EPA 10, 2013 HD-OBD - US, Canada

MaxxForce® 7
MaxxForce® 7

Engine Operation and Maintenance Manual

Navistar, Inc.
2701 Navistar Drive, Lisle, IL 60532 USA

0000001802
4328090R2
May 2015
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
 IMPORTANT
The information, specifications, and illustrations contained in this manual are based on data that was current at the time of
publication. Navistar, Inc. reserves the right to make changes and/or improvements at any time without notification, liability,
or without applying those changes or improvements to vehicles previously manufactured and/or sold.

NOTICE CALIFORNIA
Be advised that this motor vehicle may be equipped with Proposition 65 Warning
computer / recording devices. Their function is to allow an
authorized individual to download data or information relating Diesel engine exhaust and some of its constituents are
to the operation or performance of this vehicle. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
The stored data or information may be neither downloaded
nor retrieved except by the vehicle’s registered owner, or, in Battery posts, terminals and related accessories contain
the alternative, by another individual or entity authorized by lead and lead compounds, chemicals known to the State
the registered owner, (e.g., International Dealer) who may of California to cause cancer and reproductive harm.
need this data or information to properly service or diagnose Wash hands after handling.
this vehicle for repair or following an accident.
Any access to this information without the owner’s consent
may be in violation of law and may subject that person or
entity to criminal penalties.
Summary of Changes
Section Description

Forward Removed publications from Technical Service Literature

Warranty Edited California Emission System Warranty

Section 4 Changed instruction for installing wheel chocks

Section 5 Placed U.S. units before metric units

Section 5 Changed instruction for installing wheel chocks

Section 5 Changed Oil Check Timing Interval to 15 minutes

Section 5 Edited Tool Number for the Navistar Coolant Management Tool Kit

Section 7 Changed instruction for installing wheel chocks

 TABLE OF CONTENTS

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

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

WARRANTY......................................................................................7
U.S. Federal Emission System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Required Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Warranty Repairs and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Recommended Maintenance or Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Emergency Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
What is not Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Warranty Rights and Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
California Emission System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Required Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Warranty Repairs and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Recommended Maintenance or Repair Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Emergency Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
What is Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
What is not Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Warranty Rights and Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

SECTION 1 – ENGINE SYSTEMS

Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Engine Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
 TABLE OF CONTENTS

Engine Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Engine Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Component Location – Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Component Location – Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Component Location – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Component Location – Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Component Location – Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

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

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Ultra Low Sulfur Diesel (ULSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Unacceptable Fuel and Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Acceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Use of Higher Biodiesel Fuel Blends (B6 to B20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Engine Oil Quality and Service Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
API CJ-4 for High Performance Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Coolant Mixtures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Extended Life Coolant (ELC) - Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Contamination of Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Warning Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Wait to Start Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
 TABLE OF CONTENTS

Idle Shutdown Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Maintenance Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Amber Warning Lamp (AWL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Red Stop Lamp (RSL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
High Exhaust System Temperature (HEST) Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Diesel Particulate Filter (DPF) Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Malfunction Indicator Lamp (MIL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Typical Water Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Engine Exhaust Brake On / Off Toggle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Air Cleaner Restriction Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

SECTION 4 – ENGINE OPERATION

Preoperation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Priming the Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Priming the Fuel System After Servicing the Fuel Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Priming the Fuel System After Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Emergency Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Suggested Warm-up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Extended Idling Periods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Engine Idle Shutdown Timer (U.S. Federal-Optional [2010 and 2011 vehicles]). . . . . . . . . . . . . . . . . . . .56
Engine Idle Shutdown Timer (California and all state - optional [2012 and newer vehicles]). . . . . . .57
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Cold Ambient Protection (CAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
 TABLE OF CONTENTS

Engine Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Engine Warning Protection System (EWPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
HD-OBD Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Radiator Shuttle Enable (RSE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Road Speed Limiting (RSL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Road Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Charge Air Cooler (CAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
External Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Air Cleaner Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Fuel Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Resetting Change Engine Oil Service Interval Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Belt, Air Intake Piping and Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Air Intake Piping and Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Coolant Freeze Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Secondary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Resetting Change Service Breather Element Message (Serviceable Crankcase breather only). . .88
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Extended Life Coolant (ELC) Extender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
 TABLE OF CONTENTS

Cleaning Diesel Particulate Filter (DPF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Service Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

SECTION 6 – LONG TERM STORAGE

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

SECTION 7 – SERVICE RECORDS

Maintenance Service Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Daily Care and Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
 FOREWORD

Foreword About the Manual

Navistar, Inc. is committed to continuous research and This manual contains information needed to correctly operate
development to improve products and introduce technological and maintain your engine as recommended by Navistar, Inc.
advances. Procedures, specifications, and parts defined in Numerous illustrations, symbols and feature descriptions
published technical service literature may be altered. are used to aid in understanding the meaning of the text.
The illustrations, symbols or feature descriptions will not be
NOTE: Photo illustrations identify specific parts or assemblies available for all applications; please reference your Vehicle
that support text and procedures; other areas in a photo Operator Manual for complete information. Both metric and
illustration may not be exact. U.S. customary values are listed in this manual. The U.S.
customary value is listed first, followed by the metric value in
This manual includes necessary information and specifications
brackets. For additional information refer to service literature
for operators to service Navistar® diesel engines. Contact your
noted in this manual. This manual does not cover vehicle
dealer for more information.
or equipment maintenance procedures. Consult the original
vehicle or equipment manufacturer for specific maintenance
Technical Service Literature
recommendations.
MaxxForce® 7 Engine Operation and Maintenance Manual
MaxxForce® 7 Engine Service Manual
MaxxForce® 7 Engine Diagnostic Manual

Technical Service Literature is revised periodically. Use only

up-to-date service information.
To order technical service literature, contact your dealer.
All marks are trademarks of their respective owners.

Page 1
 FOREWORD

Page 2
 SAFETY INFORMATION

Safety Information Safety Instructions

This manual provides general and specific maintenance Work Area

procedures essential for reliable engine operation and your • Keep work area clean, dry, and organized.
safety. Since many variations in procedures, tools, and service
parts are involved, advice for all possible safety conditions and • Keep tools and parts off the floor.
hazards cannot be stated. • Make sure the work area is ventilated and well lit.
Read safety instructions before doing any service and test • Make sure a First Aid Kit is available.
procedures for the engine or vehicle. See related application
manuals for more information. Safety Equipment

Disregard for Safety Instructions, Warnings, Cautions, and • Use correct lifting devices.
Notes in this manual can lead to injury, death or damage to the • Use safety blocks and stands.
engine or vehicle.
Protective Measures
Safety Terminology • Wear protective safety glasses and shoes.
Three terms are used to stress your safety and safe operation of • Wear correct hearing protection.
the engine: Warning, Caution, and Note.
• Wear cotton work clothing.
Warning: A warning describes actions necessary to prevent
or eliminate conditions, hazards, and unsafe practices that can • Wear sleeved heat protective gloves.
cause personal injury or death. • Do not wear rings, watches or other jewelry.
Caution: A caution describes actions necessary to prevent or • Restrain long hair.
eliminate conditions that can cause damage to the engine or
vehicle.
Note: A note describes actions necessary for correct, efficient
engine operation.

Page 3
 SAFETY INFORMATION

Vehicle Fire Prevention

• Make sure the vehicle is in park or neutral, the parking brake • Make sure charged fire extinguishers are in the work area.
is set, and the wheels are blocked before servicing engine.
NOTE: Check the classification of each fire extinguisher to
• Clear the area before starting the engine.
ensure that the following fire types can be extinguished.
Engine
1. Type A — Wood, paper, textiles, and rubbish
• The engine should be operated or serviced only by qualified
2. Type B — Flammable liquids
individuals.
3. Type C — Electrical equipment
• Provide necessary ventilation when operating engine in a
closed area. Batteries
• Keep combustible material away from engine exhaust • Always disconnect the main negative battery cable first.
system and exhaust manifolds.
• Always connect the main negative battery cable last.
• Install all shields, guards, and access covers before
• Avoid leaning over batteries.
operating engine.
• Protect your eyes.
• Do not run engine with unprotected air inlets or exhaust
openings. If unavoidable for service reasons, put protective • Do not expose batteries to open flames or sparks.
screens over all openings before servicing engine.
• Do not smoke in workplace.
• If an engine is not safe to operate, tag the engine and ignition
Compressed Air
key.
• Use an OSHA approved blow gun. Limit blow gun air
pressure to 30 psi (207 kPa).
• 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.

Page 4
 SAFETY INFORMATION

Tools Fuel
• Make sure all tools are in good condition. • Do not overfill the fuel tank. Overfill creates a fire hazard.
• Make sure all standard electrical tools are grounded. • Do not smoke in the work area.
• Check for frayed power cords before using power tools. • Do not refuel the tank when the engine is running.
Fluids Under Pressure Removal of Tools, Parts, and Equipment
• Use extreme caution when working on systems under • Reinstall all safety guards, shields, and covers after
pressure. servicing the engine.
• Follow approved procedures only. • Make sure all tools, parts, and service equipment are
removed from the engine and vehicle after all work is done.

Page 5
 SAFETY INFORMATION

Page 6
 WARRANTY

Warranty is based on the engine model year, not the model year of the
vehicle. The warranty period begins on the date the new vehicle
is delivered to the first retail purchaser.
U.S. Federal Emission System Warranty
REQUIRED MAINTENANCE
WARRANTY PERIOD
As the vehicle owner, you are responsible for all required
Navistar, Inc. warrants your heavy-duty diesel engine for the maintenance described in this manual. Navistar, Inc.
following warranty period (whichever comes first): recommends that you retain all maintenance receipts. Navistar
will not deny an emission warranty claim solely because you
Light Heavy Diesel Engine have no record of maintenance. However, a claim may be
• 5 years denied if your failure to perform proper maintenance resulted
in the failure of a warranted part and you cannot provide
• 50,000 miles (80,000 km) appropriate evidence of maintenance. Take your vehicle to an
• Or if covered by any basic or extended warranty (if greater authorized service provider when a problem occurs.
than above)
WARRANTY REPAIRS AND SERVICE
Medium Heavy Diesel Engine
• 5 years All emission control system parts proven defective during normal
use will be repaired or replaced during the warranty period.
• 100,000 miles (160,000 km) Warranty repairs and service will be done by an authorized
• Or if covered by any basic or extended warranty (if greater service provider with no charge for parts, labor and diagnostics.
than above) Warranty repairs should be completed in a reasonable time, not
to exceed 30 days. Navistar, Inc. may deny warranty coverage if
Your heavy-duty diesel engine conforms to U.S. Environmental your vehicle or a part has failed due to abuse, neglect, improper
Protection Agency regulations for emission systems. maintenance or unapproved modifications.
The engine model year, service class (light heavy or medium
heavy), and required emission information is on the exhaust
emission label located on top of the Exhaust Gas Recirculating
(EGR) manifold mixer on the front of the engine. This warranty

Page 7
 WARRANTY

U.S. Federal Emission System Warranty (cont.)

RECOMMENDED MAINTENANCE OR REPAIR PARTS WHAT IS NOT COVERED BY WARRANTY

MaxxForce® service parts or MaxxForce® ReNEWed® parts Unauthorized parts or expendable parts:
are recommended for maintenance or repairs to maintain the
• Parts other than MaxxForce® service parts or ReNEWed®
original quality of your emission certified engine. If parts not
parts
recommended by Navistar. cause damage to the engine or
vehicle, the warranty is invalid and maintenance and repair • Aftermarket parts or service kits
costs will not be covered.
• Nondefective parts replaced by an unauthorized service
provider
EMERGENCY REPAIRS
• Parts requiring replacement at inspection or adjustment
Emergency repairs are recognized if parts are not available maintenance intervals for reasons other than being defective
within 30 days or repairs are not completed within 30 days.
If an authorized service provider is not reasonably available, • Replacement of expendable items made in connection with
the vehicle owner or any service establishment may install any scheduled maintenance
replacement part. Vehicle, engine, and part malfunctions caused by the
Navistar, Inc. will reimburse you for emergency repairs following:
(including diagnostics) for the following: • Use of incorrect fuel, engine oil, or coolant
• Replacement parts that do not exceed manufacturer's • Failure to maintain correct maintenance schedule
suggested retail price
• Incorrect adjustments, modifications, alterations, tampering
• Labor charges based on manufacturer's recommended time or disconnection of vehicle components
allowance and geographic hourly rate
• Abuse or misuse of engine
Replaced parts and paid invoices must be given to your dealer
for reimbursement of emergency repairs • Accidents, acts of nature or other events beyond control of
Navistar, Inc.

Page 8
 WARRANTY

U.S. Federal Emission System Warranty (cont.)

WHAT IS NOT COVERED BY WARRANTY (cont.)

Conditions Not Covered by Warranty: California Emission System Warranty

• Loss of time, inconvenience, use of vehicle / engine or
WARRANTY PERIOD
commercial loss
• Vehicles with an altered or disconnected odometer or The California Air Resources Board and Navistar, Inc. are
hourmeter when mileage or hours cannot be determined pleased to explain the emission control system warranty on
your 2014 heavy-duty diesel engine. In California, new motor
WARRANTY RIGHTS AND RESPONSIBILITIES vehicles must be desiged, built and equipped to meet the State's
stringent anti-smog standards.
Navistar, Inc. ensures that the emission warranty is being
Navistar warrants your light or medium heavy-duty diesel engine
properly administered. If you have not received satisfactory
for the following warranty period (whichever comes first):
service or have questions regarding your warranty rights
and responsibilities, contact the Navistar regional office for • 5 years
assistance. The address and phone number of each regional
• 100,000 miles (160,000 km) or 3000 hours
office is listed in your Vehicle Operator Manual. If additional
assistance is required, contact the Manager of Customer • Or if covered by any basic or extended warranty (if greater
Relations. than above)
Manager, Customer Relations Your heavy-duty diesel engine conforms to applicable California
Navistar, Inc. Air Resources Board regulations. This vehicle is registered and
2701 Navistar Drive certified for sale in California.
Lisle, Illinois 60532
The engine model year, service class (light heavy or medium
(Telephone 1-800-448-7825)
heavy), and required emission information are on the exhaust
emission label located on top of the Exhaust Gas Recirculating
(EGR) manifold mixer on the front of the engine. This warranty
is based on the engine model year, not the model year of the

Page 9
 WARRANTY

California Emission System Warranty (cont.)

WARRANTY PERIOD (cont.)

vehicle. The warranty period begins on the date the new vehicle not to exceed 30 days. Navistar, Inc. may deny you warranty
is delivered to the first retail purchaser. coverage if your vehicle or a part has failed due to abuse,
neglect, improper maintenance or unapproved modifications.
REQUIRED MAINTENANCE
RECOMMENDED MAINTENANCE OR REPAIR PARTS
As the vehicle owner, you are responsible for all required
maintenance described in this manual. Navistar, Inc. MaxxForce® service parts or MaxxForce® ReNEWed® parts
recommends that you retain all receipts covering maintenance are recommended for maintenance or repairs to maintain the
on your truck, but Navistar will not deny warranty solely for the original quality of your emission certified engine. If parts not
lack of receipts or your failure to ensure the performance of recommended by Navistar, Inc. cause damage to the engine
all scheduled maintenance. However, a claim may be denied or vehicle, the warranty is invalid and maintenance and repair
if Navistar demonstrates that the (engine / vehicle) has been costs will not be covered.
abused, neglected, or improperly maintained, and that such
abuse, neglect, or improper maintenance was the cause of the EMERGENCY REPAIRS
need for the repair or replacement of the part. Take your vehicle
to an authorized service provider when a problem occurs. Emergency repairs are recognized if parts are not available
within 30 days or repairs are not completed within 30 days.
WARRANTY REPAIRS AND SERVICE If an authorized service provider is not reasonably available,
the vehicle owner or any service establishment can install
All emission control system parts proven defective, or fail to replacement parts.
meet the requirements in the California Code of Regulations,
Navistar, Inc. will reimburse you for emergency repairs
Title 13, Sections 2700 to 2706, and 2710 during normal
(including diagnostics) for the following:
use, will be repaired or replaced during the warranty period.
Warranty repairs and service will be done by an authorized • Replacement parts that do not exceed manufacturer's
service provider with no charge for parts, labor and diagnostics. suggested retail price
Warranty repairs should be completed in a reasonable time,

Page 10
 WARRANTY

California Emission System Warranty (cont.)

EMERGENCY REPAIRS (cont.)

• Labor charges based on manufacturer's recommended time for an extended warranty is shared between the owner and the
allowance and geographic hourly rate manufacturer, the emission warranty shall also be shared in the
same manner as specified in the warranty agreement.
Replaced parts and paid invoices must be given to your dealer
for reimbursement of emergency repairs.

WHAT IS COVERED BY WARRANTY

Where a warrantable condition exists, Navistar, Inc. will repair

your diesel engine at no cost to you including diagnosis,
parts, and labor. If your (vehicle or truck) fails a Smog Check
inspection, all necessary repairs and adjustments will be
made by Navistar to ensure that your emission control system
Performance Warranty.
If any emission-related part on your diesel engine is defective,
the part will be repaired or replaced by Navistar. This is your
short-term emission control system Defects Warranty. For
diesel-powered heavy-duty vehicles (except medium-duty
vehicles), and motor vehicle engines used in such vehicles, a
period of use of five years, 100,000 miles, or 3000 hours of
operation, whichever first occurs. However, in no case may
this period be less than the basic mechanical warranty that the
manufacturer provides (with or without additional charge) to the
purchaser of the engine. Extended warranties on select parts do
not extend the emissions warranty requirements for the entire
engine but only for those parts. In cases where responsibility

Page 11
 WARRANTY

California Emission System Warranty (cont.)

WHAT IS COVERED BY WARRANTY (cont.)

New vehicles and engines, registered and certified for sale in WHAT IS NOT COVERED BY WARRANTY
California, have the following items covered by the emission
warranty when first installed on the engine as original equipment: Unauthorized parts or expendable parts:

• Fuel injection system • Parts other than MaxxForce® service parts or ReNEWed®
parts
• Air induction system (includes turbocharger, exhaust
manifold, Exhaust Gas Recirculation [EGR] system, EGR • Aftermarket parts or service kits
rate and feedback control system, and intake manifold) • Nondefective parts replaced by an unauthorized service
• Positive crankcase ventilation system (includes Crankcase provider
Ventilation Valve [CCV] and oil fill cap) • Parts requiring replacement at inspection or adjustment
• Diesel Particulate Control System (includes catalytic maintenance intervals for reasons other than being defective
converter, traps, fuel additive devices, and other devices • Replacement of expendable items made in connection with
used to regenerate or aid in the regeneration of the scheduled maintenance
particulate control device)
Vehicle, engine, and part malfunctions caused by the
• Miscellaneous items used in above systems following:
A. Hoses, clamps, fittings and tubing • Use of incorrect fuel, engine oil, or coolant
B. Pulleys, belts and idlers • Failure to maintain correct maintenance schedule
C. Vacuum, temperature and time sensitive valves and • Incorrect adjustments, modifications, alterations, tampering
switches or disconnection of vehicle components
D. Electronic controls • Abuse or misuse of engine
• Accidents, acts of nature or other events beyond the control
of Navistar, Inc

Page 12
 WARRANTY

California Emission System Warranty (cont.)

WHAT IS NOT COVERED BY WARRANTY (cont.)

Conditions Not Covered by Warranty:

• Loss of time, inconvenience, use of vehicle / engine or
commercial loss
• Vehicles with an altered or disconnected odometer or
hourmeter when mileage or hours cannot be determined

WARRANTY RIGHTS AND RESPONSIBILITIES

If you have not received satisfactory service or have questions

regarding your warranty rights and responsibilities, contact the
Navistar, Inc. regional office for assistance. The address and
phone number of each regional office is listed in your Vehicle
Operator Manual. If additional assistance is required, contact
the Manager of Customer Relations.
Manager, Customer Relations
Navistar, Inc.
2701 Navistar Drive
Lisle, Illinois 60532
(Telephone 1-800-448-7825)
If further questions of warranty rights and responsibilities remain,
contact:
The Air Resources Board
9528 Telstar Avenue
El Monte, California 91731

Page 13
 WARRANTY

Page 14
 SECTION 1 – ENGINE SYSTEMS

Engine Serial Number Engine Serial Number Example

6.5HM2YXXXXXXX
6.5 – Engine family code
H – Diesel, turbocharged, Charge Air Cooler (CAC), and
electronically controlled
M2 – Motor truck or U2 power unit and OEM (sold to original
equipment manufacturer)
Y – United States, Huntsville Alabama
7-digit suffix – Engine serial number sequence

Figure 1 Engine Serial Number

The engine serial number is stamped on the crankcase pad, on

the rear left side below the cylinder head.

Page 15
 SECTION 1 – ENGINE SYSTEMS

Engine Emission Label Engine Accessories

The following engine parts may have manufacturers' labels or
identification plates:
• Air compressor
• Air conditioning compressor (single and dual)
• Alternator
• Cooling fan clutch
• Power steering pump
Figure 2 The U.S. Environmental Protection Agency (EPA) • Starter motor
Exhaust Emission Label (Example)
• Engine Control Module (ECM)
Labels or identification plates include information and
The U.S. Environmental Protection Agency (EPA) exhaust specifications helpful to vehicle operators and technicians.
emission label is located on top of the Exhaust Gas Recirculation
(EGR) manifold mixer, on the front of the engine. The label
includes the following:
• Advertised brake horsepower ratings
• Engine model code
• Service applications (light heavy or medium heavy)
• Emission family and control systems
• Year the engine was certified to meet EPA emission
standards

Page 16
 SECTION 1 – ENGINE SYSTEMS

Engine Specifications
MaxxForce® 7 Features and Specifications
Engine Configuration 4 stroke, V8 diesel
Rated power @ rpm See EPA exhaust emission label.
Peak torque @ rpm See EPA exhaust emission label.
Displacement 6.4 L (389 in3)
Compression ratio 16.5 : 1
Stroke 4.134 in (105 mm)
Bore (sleeve diameter) 3.87 in (98.2 mm)
Firing order 1-2-7-3-4-5-6-8
Aspiration Dual Turbocharger and Charge Air Cooled (CAC)
Combustion system Direct injection, turbocharged
Fuel system Direct injection common rail
1
Lube system capacity (including filter) 18.9 L (20 qts US)

NOTE: For TerraStar® 4x2 applications only, the lube system capacity
(including filter) is 20.8 L (22 qts).
2
Lube system capacity (overhaul only, with filter) 19.9 L (21 qts US)

NOTE: For TerraStar® 4x2 applications only, the lube system capacity
(overhaul only, with filter) is 21.7 L (23 qts).

Page 17
 SECTION 1 – ENGINE SYSTEMS

Engine Specifications (cont.)

Engine lubrication oil pressure at operating temperature
Low idle 12 psi (83 kPa) minimum
High idle 45 psi (310 kPa) minimum
Idle speed (no load) 700 rpm ± 50 (nonadjustable)
Thermostat operating temperature
With bypass 198°F - 205°F (92°C - 96°C)
Without bypass 188°F - 196°F (87°C - 91°C)

1 Verify engine lubrication capacities if additional equipment added to system.

2 Verify engine lubrication capacities if additional equipment added to system.

Page 18
 SECTION 1 – ENGINE SYSTEMS

Engine Specifications (cont.)

Engine Description Crankcase Assembly

The MaxxForce® 7 is a V8 engine with a displacement of 6.4 liters The crankcase is comprised of two major matching components.
(389 cubic inches). The engine has been designed for increased The upper crankcase half houses the cylinders and main bearing
durability, reliability, and ease of maintenance. saddles, with oil and coolant passages either cast or machined.
The lower crankcase consists of a structural plate with the main
Air Management System bearing caps machined into it for improved load retention and
A two-stage turbocharger provides boost air pressure to the alignment.
engine for various speed and load conditions. An electronically The upper crankcase utilizes Compact Graphite Iron (CGI)
controlled solenoid modulates boost air to a wastegate actuator material technology for a lighter and stronger crankcase.
that controls the turbocharger discharge pressures.
One-piece aluminum-alloy pistons are fitted with one keystone
A chassis-mounted Charge Air Cooler (CAC) is piped into the ring, one rectangular intermediate compression ring, and a
air management system between the turbocharger and intake two-piece oil control ring. The combustion bowl is located in
throttle. The CAC is an air-to-air heat exchanger that cools and the piston crown to reduce emissions. All pistons are mated to
increases the density of the air charge after the turbocharger. fractured cap joint connecting rods.
The Exhaust Gas Recirculating (EGR) system includes an EGR A gerotor lube oil pump, mounted on the front crankcase
valve and an intake throttle valve. The EGR valve is mounted in bulkhead, is driven by the crankshaft to supply pressurized oil to
an EGR mixer duct that is part of the EGR valve elbow housing. engine components. All MaxxForce® 7 engines use an engine
The intake throttle valve is mounted on the other side of the EGR oil cooler and spin on oil filter. The oil filter is located at the lower
valve elbow housing in the air stream from the CAC. driver-side corner of the engine where there is a filter header
The EGR system circulates cooled exhaust into the intake air integrated to the cast aluminum oil pan.
stream in the intake manifold. This cools the combustion process The camshaft is supported by five bushings pressed into the
and reduces the formation of NOX engine emissions. crankcase. The camshaft is crankshaft driven, and thrust is
Cold Start Assist controlled by a plate mounted behind the rear bulkhead.

A relay controlled grid (duct) heater is used in the intake air An open crankcase breather system draws crankcase vapors
stream to aid cold ambient starting. through a breather element. The breather element separates
oil from oil vapors, then routes breather air through an open
breather outlet tube assembly and returns the oil to the
crankcase through a passage in the right valve cover.

Page 19
 SECTION 1 – ENGINE SYSTEMS

Engine Description (cont.)

Crankshaft engine and aftertreatment systems to verify they are operating

within emissions limits. If an emissions fault is logged, the
The crankshaft is supported by five main bearings with fore and
Malfunction Indicator Lamp (MIL) will illuminate and one or more
aft thrust controlled at the upper half of the fourth main bearing.
fault codes will be set.
Two connecting rods are attached to each crankshaft rod journal
and are offset to minimize vibration. Piston pins are free floating, The HD-OBD system operates similarly to previous power train
allowing the pins free lateral movement within the connecting rod control systems by storing fault codes and turning on the MIL. If
as well as the piston. Piston pins are held in place with retaining the problem that caused the fault goes away, the code will clear
rings. and the MIL will go out after certain operating conditions have
been met. This may take several times operating the vehicle.
Cylinder Heads
The Crankshaft Position (CKP) sensor and the Camshaft
The cylinder heads have four valves per cylinder. Each fuel
Position (CMP) sensor are used by the ECM to calculate rpm,
injector is centrally located between the four valves and directs
fuel timing, fuel quantity, and duration of fuel injection.
fuel over the piston bowl for improved performance and reduced
emissions. Fuel System
The overhead valve train includes hydraulic roller cam followers, The high-pressure fuel system includes a High-Pressure Fuel
push rods, rocker arms, and valve bridges to open the dual Pump (HPFP), high-pressure common rails, and fuel injectors.
intake and exhaust valves. The ECM electronically controls the injectors, allowing multiple
injections and more precise fuel delivery to improve combustion,
Electronic Control System
emissions, and cold start performance.
An Engine Control Module (ECM) monitors and controls engine
The low-pressure fuel system uses an integrated low-pressure
performance to ensure maximum performance and compliance
fuel module with primary filter, secondary filter, fuel cooler, and
with EPA emissions requirements.
electric self-priming fuel pump to draw fuel from the tank(s) to
Heavy-Duty On-Board Diagnostics (HD-OBD) is a U.S. the engine. This integrated low-pressure module significantly
Government mandated standard for all 2013 and later Class 4 reduces the number of fuel lines and connection points, and
and above vehicles with a Gross Vehicle Weight Rating (GVWR) is mounted over the left valve cover. The primary fuel filter
of 14,001 pounds or more. The HD-OBD system monitors the assembly includes a Water In Fuel (WIF) sensor and an optional

Page 20
 SECTION 1 – ENGINE SYSTEMS

Engine Description (cont.)

fuel heater. Water and solids are separated from the fuel and the before they exit the exhaust pipe. The soot is captured by the
water is connected in the water separator bowl. The instrument Diesel Particulate Filter (DPF) and is periodically converted to
panel WIF lamp illuminates when water needs to be drained. A carbon dioxide (CO2) by a Regeneration (Regen) process. For
drain valve in the water separator bowl drains water out. Fuel is further information see Aftertreatment System (page 55).
discharged to the secondary fuel filter. The secondary fuel filter
assembly is pressure regulated and incorporates an air bleed
orifice to automatically purge air introduced into the system.
Optional Air Compressor
An air compressor is available for applications that require air
brakes or air suspension.
Optional Fuel Heater
A fuel heater is available and installed in the primary fuel filter
assembly. The heater warms the supply fuel to prevent waxing
during cold conditions.
Optional Coolant Heater
A coolant heater is available to raise the temperature of the
coolant surrounding the cylinders for improved performance
during cold weather startups.

Engine Features

Aftertreatment System
The engine and vehicle exhaust piping includes an
Aftertreatment System to capture soot and other particulates

Page 21
 SECTION 1 – ENGINE SYSTEMS

Engine Features (cont.)

Cold Ambient Protection (CAP) Vehicles are equipped with the EST interface for communication
between the Engine Control Module (ECM) and the EST.
CAP keeps the engine warm during cold temperatures and
may provide better fuel economy, increased operator comfort, CAN is a J1939 serial bus system, also know as the Drivetrain
and improved engine performance. This feature should only Datalink. The public Controller Area Network (CAN) provides a
be disabled for specialized applications. Engine damage may communication link between all connecting modules by sending
occur if CAP is disabled. and receiving messages.
CAP maintains engine coolant temperature by increasing engine The EST with ServiceMaxx®software communicates with the
rpm to a programmed value when ambient air temperature is ECM through the EST interface. The EST, through the public
below 32°F (0°C), coolant temperature is below 167°F (75°C), CAN, is able to retrieve Diagnostic Trouble Codes (DTCs), run
and engine has been idling at no load (or driver input) for over diagnostic tests, and view Parameter Identifiers (PIDs) from all
five minutes. inputs and outputs of the ECM.
For further information see Cold Ambient Protection (CAP) (page CAN public supports the following functions:
58).
• Transmission of engine parameter data
Electronic Governor Control
• Transmission and clearing of DTCs
The governor controls engine rpm within a safe and stable
• Diagnostics and troubleshooting
operating range.
• Programming performance parameter values
The low idle governor prevents engine rpm from dropping
below a stable speed to prevent stalling when various loads are • Programming engine and vehicle features
demanded on the engine.
• Programming calibrations and strategies in the ECM
The high idle governor prevents engine rpm from going above a
Electronic Speedometer and Tachometer
safe speed that would cause engine damage.
The engine control system calibrates vehicle speed. Any new
Electronic Service Tool (EST) Interface
speed calibration information must be programmed with an EST.

Page 22
 SECTION 1 – ENGINE SYSTEMS

Engine Features (cont.)

The tachometer signal is generated by the ECM by computing Engine Crank Inhibit (ECI)
signals for the Camshaft position (CMP) sensor and Crankshaft
ECI prevents starter engagement when the engine is running or
Position (CKP) sensor.
when the transmission is in gear.
Engine Warning Protection System (EWPS)
EWPS is designed to protect the engine from damage
by monitoring critical engine data such as engine speed,
temperature, oil pressure and coolant levels. This feature will
alert the operator by using a combination of visual and audible
warnings when critical engine parameters have been exceeded.
For further information see Engine Warning Protection System
EWPS (page 59).
Event Logging System
The event logging system, known as Trip Reporting, records
engine operation above maximum rpm (over speed), high
coolant temperature, or low oil pressure. The readings for the
odometer and hourmeter are stored in the ECM memory at the
time of an event and can be retrieved using the EST.
Fast Idle Advance
Fast idle advance increases engine idle speed for faster
warm-up to operating temperature. This occurs when the ECM
monitors Engine Coolant Temperature (ECT) sensor input and
adjusts fuel injector operation accordingly.

Page 23
 SECTION 1 – ENGINE SYSTEMS

Engine Features (cont.)

Low idle speed is increased proportionally when the ECT is Engine Optional Features
below 104°F ( 40°C) at 700 rpm to below 32°F (0°C) at 900 rpm
maximum. Cruise Control with Hardwire Cruise Switches
Service Diagnostics The Engine Control Module (ECM) controls the cruise control
feature. The cruise control system functions similarly for all
The Electronic Service Tool (EST) communicates with the control
electronic engines. Maximum and minimum allowable cruise
system through the public Controller Area Network (CAN). The
control speeds will vary based on application. To operate cruise
EST allows the user to retrieve and clear fault codes, run special
control, see appropriate Vehicle Operator Manual.
diagnostics tests, monitor control system sensors and actuators,
update control system software, and adjust special features.
Engine Fan Control
Service Interval
The engine fan control commands higher air flow through the
The service interval feature is designed to provide a visual radiator when the Air Conditioner (A/C) is on or when the coolant
reminder to the operator that the engine oil change interval or inlet air temperature goes above a set temperature.
has expired and routine maintenance procedures should be
performed. Engine Assisted Windshield Defrost (EAWD)
The term “interval” in this case is used to describe the distance, EAWD is an automated feature that assists windshield defrosting
time, or fuel used between the last maintenance performed on during cold ambient temperatures by increasing engine rpm to
the vehicle and the next maintenance that is due. heat up the engine faster.
It is essential that operators are trained to know the maintenance
Engine Exhaust Brake
schedules and instructions regarding the operation and reset
functionality of the service interval for the feature to be effective. An exhaust brake is available to provide additional brake torque
For further information see Resetting Change Engine Oil Service to reduce stress on the vehicle brakes. The exhaust brake has
Interval Message (page 76). three operation modes: OFF, LATCH, and COAST.

Page 24
 SECTION 1 – ENGINE SYSTEMS

Engine Optional Features (cont.)

Idle Shutdown Timer (IST) 2012 and newer model year vehicles with U.S. Federal
MaxxForce® 7 engines have idle time that can be programmed
IST allows the ECM to shut down the engine during extended
from 2 to 120 minutes.
engine idle times.
For further information see Engine Shutdown (page 56).

In-Cab Power Take-off (PTO) Control

The in-cab engine speed control feature, commonly referred to
as Power Take-off (PTO), allows the operator to set and maintain
a constant engine speed without using the accelerator pedal. It
is commonly used for powering auxiliary devices.
Customer programmable parameters within the Engine Control
Module (ECM) provide in-cab engine speed control related
options that can be adjusted to suit the customer's needs.
Choosing whether the operator is allowed to increase the engine
speed using the accelerator pedal without disengaging the PTO
is an example.
Figure 3 Certified Clean Idle label

Vehicles that comply with the clean idle regulations will have
a Certified Clean Idle label applied to the hood or door of the
vehicle.
2010 and 2011 model year vehicles with (non-California) U.S.
Federal MaxxForce® 7 engines have idle time that can be
programmed from 2 to 120 minutes.

Page 25
 SECTION 1 – ENGINE SYSTEMS

Engine Optional Features (cont.)

Radiator Shutter Enable (RSE) Road Speed Limiting (RSL)

RSE provides a signal to open or close the radiator shutters. RSL is designed to regulate the maximum vehicle speed as
Closing the shutters will keep the engine warm during cold controlled by the accelerator pedal.
weather operation. This provides faster warm-up of the
Customer programmable parameters within the ECM provide
passenger cab and enables faster windshield defrosting.
vehicle speed governor related options that can be adjusted
Remote Engine Speed Control (RESC) to suit the customer's needs. A parameter is used to set the
maximum accelerator controlled vehicle speed.
RESC, commonly referred to as remote PTO, provides a method
for an operator to set and maintain engine speed without using Additional programming flexibility is included to allow a trade-off
the accelerator pedal. It is commonly used for powering auxiliary to be made between performance and fuel economy.
devices.
When control over engine speed is required from outside the
vehicle's cab, remote mounted switches must be used to turn on
PTO engine speed control and select the desired engine speed.
Engine speed can be ramped up and down with RESC similar
to the way the in-cab PTO feature works; however, the RESC
feature includes two additional switches (remote preset and
remote variable), which allow the operator to choose the mode
of engine speed control operation.
Customer programmable parameters within the ECM provide
RESC related options that can be adjusted to suit the customer's
needs. Choosing whether a remote throttle pedal is used for
PTO operation is an example.

Page 26
 SECTION 1 – ENGINE SYSTEMS

Component Location – Top

Figure 4 Top
1. Pump cover heat shield (right) 9. Turbocharger outlet 15. Turbocharger inlet duct assembly
2. Right exhaust tube assembly 10. Turbocharger Outlet Temperature (TCOT) 16. Primary Freon compressor mount
3. Exhaust turbocharger inlet manifold sensor 17. Turbocharger oil supply tube
4. Left exhaust tube assembly 11. Manifold mixer (exhaust emission label 18. Low-pressure turbocharger assembly
5. Exhaust Gas Recirculation (EGR) cooler location) 19. Heater supply
6. High-pressure turbocharger assembly 12. EGR valve 20. Thermal Management Valve (TMV)
7. Engine coolant vent 13. Inlet Air Heater (IAH)
8. Air compressor assembly 14. Engine Throttle Valve (ETV)

Page 27
 SECTION 1 – ENGINE SYSTEMS

Component Location – Front

Figure 5 Front
1. Grooved idler pulley 5. Lifting eye (2) 9. Vibration damper and pulleys
2. Fan pulley 6. Air compressor pulley 10. Heater return
3. Flat idler pulley (2) 7. Coolant inlet 11. Thermostat housing (coolant outlet)
4. Belt tensioner (3) 8. Water pump pulley

Page 28
 SECTION 1 – ENGINE SYSTEMS

Component Location – Left

Figure 6 Left
1. Oil fill tube cap 9. Left valve cover 17. Power Take Off (PTO) air compressor
2. Oil level gauge (dipstick) 10. Left exhaust tube assembly front pulley
3. Fuel supply port (from tank) 11. Left exhaust manifold 18. Auxiliary Freon compressor mounting
4. Primary fuel filter housing 12. Starter motor mounting location bracket
5. Secondary fuel filter housing 13. Oil filter 19. Oil level gauge tube
6. Fuel cooler 14. Diagnostic test port (oil pressure port) 20. Water drain valve
7. Fuel return port (to tank) 15. Power steering return tube
8. Fuel pump 16. Power steering supply tube

Page 29
 SECTION 1 – ENGINE SYSTEMS

Component Location – Right

Figure 7 Right
1. Breather filter cover 7. Front engine mounting support 12. Rear crankcase cover assembly (flywheel
2. Engine Throttle Valve (ETV) 8. Inner front pulley (alternator and primary housing)
3. Primary Freon compressor mounting Freon compressor) 13. Power steering pump
4. Fan clutch mounting 9. Oil pan drain plug 14. Draft tube assembly
5. Thermostat housing 10. Oil pan 15. Rear engine mounting bracket (2)
6. Power Take Off (PTO) air compressor 11. Right exhaust manifold 16. Right exhaust tube assembly
front pulley 17. Right valve cover

Page 30
 SECTION 1 – ENGINE SYSTEMS

Component Location – Rear

Figure 8 Rear
1. Exhaust Gas Recirculation (EGR) cooler 6. Draft tube assembly 9. High-pressure pump cover heat shield
2. Exhaust turbocharger inlet manifold 7. Rear crankcase cover assembly (flywheel (right)
3. Low-pressure turbocharger assembly housing) 10. Rear engine mounting bracket (2)
4. Right exhaust tube assembly 8. Flexplate 11. Left exhaust tube assembly
5. Lifting eye

Page 31
 SECTION 1 – ENGINE SYSTEMS

Page 32
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Fuel
ULTRA LOW SULFUR DIESEL (ULSD) GOVERNMENT REGULATION: Diesel fuel sold for
use in 2007 and later highway vehicles must be limited
to a sulfur content of 15 parts per million (ppm).

Ultra Low Sulfur Diesel (ULSD) fuel is required for MaxxForce®

7 Diesel Engines used with advanced aftertreatment systems.
The fuel should meet all the specifications of ASTM D975
standard (current year revision), including the EPA specification
for sulfur content (0.0015 % mass or 15 ppm maximum). These
specifications are included in 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 higher volatility than grade No. 2-D; it may
be blended with grade No. 2-D in wintertime to provide engine
operability under low ambient temperature.

UNACCEPTABLE FUEL AND BLENDS

Figure 9 American Petroleum Institute (API) Diesel Pump • Low Sulfur Diesel (LSD) fuel 0.05% (500 ppm)
Label
• Commercial Jet A or JP8 aviation fuel
• Heating or furnace oil
The API Diesel Pump Label is compliant with Environmental
• Biodiesel B100 (neat biodiesel)
Protection Agency (EPA) CFR 80.570.
• Biodiesel blends higher than 20%
• Any fuel mixed with used motor oil

Page 33
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Fuel (cont.)
UNACCEPTABLE FUEL AND BLENDS (cont.)

Biodiesel fuels are methyl or ethyl esters derived from a broad USE OF HIGHER BIODIESEL FUEL BLENDS (B6 TO B20)
variety of renewable sources such as vegetable oils, animal fats,
and waste cooking oils. These oxygenated organic compounds Standard ASTM D7467 (current revision) covers the
have key properties that are comparable to those in diesel fuel. specifications for blends between 6% and 20% (B6 to B20).
These blends may be used in vehicles that operate in populated
ACCEPTABLE FUEL BLENDS areas or in fleets that require use of alternative fuels to reduce
urban pollution.
• Ultra low sulfur kerosene (No. 1-D S15 diesel fuel) blended
Use of B6 to B20 blends is at the discretion of the customer
with No. 2-D S15 fuel to improve cold weather performance.
/ operator and will not automatically void an engine warranty.
Blend rate would depend upon regional low temperatures.
However, if engine component failure can be directly attributable
• Lower biodiesel blends up to B5 (a blend of 5% neat to use of a B6 to B20 blend not provided by a BQ9000 certified
biodiesel with 95% diesel fuel). fuel supplier or not meeting the ASTM D7467 (current revision)
Standard, Navistar may deny warranty on the affected engine or
Such blends have characteristics indistinguishable from
engine component.
diesel fuel, if the two components meet the requirements of
their respective standards: ASTM D6751 current revision, Navistar, Inc. recommends that users of B20 select a BQ9000
for neat biodiesel and ASTM D975 current revision, for ultra certified fuel supplier and request proof from the supplier the
low sulfur diesel fuel. fuel meets ASTM D7467 (current revision) Standard. Fuels
not meeting the specification may cause fuel system deposits,
As of 1 October 2008, blends of up to 5% biodiesel are
plugged filters, contaminated engine oil, and fuel degradation.
included in the diesel fuel Standard ASTM D975-08a
(D975-08a designates the 2008 revision of the standard). If providers and customers follow correct storage and
maintenance procedures for fuel and equipment, blends of B6 to
Navistar, Inc. approves of blends up to B5, provided that the
B20 that meet ASTM D7467 (current revision) Standard should
two components satisfy current standard specifications. Quality
perform satisfactorily in diesel engines. Contact your dealer
biodiesel blends up to B5 should not cause engine or fuel system
for recommendations for correct storage and maintenance
problems.
procedures.

Page 34
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

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

Navistar, Inc. follows the official position of the Truck and Engine Oil
Engine Manufacturers Association (EMA) on biodiesel fuel. See
www.truckandenginemanufacturers.org for more information. ENGINE OIL QUALITY AND SERVICE CATEGORIES

UNSAFE PRACTICES The American Petroleum Institute (API) defines engine oil quality
by service categories that define oil performance measured in
standardized engine tests.
WARNING: To prevent personal injury or death, do
not mix gasoline, gasohol, or alcohol with diesel fuel. An API CJ-4 FOR HIGH PERFORMANCE DIESEL ENGINES
open heat source, spark, cell phone or electronic device
can ignite these fuel mixtures. This creates a fire hazard
and possible explosion.

CAUTION: To prevent engine damage, do not mix propane with

diesel fuel. Navistar, Inc. will not honor warranty claims against
engines that have used propane.

Figure 10 API Identification Symbol

API CJ-4 oils are recommended for high speed diesel engines
with advanced exhaust aftertreatment systems that meet 2007
and beyond on-highway exhaust emission standards.

Page 35
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Engine Oil (cont.)

API CJ-4 FOR HIGH PERFORMANCE DIESEL ENGINES
(cont.)

NOTE: Mineral and synthetic oils are acceptable for use OIL VISCOSITY
provided they meet the API category recommendations and
ambient temperature guidelines. Always follow recommended
oil change guidelines no matter what oil is used.
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 required to Figure 11 SAE Viscosity Grades And Temperature Ranges
maintain performance and durability of aftertreatment systems
meeting 2007 and beyond diesel emission regulations.
The Society of Automotive Engineers (SAE) defines oil viscosity
API CI-4 oils are allowed in diesel engines that meet these
(thickness) by grade. Colder temperatures require lower grade
regulations. Use of the CI-4 engine oil shortens Diesel
Particulate Filter (DPF) cleaning service intervals.

Page 36
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Engine Oil (cont.)

OIL VISCOSITY (cont.)

oils for correct flow during starting. Higher temperatures require EXTENDED LIFE COOLANT (ELC) - RED
higher grade oils for satisfactory lubrication.
Heavy Duty Extended Life Coolant (ELC) 50 / 50 Premix
• A block coolant heater is required, if temperatures are below meeting CEMS B-1 Type III is the standard factory fill for the
10°F (-12°C). cooling system. The coolant should minimally meet ASTM
• A block coolant heater and oil pan heater are required, if D6210, Standard Specification for fully Formulated Glycol Base
temperatures are below -10°F ( -23°C). Engine Coolant for Heavy Duty Engines.

• For heavy duty driving or trailer towing, higher oil grades ELC 50 / 50 Extender is added at the designated service
15W-40 and 5W-40 oils are required, if temperatures are interval. For further information see Extended Life Coolant
over 50°F (10°C). (ELC) Extender (page 89).

Freeze Point Protection Levels Concentrate (Ethylene

Coolant Glycol) and Water Mixtures
Concentrate and Water Freeze Point Protection
COOLANT MIXTURES
Mixtures
Engine coolant mixtures include water, glycol (ethylene or 40% Concentrate and 60% -12°F (-24°C)
propylene), and inhibitors. Conventional and fully formulated water
coolants require regular testing of inhibitor levels to maintain
50% Concentrate and 50% –34°F (37°C)
safe levels of protection. Testing of conventional coolant
water
determines levels of nitrite, nitrite / molybdate, and freeze
point protection. If necessary, Supplemental Coolant Additives 60% Concentrate and 40% –62°F (52°C)
(SCAs) are added to replenish inhibitors. water

Extended life coolant mixtures (water and ethylene glycol) do 67% Concentrate and 33% -95°F (-71°C)
not require regular testing of inhibitor levels or addition of SCAs. water
See service intervals (page 63).

Page 37
 SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Coolant (cont.)
EXTENDED LIFE COOLANT (ELC) - RED (cont.)

For vehicles operating in extremely cold climates, coolant

mixtures of 60% Concentrate and 40% water or 67%
Concentrate and 33% water provide additional freeze protection
as shown in table above. Mixtures having more than 67%
Concentrate are not recommended.
For further information see Coolant Freeze Point (page 78).

CONTAMINATION OF COOLANT

The coolant color should indicate the condition of the coolant.

• Coolant color should be a reddish orange (clear – not
cloudy).
• Coolant must not have floating debris or visible oil.
Contamination of ELC with other coolant products will not be
obvious.
To verify coolant quality, contact an authorized service provider,
or use a refractometer to verify coolant strength. For further
information see Freeze Point Protection Levels Concentrate and
Water Mixtures(page 37).

Page 38
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Instrument Panel Gauge Cluster Wait to Start Lamp

During engine starts and engine operation, gauges and indicator
lamps should be checked periodically.
Gauges may vary with vehicle applications. Warning and
indicator lamps show conditions not indicated by the gauges.
See the Vehicle Operator Manual for description of indicator
lamps for the drivetrain, chassis components, and cabin.
Figure 12 Wait To Start Lamp

Warning Lamps
The Wait To Start lamp will illuminate Yellow when inlet air heater
Warning lights signal when a reading is outside preset limits. is required. Wait until the lamp goes off before cranking engine.
For further information see Starting the Engine (page 51).
• Warning lamps indicate situations that must be inspected
before operating the vehicle.

Page 39
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Idle Shutdown Indicator Maintenance Lamp

Figure 14 Maintenance Lamp

Figure 13 Idle Shutdown Indicator
The Maintenance lamp will illuminate in conjunction with other
warning lights or general text and warning messages. It may be
The Idle Shutdown indicator will illuminate Yellow when the accompanied by an audible alarm to indicate an alert condition
vehicle shutdown timer will turn the engine off in 30 seconds. to the operator.
For further information see Engine Idle Shutdown Timer (page
56).

Page 40
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Amber Warning Lamp (AWL) Red Stop Lamp (RSL)

Figure 15 AWL
Figure 16 RSL

The Amber Warning Lamp (AWL) will illuminate YELLOW by

itself, or in conjunction with other warning lights or general CAUTION: To prevent engine damage, shut down engine
text and warning messages, to indicate an alert condition to immediately , if the Red Stop Lamp flashes.
the operator. This lamp indicates the Engine Control Module
(ECM) is taking action to protect the engine. It is normal for The Red Stop Lamp will flash and an alarm will sound when a
this lamp to illuminate under certain high load and / or high serious problem arises. The lamp is used in conjunction with
ambient temperature conditions. It is safe to drive the vehicle. other warning lights or general text and warning messages
However, if the lamp continues to light or remains on, contact to indicate a STOP alert. For further information see Engine
an authorized service provider immediately to have the problem Warning Protection System (EWPS) (page 59). Consult an
corrected. authorized service provider immediately to correct the problem.

Page 41
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

High Exhaust System Temperature (HEST) Lamp Diesel Particulate Filter (DPF) Indicator

Figure 17 HEST Lamp Figure 18 Diesel Particulate Filter Indicator

The diesel particulate filter indicator operates at three different

WARNING: Exhaust components are operating under levels.
normal conditions and exhaust gases are at extremely high
temperatures. When stationary, keep away from people Level One
and flammable materials, vapors, or structures, or stop the • DPF indicator will illuminate solid and remain on when the
engine. levels of soot exceed acceptable levels. The regeneration
The HEST lamp will illuminate when the exhaust system is hot process should begin by using either of the following two
and regeneration is in progress. For additional information see methods. The lamp will turn off when the regeneration
the applicable Vehicle Operator Manual. process is complete.
• The vehicle can be safely driven on the highway at
highway speeds while the regeneration process is in
operation.
• The vehicle should be parked in a safe location and
start the Parked Regeneration process to prevent loss
of power.

Page 42
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Diesel Particulate Filter (DPF) Indicator (cont.)

Level Two Malfunction Indicator Lamp (MIL)
The DPF indicator will be flashing indicating the exhaust filter
is full. The vehicle should be safely pulled off the roadway
and parked. Start the Parked Regeneration process to prevent
loss of engine power. The lamp will stop flashing when the
regeneration process is complete. For additional information
see the applicable Vehicle Operator Manual.

Level Three

WARNING: Pull vehicle safely off roadway and start

Parked Regeneration to prevent engine stopping.
The DPF indicator will be flashing and an alarm will beep
continuously while the ignition is on. This indicates the exhaust
filter is full and engine performance is limited. Pull the vehicle
safely off the roadway and start Parked Regeneration process
to prevent the engine from stopping. For additional information
Figure 19 MIL
see the applicable Vehicle Operator Manual.

The Malfunction Indicator Lamp (MIL) illuminates when the

Heavy-Duty On-Board Diagnostics (HD-OBD) system detects
a malfunction related to the emissions control system. The
illuminated MIL indicates the vehicle needs to be serviced at
the first convenient opportunity. Lamp may remain active after
repair until system operation confirms repair.

Page 43
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Typical Water Temperature Gauge CAUTION: To prevent engine damage do not operate engine
above 228°F (109°C); this may cause internal damage.
The indicator lamp will be activated at engine coolant
temperatures above 228°F (109°C). If engine temperature
suddenly rises, shut down engine and determine the cause
of overheating. If necessary, contact an authorized service
provider.

Figure 20 Water Temperature Gauge

The water temperature gauge indicates the temperature of

coolant in the cooling system. The gauge operates only when
the ignition switch is turned to ON. Normal engine operating
temperature is 190°F – 228°F (88°C – 109°C).

Page 44
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Oil Temperature Gauge Oil Pressure Gauge

Figure 22 Oil Pressure Gauge

Figure 21 Oil Temperature Gauge

The engine oil pressure gauge indicates operating oil pressure.

The engine oil temperature gauge indicates the oil temperature The engine oil pressure indicator lamp and alarm will be
of the engine. activated when oil pressure falls below acceptable levels.
Shut down the engine immediately if the lamp and alarm are
activated. Contact an authorized service provider immediately
to have the problem corrected.

Page 45
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Oil Pressure Gauge (cont.)

Lubrication Oil Pressure Engine Exhaust Brake On / Off Toggle Switch
Lube Oil Pressure
At normal operating temperature
Low idle 12 psi (83 kPa) min.
High idle 45 psi (310 kPa)

CAUTION: To prevent engine damage, shut down engine

immediately if the oil pressure indicator lamp and alarm are
active.

Figure 23 Exhaust Brake Toggle Switch

The exhaust brake toggle switch turns the engine exhaust brake
ON or OFF.

Page 46
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Air Cleaner Restriction Indicator induction system or instrument panel depending on your specific
application.
Air restriction is resistance of airflow through the air cleaner.
Accurate air restriction is measured at maximum airflow. Air Restriction Indicator Calibration
• The indicator is calibrated in inches of water.
• The indicator should be tested periodically (using a master
vacuum gauge) to ensure a correct calibration.
Air Restriction Indicator Operation
• The yellow position indicator progressively fills the window
as air filter restriction increases, locking at the highest
restriction at full load.
• When the yellow position indicator reaches and locks in the
red zone, a new air filter should be installed at the earliest
convenience.

NOTE: If the yellow indicator locks in the red zone, it is not

necessary to shut down the engine immediately, but a new air
filter should be installed at the earliest convenience.
Air Restriction Indicator Reset
• Once the filter has been changed, reset the air restriction
indicator as follows:
Figure 24 Air Cleaner Restriction Indicator
• If the air restriction indicator is mounted on the air
cleaner, push the button on the indicator to reset.
Air cleaner restriction is measured by an air restriction indicator.
The restriction indicator may be located anywhere within the air

Page 47
 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Page 48
 SECTION 4 – ENGINE OPERATION

Preoperation Checklist 7. Check belt condition and alignment.

8. Fill the tank with recommended fuel. For further information
WARNING: To prevent personal injury or death, see Acceptable Fuel Blends (page 34).
provide ventilation when operating an engine in a closed 9. Inspect exhaust system for obstruction or damage.
area. Inhalation of exhaust gas can be fatal.
10. Drain water from fuel system.
This engine has been given predelivery and delivery service by
your dealer and is ready for operation. The operator should fully
understand the use and function of all controls and instruments.
1. Check cooling system level.
CAUTION: To prevent engine damage, do not overfill with oil.

Figure 25 Oil Level Gauge (Typical)

2. Check for correct oil level.

3. If oil level is below operating range, fill with recommended
oil for operating climate. The ADD mark indicates 2 quarts
(1.9 liters) of oil should be added. For further information
see Engine Oil Quality and Service Categories (page 35).
4. Inspect for coolant, fuel or oil leaks.
5. Inspect air cleaner and piping for tightness and correct
installation of filter element.
6. Check for loose or hanging electrical connections.

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 SECTION 4 – ENGINE OPERATION

Priming the Fuel System 3. There are two ways to prime the fuel system; use only
one of the following two ways.

PRIMING THE FUEL SYSTEM AFTER SERVICING THE

GOVERNMENT REGULATION: Engine fluids FUEL FILTERS
(oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and 1. Prime the engine after the primary and secondary fuel filters
other contaminated materials (e.g. filters, rags) in have been serviced as follows:
accordance with applicable regulations. Recycle
a. Key - On for 10 seconds
or dispose of engine fluids, filters, and other
contaminated materials according to applicable b. Key - Off for 15 seconds
regulations.
c. Key - On for 10 seconds
d. Key - Off for 15 seconds

WARNING: To prevent property damage, personal e. Key - On for 10 seconds

injury and / or death, shift transmission to park or neutral, 2. Check for fuel leaks prior to starting engine. If leaks are
set parking brake, and install wheel chocks before doing found, correct the problem.
diagnostic or service procedures.
3. Start the engine and check for leaks. For further information
see Starting the Engine (page 51).
WARNING: To prevent personal injury or death, do not
4. If leaks are found, shut down the engine and correct the
smoke and keep fuel away from open flames and sparks.
problem.
CAUTION: To prevent engine damage, do not add fuel to the 5. If engine does not start, see the Engine Diagnostic Manual.
fuel filter header. This can contaminate the fuel.
1. Set parking brake and shift transmission to park or
neutral.
2. Verify water drain valve on primary fuel filter housing is
closed and fuel filter caps are on tight.

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 SECTION 4 – ENGINE OPERATION

Priming the Fuel System (cont.)

PRIMING THE FUEL SYSTEM AFTER RUNNING OUT OF Starting the Engine
FUEL

1. If the vehicle has run out of fuel, turn ignition switch to OFF WARNING: To prevent personal injury or death, do not
and fill the fuel tank(s). Prime the engine fuel system with use ether, propane, gasoline or gasohol as starting aids.
seven Key ON / Key OFF sequences as follows:
a. Key - Off for 20 seconds WARNING: To prevent personal injury or death, do not
install ether start equipment, if an engine has an intake air
b. Key - On for 15 seconds heater or other cold climate starting aid.
2. Check for fuel leaks prior to starting engine. If leaks are
found, correct the problem. WARNING: To prevent personal injury or death, do not
3. Start the engine and check for leaks. For further information use ether starting fluid to start engine.
see Starting the Engine (page 51).
4. If leaks are found, shut down the engine and correct the
problem.
5. If engine does not start, see the Engine Diagnostic Manual.

Figure 26 Ignition Switch Positions

1. Set parking brake and shift transmission to park or neutral.

Page 51
 SECTION 4 – ENGINE OPERATION

Starting the Engine (cont.)

CAUTION: To prevent damage to the engine, do not depress the CAUTION: To prevent damage to the engine, if the engine fails
accelerator pedal. to start within 20 seconds, do the following:
2. Depress clutch pedal if equipped. • Turn ignition switch to OFF and wait 2 to 3 minutes.
3. Turn ignition switch to ON to preheat the grid (duct) heater. • Repeat Steps 1 – 6.
• If after three attempts the engine does not start, determine
NOTE: The Engine Control Module (ECM) normally does not
the cause.
energize the grid (duct) heater during hot starts. However, the
ECM senses reduced atmospheric pressure at high altitude and • If starting attempts are continued, the starter motor can be
could energize the grid (duct) heater during hot starts. damaged.
4. Watch for the WAIT TO START lamp to go off. Do not crank 8. Warm engine low idle speed is 700 rpm (nonadjustable).
engine until the lamp is off. Extended idling periods should be avoided. For further
information, seeExtended Idling Periods. Check all gauges
NOTE: Observe battery voltage gauge while cranking the during warm-up.
engine. If voltage drops below 10V recharge batteries, or
9. Within 20 – 30 seconds after engine start, engine oil
replace batteries if needed.
pressure should exceed 12 psi (83 kPa).
5. When the WAIT TO START lamp goes off, turn ignition
switch to START. If the engine has push button starting, CAUTION: To prevent engine damage – do not increase engine
press and hold starter button. speed until oil pressure gauge indicates normal. If oil pressure
does not reach the minimum limit within 20 – 30 seconds, shut
6. When the engine starts, release the ignition switch or starter down engine.
button. The ignition switch will return to ON and the engine
will continue to run. 10. If oil pressure, at low idle, does not meet the minimum limit
12 psi (83 kPa), stop the engine and correct the problem.
7. With the transmission in neutral, release clutch pedal, if
equipped.

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 SECTION 4 – ENGINE OPERATION

Emergency Starting 4. Connect one end of the first jumper cable to the positive (+)
terminal of the dead battery or to the positive (+) terminal of
the jump start stud. Connect the other end to the positive (+)
WARNING: To prevent personal injury or death, do not terminal of the booster battery.
use ether starting fluid to start the engine.

WARNING: To prevent personal injury or death, do not

WARNING: To prevent personal injury or death, do the
attach jumper cable to the negative (-) terminal of the dead
following when jump starting an engine:
battery and the negative (-) terminal of the booster battery.
• Wear eye protection. This can cause sparks and an explosion.
• Do not smoke. 5. Connect one end of the second jumper cable to the negative
(-) terminal of the charged battery and the other end to
• Keep flames and sparks away from battery.
chassis frame of the vehicle with the dead battery.
• Protect against inhaling hydrogen gas fumes from battery.
6. Start engine in vehicle that has the charged battery.
• Use a 12-volt system with a negative ground.
7. Start engine in vehicle that has the dead battery.
• Do not exceed 16.0 volts, if the ignition switch is turned to
OFF, ACC or ON during engine cranking.
WARNING: To prevent personal injury or death,
CAUTION: To prevent engine damage, do not allow metal tools always disconnect jumper cable from negative contacts
to contact positive terminal of battery. first.
1. Set parking brake and shift transmission to Park or Neutral. 8. Disconnect jumper cable from negative terminal and chassis
frame.
2. Shut off lights, heater, air conditioner, and other electrical
loads in both vehicles. 9. Disconnect jumper cable from positive battery terminals or
one terminal and jump start stud.
3. Make sure vehicles are not touching.

WARNING: To prevent personal injury or death,

always connect jumper cable for positive battery terminals
first.

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 SECTION 4 – ENGINE OPERATION

Operation IDLE SPEED

SUGGESTED WARM-UP TIME

WARNING: To prevent personal injury or death,
provide ventilation when operating an engine in a closed
NOTE: The warm–up period allows lubricating oil to establish a
area. Inhalation of exhaust gas can be fatal.
film between moving parts. Keep the engine lower than 1800
rpms and below half throttle for the first 5 minutes. Low idle speed for the MaxxForce® 7 Diesel Engines is 700
rpm (nonadjustable). If the engine coolant temperature is below
Cold ambient engine warm-up time can be reduced by operating 167°F (75°C) and CAP is enabled, the Engine Control Module
the engine under load at reduced engine speed. Begin normal (ECM) adjusts the low idle speed from 700 rpm to a maximum of
operation when engine systems reach operating temperature. 1400 rpm. High idle speed (2950 rpm) is a nonadjustable factory
The Cold Ambient Protection (CAP) system aids in engine setting.
warm-up and maintains engine heat during extended idling
periods. For further information seeExtended Idling Periods.

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 SECTION 4 – ENGINE OPERATION

Operation (cont.)
EXTENDED IDLING PERIODS AFTERTREATMENT SYSTEM

CAUTION: To prevent engine damage, do not extend low idle The engine and vehicle exhaust piping includes an
periods. Aftertreatment System to capture soot and other particulates
before they exit the exhaust pipe. The soot is captured by the
Extended idling periods should be avoided. Diesel engine
Diesel Particulate Filter (DPF) and is periodically converted to
efficiency is improved when the cylinder temperature remains
carbon dioxide (CO2) by a Regeneration (Regen) process.
high. Low temperature in cylinders may cause the following:
The Regen process may take place during vehicle operation
• Unburned fuel may seep from exhaust manifold gaskets and
(Active Regen). The Active Regen process will be triggered by
vehicle exhaust system connections. This seepage has the
either a time-based soot or a soot mass buildup-based strategy.
dark colored appearance of lubricating oil.
A Parked Regen process is required when sufficient thermal
• Incomplete combustion and unburned fuel will wash
energy has not been present to initiate the process for Diesel
lubricating oil from cylinder sleeves. Unburned fuel will be
Oxidation Catalyst (DOC) light off. The vehicle is required to be
carried into the lubricating oil, dilute the oil, and change oil
parked (stationary).
viscosity.
• A Parked Regeneration will be requested if the Regeneration
• Carbon will form on internal components of turbocharger
cannot be completed during driving.
and Exhaust Gas Recirculation (EGR), reducing engine
efficiency. • In this case, a dash-mounted lamp will be lit to alert the driver
to perform a Parked Regeneration.
• Carbon will clog and damage the Diesel Particulate Filter
(DPF). • The driver must park the vehicle and then perform the Regen
as required.
• Follow the Parked Regeneration process listed in the Vehicle
Operator Manual.
• If the Parked Regeneration process is ignored, the engine
may stop running.

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 SECTION 4 – ENGINE OPERATION

Operation (cont.)
AFTERTREATMENT SYSTEM (cont.)

• See “Safety Information” (page 3) for safety precautions. • Engine speed is not at idle speed (700 rpm).
A DOC operates to oxidize the injected fuel to increase the • Vehicle movement or a Vehicle Speed Sensor (VSS) fault is
exhaust gas temperature as needed for DPF Regen. detected.
• Manual DPF Regeneration is enabled (Parked Regen).
ENGINE IDLE SHUTDOWN TIMER (U.S.
FEDERAL-OPTIONAL [2010 AND 2011 VEHICLES]) • Accelerator pedal movement or an Accelerator Position
Sensor (APS) fault is detected.
• Engine coolant operating temperature is below 140°F
GOVERNMENT REGULATION: State and local (60°C).
regulations may limit engine idle time. The vehicle • Ambient temperature is below 60°F (16°C) or above 110°F
owner or operator is responsible for compliance with (44°C).
these regulations.
• Brake pedal movement is detected or a brake switch fault is
detected.
The optional Idle Shutdown Timer (IST) allows the Engine
• Parking brake transition is detected.
Control Module (ECM) to shut down the engine during extended
idle. Idle time can be programmed from 2 – 120 minutes. The • Clutch pedal is pressed or clutch pedal switch fault is
ECM can be programmed to deactivate the IST when the PTO detected (manual transmissions, if equipped with a clutch
is active. switch).
Thirty seconds before engine shutdown, the IDLE SHUTDOWN • Shift selector is moved from neutral (automatic
indicator illuminates. This continues until the engine shuts down transmissions).
or the low idle shutdown timer is reset. The engine must be out of
• If the IST is enabled, the Cold Ambient Protection (CAP) will
gear for the IST to work. Engine shutdown timer will deactivate
not function.
for one or more of the following conditions:

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 SECTION 4 – ENGINE OPERATION

Operation (cont.)
ENGINE IDLE SHUTDOWN TIMER (CALIFORNIA AND ALL work. Engine shutdown timer will deactivate for one or more of
STATE - OPTIONAL [2012 AND NEWER VEHICLES]) the following conditions:
• Engine speed is not at idle speed (700 rpm).
• Vehicle movement or a Vehicle Speed Sensor (VSS) fault is
GOVERNMENT REGULATION: State and local detected.
regulations may limit engine idle time. The vehicle
owner or operator is responsible for compliance with • Manual DPF regeneration is enabled (Parked Regen).
these regulations. • Accelerator pedal movement or an Accelerator Pedal
Sensor (APS) fault is detected.
Your heavy duty diesel engine conforms to applicable California • Engine coolant operating temperature is below 60°F (16°C).
Air Resources Board (CARB) Engine Shutdown System (ESS)
• Brake pedal movement or a brake switch fault is detected.
regulations. This vehicle is registered and certified for sale in
California. • Parking brake transition is detected.
The CARB Idle Shutdown Timer (IST) allows the Engine Control • Clutch pedal is pressed or clutch pedal switch fault is
Module (ECM) to shut down the engine during extended idle. detected (manual transmissions, if equipped with a clutch
When parking brake is set, the idle time can be programmed up switch).
to 5 minutes. When parking brake is released, the idle time can
• Shift selector is moved from neutral (automatic
be programmed up to 15 minutes. No parking brake, the idle
transmissions).
time can be programmed up to 15 minutes. During service, the
idle time can be programmed up to 60 minutes. The ECM will • If the IST is enabled, the Cold Ambient Protection (CAP) will
deactivate the IST when the PTO is active. not function.
Thirty seconds before engine shutdown, the IDLE SHUTDOWN
indicator in the instrument panel gauge cluster illuminates. This
continues until the engine shuts down or the low idle shutdown
timer is reset. The engine must be out of gear for the IST to

Page 57
 SECTION 4 – ENGINE OPERATION

Operation (cont.)
COLD WEATHER OPERATION • Check oil level.
• Clean external surfaces of the engine and accessories
NOTE: If operating in temperatures below -20°F (-29°C), contact
to prevent dirt or snow buildup.
an authorized service provider for information about special cold
weather equipment and precautions. • Clean outside and in between radiators to prevent dirt
or snow buildup.
NOTE: At temperatures below 10°F (-12°C), a crankcase
mounted cup plug coolant heater is recommended to improve COLD AMBIENT PROTECTION (CAP)
cold starting.
CAP safeguards the engine from damage caused by prolonged
1. Before operating the engine at 32°F (0°C) or lower, check or idle at no load during cold weather. This feature should only be
service the following: disabled for specialized applications. Engine damage may occur
• Correct battery size if CAP is disabled.

• Correct amount of electrolyte, if not a maintenance free CAP maintains engine coolant temperature by increasing engine
battery rpm to a programmed value when ambient air temperature is
below 32°F (0°C), coolant temperature is below 167°F (75°C),
• Full battery charge and engine has been idling at no load for over 5 minutes.
• Condition of other electrical equipment The engine speed continues to increase or decrease to maintain
• Cooling system hoses for leaks a coolant temperature of 194°F (90°C) until the following occurs:

• Correct coolant and cooling system level • Engine load is greater than 45%.

• Recommended oil grade • Brake pedal is applied or brake switch fault is detected.

2. At the end of each daily operation do the following: • Clutch pedal is pressed or clutch pedal switch fault is
detected (manual transmissions, if equipped with a clutch
• Fill the fuel tank with correct fuel. switch).
• Drain water from the fuel filter housing.

Page 58
 SECTION 4 – ENGINE OPERATION

Operation (cont.)
COLD AMBIENT PROTECTION (CAP) (cont.)

• Shift selector is moved from neutral (automatic 2. At the end of each daily operation do the following:
transmissions). Shift selector must be in neutral for CAP
• Fill the fuel tank with correct fuel.
to work.
• Drain water from the fuel filter housing.
• Power Takeoff (PTO) switch, also used for electronic hand
throttle, is turned on and actively controls engine speed. • Check oil level.
• Accelerator pedal is pressed or Accelerator Pedal Position • Clean external surfaces of the engine and accessories
(APP) fault is detected. to prevent dirt build up.
• IST is enabled (2010 and 2011 vehicles only). • Clean outside and in between radiators to prevent dirt
build–up.
• Engine Coolant Temperature (ECT) sensor fault is detected.
• Intake Air Temperature (IAT) ambient temperature sensor ENGINE SHUTDOWN
fault is detected.
Before shutting down an engine that has reached operating
HOT WEATHER OPERATION temperature, idle the engine for 30 seconds, allowing the hottest
engine components to dissipate some of their internal heat.
1. Before operating the engine above 32°F (0°C), check or
• Idling is recommended, if an engine has been running at
service the following:
maximum horsepower.
• Full battery charge
ENGINE WARNING PROTECTION SYSTEM (EWPS)
• Condition of other electrical equipment
• Cooling system hoses for leaks The Engine Warning Protection System (EWPS) warns the
operator of engine conditions that can damage the engine.
• Correct coolant and cooling system level Optional engine shutdown is available and is activated if one or
more critical conditions are detected.

Page 59
 SECTION 4 – ENGINE OPERATION

Operation (cont.)
ENGINE WARNING PROTECTION SYSTEM (EWPS) (cont.)

The Standard Warning System is the base system in which Standard Warning
all engines are equipped. If one of these faults is detected,
• The engine will not shut down and will warn of an engine
the ECM will illuminate the Amber Warning Lamp (AWL), set a
fault.
corresponding Diagnostic Trouble Code (DTC), and de-rate the
engine. • RPM - Engine over-speed warning.
• Engine Coolant Temperature (ECT) - Engine overheat
warning.
• EOT - Engine Oil Temperature overheat warning
• EOP - Low Engine Oil Pressure warning
• EFT - Engine Fuel Temperature overheat warning
• ECL - Low Engine Coolant Level warning

NOTE: The protection mode is not offered for school buses or

emergency vehicles.
Protection Mode (optional)
• The protection mode is an optional calibration that can be
added to the EWPS by an authorized service provider.
Engine shutdown is available if critical condition is detected:
• ECT - Engine Coolant Temperature overheat protection
• EOT - Engine Oil Temperature overheat protection
• EOP - Low Engine Oil Pressure protection

Page 60
 SECTION 4 – ENGINE OPERATION

Operation (cont.)
ENGINE WARNING PROTECTION SYSTEM (EWPS) (cont.)

• EFT - Engine Fuel Temperature overheat protection The operator will be alerted to emissions or other system
problems when the Malfunction Indicator Lamp (MIL) illuminates.
• ECL - Low Engine Coolant Level protection
When the MIL illuminates, bring the vehicle in for service at
Warning - Temperature above specific threshold will sound a the next available opportunity. The HD-OBD system does not
buzzer, illuminate the Amber Warning Lamp, set a DTC, and change the way the vehicle should be driven, the recommended
de-rate the engine. driving style, or the way you use the vehicle.
Critical - Temperature above specific threshold will shut down
RADIATOR SHUTTLE ENABLE (RSE)
the engine and set a DTC. The operator has 30 seconds to
safely pull vehicle off the road before the engine shuts off. RSE is an optional feature that provides a signal to open or close
A Red Stop Lamp will illuminate before engine shutdown is the radiator shutters. Closing the shutters will keep the engine
approaching. The ECM allows the engine to be restarted and warm during cold weather operation.
run for 30-second periods.
Event Log - This feature logs occurrences of the event according ROAD SPEED LIMITING (RSL)
to engine hours and odometer readings, for both Standard
warning and optional Protection modes. RSL is an optional feature that limits the top vehicle speed the
ECM allows. RSL is set to one of the following two positions:
HD-OBD OVERVIEW • OFF

The HD-OBD system uses many individual pre-programmed • Vehicle speed to be determined by customer, up to a
“monitors” to ensure the vehicle is meeting emissions standards. maximum of 127 mph (204 km/h)
An HD-OBD monitor is a strategy to evaluate the performance To have the RSL set, changed, or turned off, see an authorized
of an emissions related system or component. All monitors service provider.
are designed for execution in a prescribed frequency; some
monitors run continuously, while some run a specific ratio
against the number of drive cycles.

Page 61
 SECTION 4 – ENGINE OPERATION

Operation (cont.)
ROAD OPERATION Protect your engine when driving downhill as follows:

Correct road operation of your vehicle provides the following: • Prevent overspeeding of engine when going down long and
steep grades.
• Satisfactory engine performance
• Operate the engine in a gear that allows a lower rpm.
• Maximum fuel economy
• Operate the engine closest to high idle for maximum engine
• Long service life exhaust brake effectiveness.
General guidelines for correct road operation:
1. Use the lowest gear to get the vehicle moving. This allows
the engine to easily move the load.
2. Accelerate smoothly and evenly to engine's rated speed.
Rapid acceleration causes high fuel consumption.
3. To prevent lugging, do not let engine speed to drop below
peak torque rpm during full throttle.
4. When approaching a hill, press accelerator smoothly to start
the upgrade at full power. Downshift to maintain maximum
vehicle speed.

DOWNHILL OPERATION

CAUTION: To prevent engine damage when driving downhill, do

not operate engine above high idle.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule
MaxxForce® 7 Diesel Engines
Service operation interval - whichever 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.
Before Engine Operation Check engine oil level.
Check coolant level.
Check charge air cooler.
Check for external leaks.
Check air restriction indicator.

With Oil Change or When Water In Fuel

Drain water from fuel water separator.
Sensor Light Illuminates
1
Average > 11 mpg (4.7 Kmpl) of fuel Change engine oil and oil filter.
consumption:
NOTE: For RV and motor home applications only, oil change interval duration is every 12 months instead
• 500 hours or 6 months - if average
of 6 months. Maximum hours and distance between oil change intervals remain the same.
speed < 15 mph (24 Kmph)
• 15,000 miles (24,000 km) or 6
months - if average speed is >15 mph
(24 Kmph)

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule (cont.)

MaxxForce® 7 Diesel Engines (cont.)
Service operation interval - whichever 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.
Average of 7 - 11 mpg (3.0 - 4.7 Kmpl) of Change engine oil and oil filter 1

fuel consumption:
NOTE: For RV and motor home applications only, oil change interval duration is every 12 months instead
• 500 hours or 6 months - if average
of 6 months. Maximum hours and distance between oil change intervals remain the same.
speed < 15 mph (24 Kmph)
• See Oil change interval graph
(Figure 30), or 6 months - if average
speed of > 15 mph (24 Kmph)

Average of < 7 mpg (3.0 Kmpl) of fuel Change engine oil and oil filter. 1

consumption:
NOTE: For RV and motor home applications only, oil change interval duration is every 12 months instead
• 500 hours or 6 months - if an average
of 6 months. Maximum hours and distance between oil change intervals remain the same.
of < 15 mph (24 Kmph)
• 7,000 miles (11,265 km) or 6 months-
if average speed of > 15 mph (24
Kmph)

Every Three Oil Changes Service crankcase breather filter (for 2010 & 2011 model year engines only). For engines built in July
2012 and later, no service is required for non-serviceable crankcase breather.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule (cont.)

MaxxForce® 7 Diesel Engines (cont.)
Service operation interval - whichever 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.
15,000 miles (24,000 km) Inspect belt, air intake piping, and clamps.
6 months, 500 hours Check coolant freeze point.
2000 gallons (7570 liters) of fuel

30,000 miles (48,280 km) Change primary and secondary fuel filter elements.
12 months, 1050 hours
3000 gallons (11,360 liters) of fuel
Annually Inspect electrical system.
Pressurize air induction system.

150,000 miles (240,000 km) Add Extended Life Coolant (ECL) Extender.
30 months, 6,000 hours

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule (cont.)

MaxxForce® 7 Diesel Engines (cont.)
Service operation interval - whichever 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.
2
200,000 miles (322,000 km) Cleaning Diesel Particulate Filter (DPF)
30 months, 6,000 hours

300,000 miles (483,000 km) Service cooling system.

12,000 hours 60 months, 5 years

1 Engine Control Module (ECM) will notify operator when appropriate interval is reached based on the mileage, hours, and fuel consumption
calculation. For further information see Resetting Change Engine Oil Service Interval Message (page 76). Alternatively, use the Daily Care and
Report table (page 101) to record mileage, engine hours, and fuel consumption. Calculate average miles per hour and average miles per gallon
since last oil change and use with specified intervals to determine change interval.
2 Reduced service interval required if allowed CI-4 engine lubrication oil is used. If using CI-4 oil, reduce DPF cleaning interval to 150,000 miles
(241,000 km), 22 months, or 4,500 hours.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Service Procedures OIL LEVEL

Service Interval: Before Engine Operation

GOVERNMENT REGULATION: Engine fluids 1. Park vehicle on level ground.

(oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and NOTE: Do not check oil level if engine is running or immediately
other contaminated materials (e.g. filters, rags) in after engine shutdown.
accordance with applicable regulations. Recycle 2. Shut down engine and wait 15 minutes.
or dispose of engine fluids, filters, and other
contaminated materials according to applicable 3. Remove oil level gauge from oil level gauge tube.
regulations.

WARNING: To prevent personal injury or death,

shift transmission to park neutral, set parking brake, and Figure 27 Oil Level Gauge (Typical)
install wheel chocks before doing diagnostic or service
procedures.
CAUTION: To prevent engine damage do the following:

WARNING: To prevent personal injury or death, do not • Verify oil level readings are within the crosshatched
let engine fluids stay on your skin. Clean skin and nails operating range on the oil level gauge.
using hand cleaner and wash with soap and water. Wash or • Do not overfill the engine with oil.
discard clothing and rags contaminated with engine fluids.
• Do not operate engine if oil level is above or below the
operating range.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Service Procedures (cont.)

OIL LEVEL (cont.)

4. If oil level is below operating range, fill with recommended

oil for operating climate. The ADD mark indicates 2 quarts WARNING: To prevent personal injury or death, do the
(1.9 liters) of oil should be added. For further information following when removing the radiator cap or coolant tank
see Engine Oil Quality and Service Categories (page 35). cap:
• Allow the engine to cool for 15 minutes or more.
COOLANT LEVEL
• Wrap a thick cloth around the radiator cap or coolant tank
Service Interval: Before Engine Operation cap.
Extended Life Coolant (ELC) Premix 50 / 50 is the standard • Loosen cap slowly a quarter to half turn to vent pressure.
factory fill for the cooling system. If a customer wishes to use • Pause for a moment until all pressure has escaped to avoid
a different coolant, it should minimally meet ASTM D6210, being scalded by steam.
Standard Specification for fully Formulated Glycol Base Engine
Coolant for Heavy Duty Engines. ELC Premix 50 / 50 is • Continue to turn cap counterclockwise to remove.
used to replenish coolant loss and ensure that glycol / water
concentrations stay in balance. 1. Check coolant level in the coolant tank.
• Coolant level should be at midpoint of ADD and MAX.
• If coolant level is below the ADD mark, continue with
Step 2.
2. Remove coolant tank cap and add ELC Premix 50 / 50 until
the fluid level reaches the midpoint between ADD and MAX.
3. Install and tighten the coolant tank cap until the plastic cap
clicks or the metal cap runs up against the detent.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Service Procedures (cont.)

CHARGE AIR COOLER (CAC) EXTERNAL LEAKAGE

Service Interval: Before Engine Operation Service Interval: Before Engine Operation

WARNING: To prevent personal injury or death, shut WARNING: To prevent personal injury or death, shut
down engine, set parking brake, and install wheel chocks down engine, set parking brake, and install wheel chocks
before inspecting the Charge Air Cooler. before inspecting for external leakage.
1. Inspect Charge Air Cooler (CAC) core for debris and clogged 1. Check for the following conditions:
external fins.
• Cracked hoses
2. Before starting engine, remove debris blocking the core.
• Loose clamps
• Coolant stains
• Oil stains
• Fuel stains
• Leakage at water pump (wetness from the weep hole is
normal)
2. Correct problems.

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Service Procedures (cont.)

AIR CLEANER RESTRICTION If the yellow restriction indicator is at or near the red zone,
the restriction is high and a new air filter should be installed to
Service Interval: Before Engine Operation prevent reduced fuel economy, low engine power, or engine
damage.
Push reset button and observe the movement of the air
restriction indicator to make sure it is not locked up. If the air
filter was not changed, the yellow indicator will return to the
same reading when the vehicle is driven under normal driving
conditions.
1. Remove plugged air filter element and discard.

CAUTION: To prevent engine damage, do not use compressed

air to clean filter housing.
2. Use a clean water-dampened cloth to clean inside of air filter
housing.
3. Inspect air filter housing for damage or distortion. Install new
housing, if necessary.
4. Verify nothing has fallen into the filter housing prior to
installing a new filter element.
5. Install a new air filter element.
Figure 28 Air Cleaner Restriction Indicator
6. Push reset button on air restriction indicator. The yellow
indicator will return to zero.
Observe the restriction reading on the air filter restriction gauge.

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Service Procedures (cont.)

FUEL WATER SEPARATOR

Service Interval: With Oil Change or When Water In Fuel Sensor GOVERNMENT REGULATION: Engine fluids
Light Illuminates (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and
other contaminated materials (e.g. filters, rags) in
accordance with applicable regulations. Recycle
or dispose of engine fluids, filters, and other
contaminated materials according to applicable
regulations.

WARNING: To prevent personal injury or death, do not

smoke and keep fuel away from flames and sparks.

WARNING: To prevent personal injury or death, store

diesel fuel properly in an approved container designed for
and clearly marked DIESEL FUEL.
1. If the desired collection container will not fit under the water
drain valve, connect a hose to the end of the water drain
Figure 29 Water Drain Valve
valve.
1. Primary fuel filter
2. Put a suitable container under water drain valve (or drain
2. Oil level gauge
hose).
3. Secondary fuel filter
4. Fuel cooler
5. Water drain valve

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Service Procedures (cont.)

FUEL WATER SEPARATOR (cont.)

NOTE: Drain until no water or other contaminants are observed ENGINE OIL AND FILTER
exiting from the drain valve. Upon opening the drain valve, a
hissing sound will be heard as air fills the fuel line between the
engine and the fuel tank. After the sound stops, liquid will exit
the drain valve.
3. Turn the water drain valve to open and allow the water / fuel
mixture to drain out.
4. Close water drain valve and remove drain hose.
5. Recycle or dispose of fuel according to applicable
regulations.
6. Prime the engine. For further information see Priming the
Fuel System (page 50).

Figure 30 Figure 30 Oil Change Interval Graph

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Service Procedures (cont.)

ENGINE OIL AND FILTER (cont.)

Service Interval, whichever comes first: 6 months or calculation CAUTION: To prevent engine damage, do not extend
from one of the following tables. recommended oil change intervals.
Average fuel consumption rate in Kilometers per liter (Kmpl) vs. The Engine Control Module (ECM) will notify you when the
average speed in Kilometers per hour (Kmph). appropriate interval is reached based on the mileage, hours,
and fuel consumption calculation. For further information see
< 24 Kmph > 24 Kmph Resetting Change Engine Oil Service Interval Message (page
> 4.7 Kmpl 500 hrs 24,000 km
76).

3.0 - 4.7 Kmpl 500 hrs See Oil Change Alternatively, use the Daily Care and Report table (page 101) to
Interval graph record mileage, engine hours, and fuel consumption. Calculate
(Figure 30). the average miles per hour and the average miles per gallon
since the last oil change and use with the specified intervals to
< 3.0 Kmpl 500 hrs 11,265 km determine the appropriate change interval.

Average fuel consumption Miles Per Gallon (MPG) vs. average Engine oil sampling can be utilized for the following:
speed Miles Per Hour (MPH). Engine Oil Sampling - Optional
<= 15 MPH > 15 MPH 1. Determine if specified engine oil change intervals should
be shortened, based upon specific engine application.
> 11 MPG 500 hrs 15,000 miles
7- 11 MPG 500 hrs See Oil Change
2. Catch contaminants which, if left unattended, may result
Interval graph
in engine failure.
(Figure 30) Change engine oil and oil filter procedure:
< 7 MPG 500 hrs 7,000 miles 1. Park vehicle on level ground. Set parking brake and shift
transmission to park or neutral.

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Service Procedures (cont.)

ENGINE OIL AND FILTER (cont.)

2. Run engine until operating temperature is reached, then shut 4. Inspect the oil pan drain plug and seal, if they are free of
down the engine. defects, they can be reused. Replace if necessary.
5. Using clean engine oil, liberally lubricate the oil pan drain
plug seal.
GOVERNMENT REGULATION: Engine fluids 6. Install oil pan drain plug and tighten to 18 lb·ft (25 N·m).
(oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and 7. Recycle or dispose of oil according to applicable regulations.
other contaminated materials (e.g. filters, rags) in 8. Put drain pan under oil filter.
accordance with applicable regulations. Recycle
or dispose of engine fluids, filters, and other 9. Remove oil filter and recycle or dispose of according to
contaminated materials according to applicable applicable regulations.
regulations. 10. Lubricate new oil filter gasket with clean engine oil.

CAUTION: To prevent engine damage, install the correct oil filter

for the engine application.
WARNING: To prevent personal injury or death, wear
protective clothing when draining hot oil. 11. Install new oil filter.

CAUTION: To prevent engine damage, do not overtighten oil

WARNING: To prevent personal injury or death, do not filter.
let engine fluids stay on your skin. Clean skin and nails
using hand cleaner and wash with soap and water. Wash or 12. Hand tighten oil filter 3/4 to 1 full turn after gasket first
discard clothing and rags contaminated with engine fluids. contacts oil filter header.

3. Place a drain pan under the oil pan drain plug, remove oil
pan drain plug and drain oil.

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Service Procedures (cont.)

ENGINE OIL AND FILTER (cont.)

Schedule and Service Procedures chart (page 63). Add oil

through the engine oil fill tube.

Figure 32 Oil Level Gauge (Typical)

14. Check oil level gauge. Oil level must be within the
crosshatched operating range on the gauge.
15. Start engine and run at low idle.
16. Check reading on oil pressure gauge.
Figure 31 Oil Filter Removal And Installation
• Minimum lube oil pressure is 12 psi (83 kPa) @ 700 rpm.
1. Oil filter header
• If there is no gauge reading, shut engine down
2. Oil pan
immediately. Check for oil filter and drain plug leaks.
3. Spin-on oil filter
4. Oil filter O-ring • 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.
13. Add correct oil viscosity. API CJ-4 oil is recommended but CAUTION: To prevent engine damage, do not overfill with oil.
CI-4 is allowable. Use of CI-4 engine oil will reduce DPF 18. Recheck oil level and add oil to bring oil level within the upper
cleaning interval. For further information see Maintenance half of the crosshatched operating range on oil level gauge.

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Service Procedures (cont.)

ENGINE OIL AND FILTER (cont.)

19. Reset the change engine oil service interval message. See BELT, AIR INTAKE PIPING AND CLAMPS
Resetting Change Engine Oil Service Interval Message
(page 76). Service Interval: 10,000 miles (16,000 km), 6 months, 350 hours
or 1000 gallons (3785 liters of fuel)
RESETTING CHANGE ENGINE OIL SERVICE INTERVAL
MESSAGE

Reset the Service Interval Message (change engine oil) per the
following 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 hold Figure 33 Cracks In Belt Ribs
down on the fifth time for 4 seconds. 1. Belt in good condition
2. Belt ready for replacement
7. The operation from the time the CRUISE is turned ON for the
3. Belt ribs
second time to the fifth activation of the resume switch must
4. Cracks in belt
take place within 6 seconds. If you fail to reset the message,
repeat the process.
8. The Change Engine Oil Service Interval message should
clear and reset for the next service interval.

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Service Procedures (cont.)

BELT, AIR INTAKE PIPING AND CLAMPS (cont.)

Install a new belt if any of the following conditions exist:

• Excessive wear
• Missing material
• Grease or oil contamination
• Over three cracks per inch in a belt rib

Figure 34 Square Hole In Auto Tensioner (Typical)

1. Square hole location in auto tensioner
2. Auto tensioner

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Service Procedures (cont.)

BELT, AIR INTAKE PIPING AND CLAMPS (cont.)

Removing the Belt • Ruptured hoses

1. Attach a 1/2–inch drive breaker bar to square hole in • Cracked air cleaner housing
auto tensioner.
• Damaged Charge Air Cooler (CAC)
2. Pull breaker bar clockwise and remove belt from auto
tensioner pulley and other pulleys. COOLANT FREEZE POINT
3. Slowly release breaker bar; auto tensioner automatically Service Interval: 15,000 miles (24,000 km), 6 months, 500
adjusts. hours, or 2000 gallons (7570 liters) of fuel
4. Remove breaker bar.
CAUTION: To prevent engine damage, do not use Dex-cool® in
Installing the Belt MaxxForce® 7 engines.
1. Attach a 1/2–inch drive breaker bar to square hole in ELC 50 / 50 Premix provides freeze protection to -34°F (-36°C)
auto tensioner. and maximum corrosion protection. If a customer wishes to use
a conventional (non-OAT ELC) coolant, it should minimally meet
2. Pull breaker bar clockwise and install belt over auto
ASTM D6210, Standard Specification for fully Formulated Glycol
tensioner pulley and other pulleys.
Base Engine Coolant for Heavy Duty Engines. ELC 50 / 50
3. Slowly release breaker bar; auto tensioner automatically Premix is used to replenish coolant loss and ensure that glycol /
adjusts. water concentrations stay in balance.
4. Remove breaker bar. ELC 50 / 50 Extender is added at the designated service interval.

AIR INTAKE PIPING AND CLAMPS

For any of the following conditions, install new parts:

• Loose hoses or clamps, tighten or replace as required

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Service Procedures (cont.)

COOLANT FREEZE POINT (cont.)

Freeze Point Protection Levels Concentrate (Ethylene 2. Look through eyepiece and focus.
Glycol) and Water Mixtures
3. Record freeze point.
Concentrate and Water Freeze Point Protection
4. Adjust coolant concentration as necessary to achieve
Mixtures
desired freeze point protection.
40% Concentrate and 60% -12°F (-24°C)
water PRIMARY FUEL FILTER
50% Concentrate and 50% -34°F (37°C)
water Service Interval: 30,000 miles (48,280 km), 12 months, 1050
hours, or 3,000 gallons (11,360 liters) of fuel
60% Concentrate and 40% -62°F (-52°C)
water
NOTE: Drain fuel filters if optional Water In Fuel (WIF) lamp is
67% Concentrate and 33% -95°F (-71°C) illuminated.
water
NOTE: If fuel used has more than average impurities, shorter
CAUTION: To prevent engine damage, do not use a concentrate service intervals may be required.
and water mixture of less than 40% concentrate.
For vehicles operating in extremely cold climates, coolant
mixtures of 60% Concentrate and 40% water or 67%
Concentrate and 33% water provide additional freeze protection
as shown in the table above. Mixtures having more than 67%
Concentrate are not recommended.
Check freeze point with a refractometer.
1. Put drop of coolant on refractometer window.

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Service Procedures (cont.)

PRIMARY FUEL FILTER (cont.)

WARNING: To prevent personal injury or death, do

GOVERNMENT REGULATION: Engine fluids not mix gasoline, gasohol, or alcohol with diesel fuel. A
(oil, fuel, and coolant) may be a hazard to human heat source, spark, or electronic device can ignite these
health and the environment. Handle all fluids and fuel mixtures. This creates a fire hazard and possible
other contaminated materials (e.g. filters, rags) in explosion.
accordance with applicable regulations. Recycle
or dispose of engine fluids, filters, and other WARNING: To prevent personal injury or death, do not
contaminated materials according to applicable smoke and keep fuel away from flames and sparks.
regulations.

WARNING: To prevent personal injury or death, shift

transmission to park or neutral, set parking brake, and
install wheel chocks before doing diagnostic or service
procedures.

WARNING: To prevent personal injury or death, do not

let engine fluids stay on your skin. Clean skin and nails
using hand cleaner and wash with soap and water. Wash or
discard clothing and rags contaminated with engine fluids.

WARNING: To prevent personal injury or death, store

diesel fuel properly in an approved container designed for
and clearly marked DIESEL FUEL.

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Service Procedures (cont.)

PRIMARY FUEL FILTER (cont.)

1. Set parking brake and shift transmission to park or neutral.

NOTE: Both the primary and secondary fuel filter elements

should be replaced during this service interval.

WARNING: To prevent personal injury or death,

make sure that the engine has cooled before removing
components.
2. Turn ignition switch to OFF and allow engine to cool before
removing components.

WARNING: To prevent personal injury or death, wear

safety glasses with side shields. Limit compressed air
pressure to 30 psi (207 kPa).

CAUTION: Clean area around and above fuel filter housing

Figure 35 Primary Fuel Filter Assembly before removing fuel filter cover. This protects the open fuel
1. Exhaust Gas Recirculation (EGR) cooler filter housing from contaminants falling into the housing. If
2. Primary fuel filter cap contaminants do fall in, remove them and blow out fuel filter
3. Primary fuel filter cap O-ring housing with compressed air before installing a new filter
4. Secondary fuel filter element. Contaminants reaching high-pressure fuel system
5. Fuel cooler components may cause component failure.
6. Water drain valve
7. Primary fuel element O-ring
8. Primary fuel filter element

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Service Procedures (cont.)

PRIMARY FUEL FILTER (cont.)

3. Clean engine compartment components in the area of the 14. Coat the new primary fuel filter element O-ring with clean
fuel filter housing using compressed air. Before removing diesel fuel and install it into the groove inside the fuel filter
the fuel filter cap, wipe the fuel filter cap and top portion of module.
fuel filter housing clean. This prevents contaminants from
entering the fuel system, which could cause engine failure. CAUTION: To prevent engine damage, do not add fuel to the
fuel filter housing; this can add contaminants to the fuel.
4. Loosen the primary fuel filter cap counterclockwise 3 and 1/2
turns to allow the primary fuel filter housing to vent. 15. Coat a new O-ring for the primary fuel filter cap with clean
diesel fuel and install onto the primary fuel filter cap.
5. If the desired collection container will not fit under the water
drain valve, attach a hose to the end of the water drain valve. CAUTION: To prevent engine damage, the fuel filter cap must
be tightened on the fuel filter housing.
6. Put a suitable container under the water drain valve.
16. Attach primary fuel filter cap to the primary fuel filter. Push
7. Open water drain valve and drain the fuel filter assembly.
the cap onto the element until it snaps to secure it.
8. Recycle or dispose of fuel according to applicable
17. Coat the threads of the primary fuel filter cap with clean
regulations.
diesel fuel.
9. Remove primary fuel filter cap and fuel filter element from
18. Verify a small O-ring is installed at the bottom of the primary
the fuel filter housing.
fuel filter. If the O-ring is loose (not installed) in the bottom
10. Remove O-ring from primary fuel filter cap and discard of the filter, install the O-ring in the groove located at the
O-ring. bottom of the primary fuel filter. Coat the O-ring with clean
diesel fuel.
11. Remove fuel filter element from fuel filter cap and discard
according to applicable regulations. 19. Install the primary fuel filter element with cap into the primary
fuel filter housing. Slowly lower the element into the housing
12. Remove the O-ring from the primary fuel filter element.
until primary fuel filter cap is ready to be secured to the
13. Clean mating surfaces. primary fuel filter housing.

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Service Procedures (cont.)

PRIMARY FUEL FILTER (cont.)

20. Secure the fuel filter cap and element to the fuel filter housing
by turning the fuel filter cap clockwise until finger-tight. WARNING: To prevent personal injury or death, shift
transmission to park or neutral, set parking brake, and
21. Tighten fuel filter cap to 37 lb·ft (50 N·m). install wheel chocks before doing diagnostic or service
22. Close water drain valve on fuel filter housing assembly and procedures.
remove water drain hose.
23. Continue with secondary fuel filter replacement. WARNING: To prevent personal injury or death, do not
let engine fluids stay on your skin. Clean skin and nails
SECONDARY FUEL FILTER using hand cleaner and wash with soap and water. Wash or
discard clothing and rags contaminated with engine fluids.
Service Interval: 30,000 miles (42,280 km), 12 months, 1050
hours or 3,000 gallons (11,360 liters) of fuel. WARNING: To prevent personal injury or death, store
diesel fuel properly in an approved container designed for
and clearly marked DIESEL FUEL.
GOVERNMENT REGULATION: Engine fluids
(oil, fuel, and coolant) may be a hazard to human WARNING: To prevent personal injury or death, do
health and the environment. Handle all fluids and not mix gasoline, gasohol, or alcohol with diesel fuel. A
other contaminated materials (e.g. filters, rags) in heat source, spark, or electronic device can ignite these
accordance with applicable regulations. Recycle fuel mixtures. This creates a fire hazard and possible
or dispose of engine fluids, filters, and other explosion.
contaminated materials according to applicable
regulations.
WARNING: To prevent personal injury or death, do not
smoke and keep fuel away from flames and sparks.

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Service Procedures (cont.)

SECONDARY FUEL FILTER (cont.)

NOTE: If fuel used has more than average impurities, shorter

service intervals may be required.
1. If not already done, replace the primary fuel filter element.
For further information see Primary Fuel Filter (page 79).

Figure 36 Secondary Fuel Filter Assembly

1. Primary fuel filter cap
2. Secondary fuel filter cap
3. Secondary fuel filter cap O-ring
4. Fuel cooler
5. Fuel filter element

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Service Procedures (cont.)

SECONDARY FUEL FILTER (cont.)

2. Loosen the secondary fuel filter cover counterclockwise 3

and 1/2 turns to allow the secondary fuel filter housing to
vent.
3. Remove fuel filter cap and fuel filter element from the
secondary fuel filter housing.
4. Remove O-ring from fuel filter cap and discard O-ring.
5. Remove fuel filter element from fuel filter cap and discard
according to applicable regulations.
6. Clean mating surfaces.

CAUTION: To prevent engine damage, do not add fuel to the

fuel filter housing; this can add contaminants to the fuel.
7. Coat a new O-ring for the fuel filter cap with clean diesel fuel
and install onto the fuel filter cap.

CAUTION: To prevent engine damage, the fuel filter cap must

be tightened on the fuel filter housing.
8. Attach fuel filter cap to the fuel filter element. Push the cap
onto the element until it snaps to secure it.
9. Coat the threads of the fuel filter cap with clean diesel fuel.

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Service Procedures (cont.)

SECONDARY FUEL FILTER (cont.)

10. Install the fuel filter element with cap into the secondary fuel CRANKCASE BREATHER
filter housing. Slowly lower the fuel filter element into the
housing until fuel filter cap is ready to be secured to the NOTE: Engines built in July 2012 and later have a
secondary fuel filter housing. non-servicable crankcase breather.
11. Secure the fuel filter cap and element to the fuel filter housing
by turning the fuel filter cap clockwise until finger-tight.
12. Tighten fuel filter cap to 29 lb·ft (40 N·m).
13. Prime the engine as follows:
• Key - On for 10 seconds
• Key - Off for 15 seconds
• Key - On for 10 seconds
• Key - Off for 15 seconds
• Key - On for 10 seconds
14. Check for fuel leaks prior to starting engine. If leaks are
found, correct the problem.
15. Start the engine and check for leaks. For further information Figure 37 Non-Serviceable Crankcase Breather Identifier
see Starting the Engine (page 51).
16. If leaks are found, shut down the engine and correct the
problem. The non-serviceable crankcase breather can be identified by a
bar code label on the side. Serviceable crankcase breathers will
17. If engine does not start, see the Engine Diagnostic Manual. not have a barcode on the side.

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Service Procedures (cont.)

CRANKCASE BREATHER (cont.)

1. For serviceable crankcase breather only: Install a new filter

element per instructions in the Engine Service Manual.
2. Reset the service breather element message. See
Resetting Change Service Breather Element Message
(page 88).

NOTE: Replace the crankcase breather if the engine oil is

contaminated with fuel or coolant.

Figure 38 Crankcase Breather Assembly

1. Breather assembly
2. M6 captive bolt (10)
3. Jet pump boost tube connector
4. Draft tube clamp

Service Interval: Every three oil changes (for engines with a

serviceable crankcase breather built before July 2012 only). The
serviceable crankcase breather assembly can be replaced with
a new non-serviceable crankcase breather at the next service
interval.

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Service Procedures (cont.)

RESETTING CHANGE SERVICE BREATHER ELEMENT ELECTRICAL SYSTEM
MESSAGE (SERVICEABLE CRANKCASE BREATHER
ONLY) Service Interval: Annually
1. Check wiring harness for cracks, rubbing, and loose
Reset the Service Breather Element Message (change breather
connections.
element) per the following procedure:
2. Check sensors for loose connections, corrosion, or cracks.
1. If not already done, set the parking brake. (Required for the
correct Electronic System Controller [ESC] signal) 3. Check battery cables for the following conditions:
2. Turn ignition switch to ON. • Broken insulation
3. Turn CRUISE ON. • Rubbing or chafing
4. Turn CRUISE OFF. • Corroded or loose connections
5. Turn CRUISE ON. Electronics
6. Very rapidly push the SET / CRUISE switch four times and Check for fault codes and repair as required. After repairs
then hold down on the fifth time for 4 seconds. are made, clear fault codes and verify they do not reappear.
For correct procedures, see MaxxForce® 7 Engine Diagnostic
7. The operation from the time the cruise is turned ON for
Manual or contact an authorized service provider.
the second time to the fifth activation of the SET / CRUISE
switch must take place within 6 seconds. If you fail to reset
INDUCTION SYSTEM
the message, repeat the process.
8. The Change Breather Element message should clear and Service Interval: Annually
reset for the next service interval. Have an authorized service provider pressure test the air
induction system.

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Service Procedures (cont.)

EXTENDED LIFE COOLANT (ELC) EXTENDER ELC Extender

Service Interval: 150,000 miles (240,000 km), 30 months, or Cooling System Drain ELC Coolant Add ELC Extender
6,000 hours Capacity
6-8 gallons (22-30 0.5 quart (0.2 liter) 0.5 quart (0.2 liter)
liters )
WARNING: To prevent personal injury or death, do the
following when removing the radiator cap or coolant tank 8-13 gallons (30-49 1.0 quart (0.5 liter) 1.0 quart (0.5 liter)
cap: liters)
• Allow the engine to cool for 15 minutes or more. 13-22 gallons (49-83 1.5 quart (0.7 liter) 1.5 quart (0.7 liter)
liters)
• Wrap a thick cloth around the radiator cap or coolant tank
cap.
NOTE: ELC 50 / 50 Premix is the standard factory fill for the
• Loosen cap slowly a quarter to half turn to vent pressure. cooling system. ELC 50 / 50 Premix is used to replenish coolant
• Pause for a moment to avoid being scalded by steam. loss and ensure that glycol / water concentrations stay in
balance. If a customer wishes to use a conventional (non-OAT
• Continue to turn cap counterclockwise to remove. ELC) coolant, it should minimally meet ASTM D6210, Standard
Specification for fully Formulated Glycol Base Engine Coolant
1. Remove coolant tank cap. for Heavy Duty Engines.

2. Confirm coolant system capacity. 4. Add the same volume of ELC Extender to the cooling
system.
3. According to cooling system capacity in the ELC Extender
table, drain the correct volume of coolant from the cooling 5. Check coolant level. If necessary, add ELC 50 / 50 Premix
system. to bring coolant level between ADD and MAX of deaeration
tank.
6. Install and tighten the coolant tank cap until the plastic cap
clicks or the metal cap runs up against the detent.

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Service Procedures (cont.)

CLEANING DIESEL PARTICULATE FILTER (DPF) SERVICE COOLING SYSTEM

CJ-4 Engine Oil Service Interval: 300,000 miles (483,000 km), 12,000 hours, 60
months, or 5 years
Service Interval: 200,000 miles (322,000 km), 30 months or
6,000 hours
WARNING: To prevent personal injury or death, do the
Clean DPF at designated service interval. The ECM will
following when removing the radiator cap or coolant tank
illuminate the Maintenance Lamp and generate an ASH
cap:
Servicing Required message on the integral digital display. Take
vehicle to an authorized service provider for cleaning. • Allow the engine to cool for 15 minutes or more.
CI-4 Engine Oil • Wrap a thick cloth around the radiator cap or coolant tank
cap.
Service Interval: 150,000 miles (241,000 km), 22 months or
4,500 hours • Loosen cap slowly a quarter to half turn to vent pressure.
Clean DPF at designated service interval. Take vehicle to an • Pause for a moment to avoid being scalded by steam.
authorized service provider for cleaning.
• Continue to turn cap counterclockwise to remove.
It is recommended that the coolant be replaced using a coolant
extraction tool. The advantage to using this tool is that the
coolant system will evacuate and fill more completely, in less
time, and in a sanitary fashion. Extraction and filling is done
through quick disconnect fittings installed in the radiator end
tanks from the factory.

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Service Procedures (cont.)

SERVICE COOLING SYSTEM (cont.)

1. Park vehicle so the engine is level and shut engine off. 4. After one radiator has drained, close the drain valve, remove
female quick connect, and repeat Steps 3 – 5 for the other
2. Set parking brake and shift transmission to Park or
radiator.
Neutral.
5. Begin draining the engine block by moving the drain pan
3. Drain the coolant using one of the following two
under the right side of the engine.
methods.

NOTE: If using the coolant extraction service tool method, order

KL5007NAV - Navistar Coolant Management Tool Kit. If the
vehicle is not equipped with a male quick-connect fitting at the
coolant drain location, see your authorized service provider for
part and installation.
Coolant Replacement Using Extraction Service Tool
1. See instructions included with the extraction tool for
proper operation.
2. Both the high temperature and low temperature radiator
must be drained.
Coolant Replacement Using Gravity Method
1. Put a drain pan under the radiator.
2. Remove coolant tank pressure cap.
3. Open radiator drain cock (if present) or install a female
quick-connect fitting and hose to the quick disconnect fitting
installed in the radiator end tank(s) from the factory.

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Service Procedures (cont.)

SERVICE COOLING SYSTEM (cont.)

Figure 39 Right Side Coolant Drain Plug Figure 40 Left Side Coolant Drain Plug

6. Remove right side coolant drain plug. 8. Move the drain pan under left side coolant drain plug.

7. After coolant has drained, put a new O-ring on drain plug 9. Remove left side coolant drain plug.
and install plug into crankcase. Tighten plug to 15 lb·ft (20
N·m).

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Service Procedures (cont.)

SERVICE COOLING SYSTEM (cont.)

10. After coolant has drained, put a new O-ring on drain plug 17. As the engine warms up, make sure coolant is flowing
and install plug into crankcase. Tighten plug to 15 lb·ft (20 through coolant line – coolant will feel warm to the touch.
N·m).
18. After engine reaches normal operating temperature and the
11. Recycle or dispose of coolant, according to applicable thermostat has opened, shut engine off.
regulations.
NOTE: Use of a Coolant Extraction / Fill Service Tool will provide
NOTE: ELC 50 / 50 Premix is the standard factory fill for the faster and more complete filling. Gravity filling will likely cause
cooling system. ELC 50 / 50 Premix is used to replenish coolant a need for topping off the coolant level again after the first heat
loss and ensure that glycol / water concentrations stay in and cool-down cycle.
balance. If a customer wishes to use a conventional (non-OAT
19. If necessary, after the engine has cooled fully, add coolant
ELC) coolant, it should minimally meet ASTM D6210, Standard
to the coolant tank to bring the level up to the MAX mark.
Specification for fully Formulated Glycol Base Engine Coolant
for Heavy Duty Engines.
12. Slowly fill cooling system with new ELC 50 / 50 Premix or
Concentrate and water mixture until coolant is at the FULL
level in the coolant tank.
13. Install and tighten the coolant tank cap until the plastic cap
clicks or the metal cap runs up against the detent.
14. Disconnect the Exhaust Gas Recirculation (EGR) valve
electrical connector.
15. Start the engine.
16. Allow the engine to operate at a fast idle until the engine
reaches normal operating temperature.

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 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Page 94
 SECTION 6 – LONG TERM STORAGE

General Information • Check state -of- charge eye in batteries. If any of the
batteries has a dark state -of- charge indication, charge all
Engines in storage 30 days or longer require the following batteries. If the battery eye charge indicators of all batteries
procedures: are green, batteries are charged. If batteries do not have
• Maintain a “Full” fuel tank with the addition of diesel fuel an indicator eye, recharge if below 12.6 volts. Check the
stabilizer to minimize microbial growth within the fuel battery charge and recharge if needed. Remove batteries
system. Run engine long enough to allow the fuel stabilizer and store in an area to protect from freezing if applicable. If
to enter the entire fuel system. If the engine is utilized in a battery removal is not required (warm climate), maintain the
mobile application, drive vehicle to mix the stabilizer in the battery charge every 30 days.
fuel tank. • Test the cooling system, additive levels, and coolant freeze
• Before storage replace engine fuel filter(s) and drain all protection. Coolant freeze protection must be set below the
water separators of any water. coldest anticipated temperature during storage.

• Every 30 days or less, run engine until full operating

temperature has been maintained. For an engine with less
than 750 miles, run the engine to operating temperature
every time the engine is started. Run engine smoothly
through entire operating rpm range. If the High Exhaust
System Temperature (HEST) light is on, wait until it turns
off. If the Diesel Particulate Filter (DPF) light is on, do a
parked regeneration.
• Before storage, change the engine oil and filter with
the appropriate engine oil for conditions the engine will
experience during storage.
• Check and replace the air filter element and cover air
intake ducts to prevent moisture and debris intrusion during
storage.
• Cover vertical exhaust stack.

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 SECTION 6 – LONG TERM STORAGE

Page 96
 SECTION 7 – SERVICE RECORDS

Maintenance Service Record

WARNING: To prevent personal injury or death, read

all safety instructions in the “Safety Information” section of
this manual.

WARNING: To prevent personal injury or death, put

transmission in neutral or park, set parking brake, and
install wheel chocks before doing diagnostic or service
procedures.
Save scheduled maintenance work orders and receipts for proof
of correct maintenance. Failure to maintain work orders and
receipts may affect your warranty coverage.

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 SECTION 7 – SERVICE RECORDS

Maintenance Service Record (cont.)

Maintenance Service Record
Date Service Month Service Hours Miles (Km) Item Serviced

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 SECTION 7 – SERVICE RECORDS

Maintenance Service Record (cont.)

Table 1 Maintenance Service Record
Date Service Month Service Hours Miles (Km) Item Serviced

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 SECTION 7 – SERVICE RECORDS

Daily Care and Report Do the following daily to prevent engine failure:
• Add coolant if necessary. Make sure filler cap seal is in good
WARNING: To prevent personal injury or death, read condition and the cap is installed tightly.
all safety instructions in the “Safety Information” section of • Check air cleaner indicator with engine running. When the
this manual. yellow position indicator reaches and locks in the red zone,
a new air filter should be installed.
WARNING: To prevent personal injury or death, put
• Fill the fuel tank with correct fuel.
transmission in neutral or park, set parking brake, and
install wheel chocks before doing diagnostic or service • Drain water from the fuel filter housing.
procedures.
• Clean external surfaces of the engine, radiator, and
Check the following daily to prevent engine failure. Report all accessories to prevent dirt or snow buildup.
problems for immediate service.
• Oil level
• Oil, air, fuel or coolant leaks
• Cooling system hoses for leaks
• Correct coolant and coolant system level
• Excessive use of crankcase lubricating oil, coolant, battery
fluid, or fuel
• Unusual engine noise
• Correct amount of electrolyte, if not a maintenance-free
battery
• Condition of electrical equipment

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 SECTION 7 – SERVICE RECORDS

Daily Care and Report (cont.)

Daily Care and Report
Model
Serial No.
Date Miles Hours Fuel Lube Oil Parts Labor Service Performed
Qty Cost Parts Cost Time Cost

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 SECTION 7 – SERVICE RECORDS

Daily Care and Report (cont.)

Daily Care and Report
Model
Serial No.
Date Miles Hours Fuel Lube Oil Parts Labor Service Performed
Qty Cost Parts Cost Time Cost

Page 102