 Downhill operation

CAUTION: To prevent engine damage when driving downhill, donot operate engine above high idle.

Protect your engine when driving downhill as follows:

• Prevent overspeeding of engine when going down long andsteep grades.

• Operate the engine in a gear that allows a lower rpm.



Maintenance Schedule

International® MaxxForce® 7 Diesel Engines

Service operation interval - which ever comes first: kilometers/miles, months, years, hours or liters/gallons of fuel

Service Interval Service Operation

See service procedures in this section for more information.

Daily Check engine oil level.Check coolant level.Drain water separator.Check for external leaks.Check air restriction indicator.

16,000 km (10,000 miles)6 months, 350 hours3785 liters (1000 gallons) of fuel

Change engine oil and oil filter.Inspect belt, air intake piping, and clamps.Check coolant freeze point.

32,600 km (20,000 miles)12 months, 700 hours7570 liters (2000 gallons) of fuel

Change primary and secondary fuel filters

Yearly Inspect electrical system.Pressurize air induction system.

CONTINUED ON NEXT PAGE



Maintenance Schedule (cont.)

International® MaxxForce® 7 Diesel Engines (cont.)

Service operation interval - which ever comes first: kilometers/miles, months, years, hours or liters/gallons of fuel

Service Interval Service Operation

See service procedures in this section for more information.

240,000 km (150,000 miles)30 months, 6,000 hours

Add Extended Life Coolant (ECL) Extender

322,000 km (200,000 miles)30 months, 6,000 hours

Cleaning Diesel Particulate Filter (DPF) 1

483,000 km (300,000 miles)5 years

Service cooling system.

1Reduced service interval required if allowed CI-4 engine lubrication oil is used. If using CI-4 oil, reduce DPF cleaning interval to 241,000 km(150,000 miles) 22 months, or 4,500 hours.



Service Procedures

WARNING: To prevent personal injury or death, puttransmission in neutral or park, set parking brake, and blockwheels before doing diagnostic or service procedures onthe engine or vehicle.

GOVERNMENT REGULATION: Dispose of fuelaccording to applicable regulations in a correctcontainer clearly marked DIESEL FUEL.

GOVERNMENT REGULATION: Engine fluids (oil,fuel, and coolant) may be a threat to the environment.Recycle or dispose of engine fluids according toapplicable regulations. Never put engine fluids in thetrash, on the ground, in sewers or bodies of water.

OIL LEVEL

Service Interval: Daily

1. Park vehicle on level ground.

NOTE: Do not check oil level if engine is running or immediatelyafter engine shutdown.

2. Shut down engine and wait 15 minutes.

3. Remove oil level gauge from fill tube.


CAUTION: To prevent engine damage do the following:

• Assure oil level readings are within the crosshatchedoperating range on the oil level gauge.

• Do not overfill the engine with oil.

• Do not operate engine if oil level is above or below theoperating range.

4. If oil level is below operating range, fill with recommendedoil for operating climate. The ADD mark indicates 0.95 liters(2 quarts US) of oil should be added. See Engine Oil Qualityand service categories, in Section 4.



Service Procedures (cont.)COOLANT LEVEL


Shell ROTELLA® Extended Life Coolant (ELC) 50/50 Premixis the standard factory fill for the cooling system. If a customerwishes to use a different coolant, it should minimally meet ASTMD6210, Standard Specification for fully - Formulated GlycolBase Engine Coolant for Heavy Duty Engines. ROTELLA®ELC 50/50 Premix is used to replenish coolant loss and ensurethat glycol/water concentrations stay in balance.

Figure 23 Deaeration tank

1. Deaeration tank2. Deaeration tank cap3. MAX coolant level4. ADD coolant level



Service Procedures (cont.)

COOLANT LEVEL (cont.)

WARNING: To prevent personal injury or death, do thefollowingwhen removing the radiator cap or deaeration tankcap:

• Allow the engine to cool for 15 minutes or more.

• Wrap a thick cloth around the radiator cap or deaeration tankcap.

• Loosen cap slowly a quarter to half turn to vent pressure.

• Pause for a moment to avoid being scalded by steam.

• Continue to turn cap counterclockwise to remove.

1. Check coolant level in the deaeration tank.

• Coolant level should be at midpoint of ADD and MAX.

• If coolant level is below the ADD mark, continue withstep 2.

2. Add ROTELLA® ELC Premix 50/50 to the correct coolantlevel (midpoint of ADD and MAX).

3. Install and tighten the deaeration cap until the plastic capclicks or the metal cap runs up against the detent.

WATER DRAIN VALVE


Figure 24 Water drain valve




WATER DRAIN VALVE (cont.)

WARNING: To prevent personal injury or death,comply with the following:

• When draining fuel, dispose of fuel in a container markedDIESEL FUEL, according to applicable regulations.

• Do not smoke.

• Keep vehicle away from open flames and sparks.

NOTE: If necessary, connect a hose to the end of the water drainvalve.

1. Put a suitable container under water drain valve.

2. Open water drain valve and drain water/fuel mixture.

Figure 25 Fuel primer pump assembly

1. Fuel primer pump assembly2. Fuel primer pump knob

NOTE: If the fuel/water mixture does not flow out of drain, unlockthe fuel primer pump by turning the knob counterclockwise. Pushonce on the fuel primer pump to displace fuel in the filter. Thiswill eliminate contaminants in the filter. Turn fuel primer pumpknob clockwise to lock.




WATER DRAIN VALVE (cont.)

WARNING: To prevent personal injury or death,dispose of fuel in a container marked DIESEL FUEL,according to applicable regulations.

3. Close water drain valve.

4. Dispose of fuel in a correct container.

CHARGE AIR COOLER (CAC)


WARNING: To prevent personal injury or death, shutdown engine, set parking brake, and block wheels beforeinspecting the Charge Air Cooler.

1. Inspect Charge Air Cooler (CAC) core for debris and cloggedexternal fins.

2. Before starting engine remove debris blocking the core.

EXTERNAL LEAKAGE


WARNING: To prevent personal injury or death, shutdown engine, set parking brake, and block wheels beforeinspecting for external leakage.

1. Check for the following conditions:

• Cracked hoses

• Loose clamps

• Water stains

• Oil stains

• Fuel stains

• Leakage at water pump (wetness from the weep hole isnormal)

2. Correct problems.



Service Procedures (cont.)AIR CLEANER RESTRICTION


Figure 26 Air cleaner restriction indicators

1. Mounted on air cleaner2. Mounted on instrument panel

Push reset button to check air restriction indicator. If the airfilter was not changed, the yellow indicator will return to the

same reading when the vehicle is driven under normal drivingconditions.

If the yellow position indicator has locked in the red zone, anew air filter should be installed to prevent low engine poweror engine damage.

1. Remove plugged air filter element and discard.

CAUTION: To prevent engine damage, do not use compressedair to clean filter housing.

2. Use a clean water-dampened cloth to clean inside of air filterhousing.

3. Inspect air filter housing for damage or distortion. Install newhousing if necessary.

4. Install a new air filter element.

5. Push reset button on air restriction indicator. The yellowindicator will return to zero.



Service Procedures (cont.)ENGINE OIL AND FILTER

Service Interval: 16,000 km (10,000 miles), 6 months, 350 hoursor 3785 liters (1000 gallons of fuel)

CAUTION: To prevent engine damage, do not extendrecommended oil change intervals.

1. Park vehicle on level ground. Set parking brake and shifttransmission to Park or Neutral.

2. Run engine until operating temperature is reached, then shutengine down.

WARNING: To prevent personal injury or death, wearprotective clothing when draining hot oil.

WARNING: To prevent personal injury or death, do notlet engine fluids stay on your skin. Clean skin and nailsusing hand cleaner and wash with soap and water. Wash ordiscard clothing and rags contaminated with engine fluids.

Figure 27 Oil filter removal and installation

1. Oil filter cap2. O-ring seal3. Oil filter element4. Oil filter housing

3. Remove oil filter cap.

4. Remove and dispose of O-ring seal on oil filter cap.

5. Remove and dispose of old oil filter element.

6. Install new oil filter element.




ENGINE OIL AND FILTER (cont.)

7. Install new O-ring seal on oil filter cap.

CAUTION: To prevent engine damage, do not over overtightenoil filter cap.

8. Install oil filter cap and tighten to the special torque 25 N·m(18 lbf-ft).

9. Put drain pan under the oil pan drain plug, remove oil pandrain plug, and drain oil.

10. Install new O-ring on oil pan drain plug and install drain plug.

11. Tighten oil pan drain plug to 68 N·m (50 lbf·ft).

WARNING: To prevent personal injury or death,dispose of oil or discard components, according toapplicable regulations.

12. Dispose of oil according to applicable regulations.

CAUTION: To prevent engine damage, do not overfill with oil.

13. Add correct oil viscosity, API CJ-4 oil is recommended butCI-4 is allowable. Use of CI-4 oils will reduce DPF cleaninginterval, see Maintenance Schedule (page 49). Add oilthrough the engine oil fill tube.


14. Check oil level gauge. Oil level must be within thecrosshatched operating range on the gauge.

15. Start engine and run at low idle.

16. Check reading on oil pressure gauge.

• Minimum lube oil pressure is 83 kPa (12 psi) @ 700 rpm.

• If there is no gauge reading, shut engine off immediately.Check for oil filter leaks.

• Let engine run until operating temperature is reached.Check for leaks.

17. Shut down engine for 15 minutes.

CAUTION: To prevent engine damage, do not overfill with oil.

18. Recheck oil level and add oil (if needed) to bring oil levelwithin the crosshatched operating range on gauge.



Service Procedures (cont.)RESETTING CHANGE ENGINE OIL SERVICE INTERVALMESSAGE

Reset the Service Interval Message (change engine oil) per thefollowing procedure:

1. If not already done, set the parking brake.

2. Turn ignition switch to ON.

3. Turn cruise ON.

4. Turn cruise OFF.

5. Turn cruise ON.

6. Very rapidly push the resume switch four times and then holddown on the fifth time for four seconds.

7. The Change Oil message should clear.

8. The operation from the time the cruise is turned On forthe second time to the fifth activation of the resume switchmust take place within six seconds. If you fail to reset themessage, repeat the process.

BELT, AIR INTAKE PIPING AND CLAMPS

Service Interval: 16,000 km (10,000 miles), 6 months, 350 hoursor 3785 liters (1000 gallons of fuel)

Figure 29 Cracks in belt ribs

1. Belt in good condition2. Belt ready for replacement3. Belt ribs4. Cracks in belt




BELT, AIR INTAKE PIPING AND CLAMPS (cont.)

For any of the following conditions install a new belt:

• Excessive wear

• Missing material

• Grease or oil contamination

• Over three cracks per inch in a belt rib

Figure 30 Square hole in auto tensioner (typical)

1. Attach a 1/2 inch breaker bar to square hole in autotensioner.




BELT, AIR INTAKE PIPING AND CLAMPS (cont.)

2. Pull breaker bar away from belt and install belt over autotensioner pulley and other pulleys.

3. Release auto tensioner. Tensioner will automatically adjust.

4. Remove breaker bar.

For any of the following conditions, install new parts:

• Loose hoses or clamps

• Ruptured hoses

• Cracked air cleaner housing

• Damaged Charge Air Cooler (CAC)

COOLANT FREEZE POINT

Service Interval: 24,000 km (15,000 miles), 6 months, or 550hours

ROTELLA® ELC 50/50 Premix provides freeze protection to -36°C (-34 °F) and maximum corrosion protection. If a customerwishes to use a different coolant, it should minimally meet ASTMD6210, Standard Specification for fully - Formulated GlycolBase Engine Coolant for Heavy Duty Engines. ROTELLA®ELC 50/50 Premix is used to replenish coolant loss and ensurethat glycol/water concentrations stay in balance.

ROTELLA® ELC 50/50 Extender is added at the designatedservice interval.

Freeze Point Protection Levels Provided by ROTELLA®Concentrate and Water Mixtures

Concentrate and WaterMixtures

Freeze Point Protection


-24.4 °C (-12 °F)


-36.7 °C (-34 °F)


-52.0 °C (-62 °F)


-70.6 °C (-95 °F)

For vehicles operating in extremely cold climates, a coolantmixture of 60% ROTELLA® Concentrate and 40% water or 67%ROTELLA® Concentrate and 33% water provide additionalfreeze protection as shown in the table above. Mixtures havingmore than 67% ROTELLA® Concentrate are not recommended.

Check freeze point with a refractometer.

1. Put drop of coolant on refractometer window.




COOLANT FREEZE POINT (cont.)

2. Look through eyepiece and focus.

3. Record freeze point.

PRIMARY FUEL FILTER

Service Interval: 32,000 km (20,000 miles), 12 months, 700hours or 7570 liters (2,000 gallons) of fuel

NOTE: Change fuel filter if optional fuel filter lamp is illuminated.

NOTE: If fuel used has more than average impurities, shorterservice intervals may be required.

WARNING: To prevent personal injury or death,comply with the following:

• Make sure the transmission is in neutral, parking brakeis set, and wheels are blocked before doing diagnostic orservice procedures on engine or vehicle.

• When draining fuel, dispose of fuel in a container markedDIESEL FUEL, according to applicable regulations.

• Do not smoke.

• Keep vehicle away from open flames and sparks.

Figure 31 Primary fuel element assembly

1. Fuel drain valve2. Fuel heater electrical connector3. Water In Fuel (WIF) sensor electrical connector


2. Put a suitable container under the water drain valve.

3. Open water drain valve and drain the fuel filter assembly.




PRIMARY FUEL FILTER (cont.)

WARNING: To prevent personal injury or death,dispose of fuel in a container marked DIESEL FUEL,according to applicable regulations.

4. Dispose of fuel in a correct container.

5. Disconnect electrical connector from fuel heater.

6. Disconnect electrical connector from WIF sensor.

Figure 32 Primary fuel element assembly

1. Primary filter element assembly2. Element and bowl primary seal3. Bowl assembly with fuel heater/probe

7. Remove bowl assembly. Use an oil filter wrench, ifnecessary.

8. Remove seal from bowl assembly.




PRIMARY FUEL FILTER (cont.)

9. Remove primary filter element assembly.

10. Install a new primary filter element assembly.

11. Install new seal in bowl assembly.

12. Install bowl assembly and hand tighten.

13. Close fuel drain valve by turning it clockwise.

14. Connect fuel heater electrical connector.

15. Connect WIF sensor electrical connector.

SECONDARY FUEL FILTER

Service Interval: 32,000 km (20,000 miles), 12 months, 700hours or 7570 liters (2,000 gallons) of fuel

Figure 33 Fuel filter removal and installation

1. Fuel filter cap2. O-ring3. Fuel filter element4. Fuel filter housing




SECONDARY FUEL FILTER (cont.)

1. Remove fuel filter cap.

2. Remove O-ring from fuel filter cap and discard O-ring.

3. Remove fuel filter element from fuel filter housing.

CAUTION: To prevent engine damage, the fuel filter elementmust be installed in the fuel filter housing.

NOTE: The engine will not run if the filter element is not installed.The installed filter element opens a check valve in the center ofthe stand pipe, allowing fuel to flow.

4. Install new fuel filter element.

CAUTION: To prevent engine damage, do not add fuel to thefuel filter housing; this can add contaminants to the fuel.

5. Install new O-ring fuel on filter cap.

CAUTION: To prevent engine damage, the fuel filter cap mustbe tightened on the fuel filter housing.

6. Install fuel filter cap and tighten to the special torque 27 N·m(20 lbf-ft).

Figure 34 Fuel priming pump

1. Fuel priming pump2. Fuel priming pump knob

7. Fill fuel filter header with fuel by pumping the fuel primerpump.



Service Procedures (cont.)ELECTRICAL SYSTEM

Service Interval: Yearly

1. Check wiring harness for cracks, rubbing and looseconnections.

2. Check sensors for loose connections, corrosion or cracks.

3. Check battery cables for the following conditions:

• Broken insulation.

• Rubbing or chaffing.

• Corroded or loose connections.

Electronics

Periodically check that all fault codes are cleared out anddo not reappear. For correct procedures, see International®MaxxForce® 7 Engine Diagnostic Manual or contact yourInternational dealer.

INDUCTION SYSTEM

Service Interval: Yearly

Pressure test the air induction system as follows:

• For inspection procedures, see International® MaxxForce®7 Engine Diagnostic Manual.

• Have your International dealer pressure test the air inductionsystem.



Service Procedures (cont.)EXTENDED LIFE COOLANT (ELC) EXTENDER

Service Interval: 240,000 km (150,000 miles), 30 months or6,000 hours

Figure 35 Deaeration tank ADD and MAX level marks







• Continue to turn cap counterclockwise to remove.

1. Remove deaeration tank cap.

ROTELLA® ELC Extender

Cooling SystemCapacity

Drain ELC Coolant Add ROTELLA®ELC Extender

22-30 liters (6-8gallons)

0.2 liter (0.5 quartUS)











EXTENDED LIFE COOLANT (ELC) EXTENDER (cont.)

2. Confirm coolant system capacity.

3. According to Cooling System Capacity in the table, drain thecorrect volume of coolant from the cooling system.

NOTE: Shell ROTELLA® ELC 50/50 Premix is the standardfactory fill for the cooling system. ROTELLA® ELC 50/50 Premixis used to replenish coolant loss and ensure that glycol/waterconcentrations stay in balance. If a customer wishes to usea different coolant, it should minimally meet ASTM D6210,Standard Specification for fully - Formulated Glycol BaseEngine Coolant for Heavy Duty Engines.

4. Add the same volume of ROTELLA® ELC Extender to thecooling system.

5. Check coolant level. If necessary, add ROTELLA® ELC50/50 Premix to bring coolant level to mid point (betweenADD and MAX) of deaeration tank.

6. Install and tighten the deaeration tank cap until the plasticcap clicks or the metal cap runs up against the detent.

CLEANING DIESEL PARTICULATE FILTER

For Engines Using CJ-4 Engine Oil

Service Interval: 322,000 km (200,000 miles) 30 months or6,000 hours

Clean DPF at designated service interval. Take vehicle to yourInternational® dealer for cleaning.

For Engines Using CI-4 Engine Oil

Service Interval: 241,000 km (150,000 miles) 22 months or4,500 hours

Clean DPF at designated service interval. Take vehicle to yourInternational® dealer for cleaning.



Service Procedures (cont.)SERVICE COOLING SYSTEM

Service Interval: 483,000 km (300,000 miles) or 5 years






• Continue to turn cap counterclockwise to remove.Figure 36 Deaeration tank


1. Park vehicle so the engine is level.


3. Put a drain pan under the radiator.

4. Remove deaeration tank pressure cap.




SERVICE COOLING SYSTEM (cont.)

5. Open radiator drain valve.

6. After radiator has drained, close the drain valve and movethe drain pan under right side coolant drain plug.

Figure 37 Right side coolant drain plug

7. Remove right side coolant drain plug.

8. After coolant has drained, install right side coolant drain plug.

Figure 38 Left side coolant drain plug

9. Move the drain pan under left side coolant drain plug.

10. Remove left side coolant drain plug.

11. After coolant has drained, install left side coolant drain plug.





Figure 39 ADD and MAX level marks on deaeration tank


NOTE: Shell ROTELLA® ELC 50/50 Premix is the standardfactory fill for the cooling system. ROTELLA® ELC 50/50 Premixis used to replenish coolant loss and ensure that glycol/waterconcentrations stay in balance. If a customer wishes to usea different coolant, it should minimally meet ASTM D6210,Standard Specification for fully - Formulated Glycol BaseEngine Coolant for Heavy Duty Engines.

12. Slowly fill cooling system with new ROTELLA® ELC 50/50Premix or ROTELLA® Concentrate and water mixture untilcoolant is at the mid point between the ADD and FULL levelin the deaeration tank.

13. Install and tighten the deaeration tank cap until the plasticcap clicks or the metal cap runs up against the detent.

14. Start the engine.

15. Allow the engine to operate at a fast idle until the enginereaches normal operating temperature.

16. As the engine warms up, make sure coolant is flowingthrough deaeration line – coolant will feel warm to the touch.

17. After engine reaches normal operating temperature and thethermostat has opened, shut engine off.





Figure 40 ADD and MAX level marks on deaeration tank


18. If necessary, add coolant to the deaeration tank to bring thelevel up to the MAX mark.



Service Procedures (cont.)Maintenance Service Record

WARNING: To prevent personal injury or death, readall safety instructions in the “Safety Information” section ofthis manual.

WARNING: To prevent personal injury or death, puttransmission in neutral or park, set parking brake, and blockwheels before doing diagnostic or service procedures.

Save scheduled maintenance work orders and receipts for proofof correct maintenance. Failure to maintain work orders andreceipts may affect your warranty coverage.



Maintenance Service Record (cont.)Maintenance Service Record

Date Service Month Service Hours km (Miles) Item Serviced



Maintenance Service Record (cont.)Table 1 Maintenance Service Record

Date Service Month Service Hours km (Miles) Item Serviced



Daily Care and Report

WARNING: To prevent personal injury or death, readall safety instructions in the “Safety Information” section ofthis manual.

WARNING: To prevent personal injury or death, puttransmission in neutral or park, set parking brake, and blockwheels before doing diagnostic or service procedures.

Check the following daily to prevent engine failure. Report allproblems for immediate service.

• Oil level.

• Oil, air, fuel or coolant leaks.


• Correct coolant and coolant system level

• Excessive use of crankcase lubricating oil, coolant, batteryfluid or fuel.

• Unusual engine noise.


• Condition of electrical equipment

Do the following daily to prevent engine failure.

• Add coolant if necessary. Make sure filler cap seal is in goodcondition and the cap is installed tightly.

• Check air cleaner indicator with engine running. When theyellow position indicator reaches and locks in the red zone,a new air filter should be installed.



• Clean external surfaces of the engine, radiator, andaccessories to prevent dirt or snow build up.



Daily Care and Report (cont.)Daily Care and Report

Model

Serial No.

Fuel Parts LaborDate Miles

Qty Cost

LubeOil Parts Cost Time Cost

Service Performed



Daily Care and Report (cont.)Table 2 Daily Care and Report

Model

Serial No.

Fuel Parts LaborDate Miles

Qty Cost

LubeOil Parts Cost Time Cost

Service Performed


CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects andother reproductive harm.

Documents

International® MaxxForce® 7 Diesel Engine · This manual includes necessary information and speciﬁcations for operators to service Navistar diesel engines. Contact an International