Navistar MaxxForce 7, Operation And Maintenance Manual

Page 1: ...3 HD OBD US Canada 4328090R1 March 2013 MaxxForce 7 Engine Operation and Maintenance Manual Navistar Inc 2701 Navistar Drive Lisle IL 60532 USA 2013 Navistar Inc All rights reserved All marks are trad...

Page 2: ...e neither downloaded nor retrieved except by the vehicle s registered owner or in the alternative by another individual or entity authorized by the registered owner e g International Dealer who may ne...

Page 3: ...Warranty Rights and Responsibilities 9 California Emission System Warranty 10 Warranty Period 10 Required Maintenance 10 Warranty Repairs and Service 10 Recommended Maintenance or Repair Parts 10 Eme...

Page 4: ...r 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...

Page 5: ...or 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 S...

Page 6: ...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 Intak...

Page 7: ...CONTENTS Cleaning Diesel Particulate Filter DPF 90 Service Cooling System 91 SECTION 6 LONG TERM STORAGE General Information 95 SECTION 7 SERVICE RECORDS Maintenance Service Record 97 Daily Care and R...

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Page 9: ...Form 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...

Page 10: ...FOREWORD Page 2...

Page 11: ...gine Warning Caution and Note Warning A warning describes actions necessary to prevent or eliminate conditions hazards and unsafe practices that can cause personal injury or death Caution A caution de...

Page 12: ...lets or exhaust openings If unavoidable for service reasons put protective screens over all openings before servicing engine If an engine is not safe to operate tag the engine and ignition key Fire Pr...

Page 13: ...e grounded Check for frayed power cords before using power tools Fluids Under Pressure Use extreme caution when working on systems under pressure Follow approved procedures only Fuel Do not overfill t...

Page 14: ...SAFETY INFORMATION Page 6...

Page 15: ...ew vehicle is delivered to the first retail purchaser REQUIRED MAINTENANCE As the vehicle owner you are responsible for all required maintenance described in this manual Navistar Inc recommends that y...

Page 16: ...g Replacement parts that do not exceed manufacturer s suggested retail price Labor charges based on manufacturer s recommended time allowance and geographic hourly rate Replaced parts and paid invoice...

Page 17: ...ARRANTY RIGHTS AND RESPONSIBILITIES Navistar Inc ensures that the emission warranty is being properly administered If you have not received satisfactory service or have questions regarding your warran...

Page 18: ...o ensure the performance of all scheduled maintenance However a claim may be denied if Navistar demonstrates that the engine vehicle has been abused neglected or improperly maintained and that such ab...

Page 19: ...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 eng...

Page 20: ...ent maintenance intervals for reasons other than being defective Replacement of expendable items made in connection with scheduled maintenance Vehicle engine and part malfunctions caused by the follow...

Page 21: ...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...

Page 22: ...WARRANTY Page 14...

Page 23: ...unit and OEM sold to original equipment manufacturer Y United States Huntsville Alabama 7 digit suffix Engine serial number sequence Engine Emission Label Figure 2 The U S Environmental Protection Age...

Page 24: ...sories 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 St...

Page 25: ...n 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 Lube system capac...

Page 26: ...inimum 45 psi 310 kPa minimum Idle speed no load 700 rpm 50 nonadjustable Thermostat operating temperature With bypass Without bypass 198 F 205 F 92 C 96 C 188 F 196 F 87 C 91 C 1 Verify engine lubric...

Page 27: ...n the intake manifold This cools the combustion process and reduces the formation of NOX engine emissions Cold Start Assist A relay controlled grid duct heater is used in the intake air stream to aid...

Page 28: ...cam followers push rods rocker arms and valve bridges to open the dual intake and exhaust valves Electronic Control System An Engine Control Module ECM monitors and controls engine performance to ens...

Page 29: ...charged 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 C...

Page 30: ...programmed value when ambient air temperature is below 32 F 0 C coolant temperature is below 167 F 75 C and engine has been idling at no load or driver input for over five minutes For further informat...

Page 31: ...he ECM Electronic Speedometer and Tachometer The engine control system calibrates vehicle speed Any new speed calibration information must be programmed with an EST The tachometer signal is generated...

Page 32: ...to describe the distance time or fuel used between the last maintenance performed on the vehicle and the next maintenance that is due It is essential that operators are trained to know the maintenanc...

Page 33: ...that can be programmed from 2 to 120 minutes 2012 and newer model year vehicles with U S Federal MaxxForce 7 engines have idle time that can be programmed from 2 to 120 minutes For further information...

Page 34: ...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 op...

Page 35: ...ocharger assembly 7 Engine coolant vent 8 Air compressor assembly 9 Turbocharger outlet 10 Turbocharger Outlet Temperature TCOT sensor 11 Manifold mixer exhaust emission label location 12 EGR valve 13...

Page 36: ...e 5 Front 1 Grooved idler pulley 2 Fan pulley 3 Flat idler pulley 2 4 Belt tensioner 3 5 Lifting eye 2 6 Air compressor pulley 7 Coolant inlet 8 Water pump pulley 9 Vibration damper and pulleys 10 Hea...

Page 37: ...7 Fuel return port to tank 8 Fuel pump 9 Left valve cover 10 Left exhaust tube assembly 11 Left exhaust manifold 12 Starter motor mounting location 13 Oil filter 14 Diagnostic test port oil pressure...

Page 38: ...ng 6 Power Take Off PTO air compressor front pulley 7 Front engine mounting support 8 Inner front pulley alternator and primary Freon compressor 9 Oil pan drain plug 10 Oil pan 11 Right exhaust manifo...

Page 39: ...t turbocharger inlet manifold 3 Low pressure turbocharger assembly 4 Right exhaust tube assembly 5 Lifting eye 6 Draft tube assembly 7 Rear crankcase cover assembly flywheel housing 8 Flexplate 9 High...

Page 40: ...SECTION 1 ENGINE SYSTEMS Page 32...

Page 41: ...ms 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 inc...

Page 42: ...esel blends up to B5 should not cause engine or fuel system problems USE OF HIGHER BIODIESEL FUEL BLENDS B6 TO B20 Standard ASTM D7467 current revision covers the specifications for blends between 6 a...

Page 43: ...se 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...

Page 44: ...ease 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...

Page 45: ...bdate and freeze point protection If necessary Supplemental Coolant Additives SCAs are added to replenish inhibitors Extended life coolant mixtures water and ethylene glycol do not require regular tes...

Page 46: ...ded For further information see Coolant Freeze Point page 79 CONTAMINATION OF COOLANT The coolant color should indicate the condition of the coolant Coolant color should be a reddish orange clear not...

Page 47: ...Operator Manual for description of indicator lamps for the drivetrain chassis components and cabin Warning Lamps Warning lights signal when a reading is outside preset limits Warning lamps indicate s...

Page 48: ...shutdown timer will turn the engine off in 30 seconds For further information see Engine Idle Shutdown Timer page 55 Maintenance Lamp Figure 14 Maintenance Lamp The Maintenance lamp will illuminate in...

Page 49: ...conditions It is safe to drive the vehicle However if the lamp continues to light or remains on contact an authorized service provider immediately to have the problem corrected Red Stop Lamp RSL Figur...

Page 50: ...le Operator Manual Diesel Particulate Filter DPF Indicator Figure 18 Diesel Particulate Filter Indicator The diesel particulate filter indicator operates at three different levels Level One DPF indica...

Page 51: ...ping 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...

Page 52: ...ion switch is turned to ON Normal engine operating temperature is 190 F to 228 F 88 C to 109 C CAUTION To prevent engine damage do not operate engine above 228 F 109 C this may cause internal damage T...

Page 53: ...Pressure Gauge Figure 22 Oil Pressure Gauge The engine oil pressure gauge indicates operating oil pressure The engine oil pressure indicator lamp and alarm will be activated when oil pressure falls b...

Page 54: ...rature 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 Engine Exhaust Brake On...

Page 55: ...lly 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 loc...

Page 56: ...SECTION 3 INSTRUMENTS INDICATORS AND SWITCHES Page 48...

Page 57: ...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 ad...

Page 58: ...el to the 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 fi...

Page 59: ...rther information 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 Starting the Engine WARN...

Page 60: ...tarter button The ignition switch will return to ON and the engine will continue to run 7 With the transmission in neutral release clutch pedal if equipped CAUTION To prevent damage to the engine if t...

Page 61: ...ath always connect jumper cable for positive battery terminals first 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 st...

Page 62: ...e If the engine coolant temperature is below 167 F 75 C and CAP is enabled the Engine Control Module ECM adjusts the low idle speed from 700 rpm to a maximum of 1400 rpm High idle speed 2950 rpm is a...

Page 63: ...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...

Page 64: ...moved from neutral automatic transmissions If the IST is enabled the Cold Ambient Protection CAP will not function ENGINE IDLE SHUTDOWN TIMER CALIFORNIA AND ALL STATE OPTIONAL 2012 AND NEWER VEHICLES...

Page 65: ...lt is detected Engine coolant operating temperature is below 60 F 16 C Brake pedal movement or a brake switch fault is detected Parking brake transition is detected Clutch pedal is pressed or clutch p...

Page 66: ...n ambient air temperature is below 32 F 0 C coolant temperature is below 167 F 75 C and engine has been idling at no load for over five minutes The engine speed continues to increase or decrease to ma...

Page 67: ...idle the engine for 30 seconds allowing the hottest engine components to dissipate some of their internal heat Idling is recommended if an engine has been running at maximum horsepower ENGINE WARNING...

Page 68: ...nd set a DTC The operator has 30 seconds to safely pull vehicle off the road before the engine shuts off A Red Stop Lamp will illuminate before engine shutdown is approaching The ECM allows the engine...

Page 69: ...changed or turned off see an authorized service provider ROAD OPERATION Correct road operation of your vehicle provides the following Satisfactory engine performance Maximum fuel economy Long service...

Page 70: ...ill do not operate engine above high idle Protect your engine when driving downhill as follows Prevent overspeeding of engine when going down long and steep grades Operate the engine in a gear that al...

Page 71: ...eck charge air cooler Check for external leaks Check air restriction indicator With Oil Change or When Water In Fuel Sensor Light Illuminates Drain water from fuel water separator Average 4 7 Kmpl 11...

Page 72: ...tor home applications only oil change interval duration is every 12 months instead of 6 months Maximum hours and distance between oil change intervals remains the same Average of 3 0 Kmpl 7 mpg of fue...

Page 73: ...ures in this section for more information 15 000 miles 24 000 km 6 months 500 hours 2000 gallons 7570 liters of fuel Inspect belt air intake piping and clamps Check coolant freeze point 30 000 miles 4...

Page 74: ...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 O...

Page 75: ...leaner and wash with soap and water Wash or discard clothing and rags contaminated with engine fluids OIL LEVEL Service Interval Before Engine Operation 1 Park vehicle on level ground NOTE Do not chec...

Page 76: ...do the following when removing the radiator cap or coolant tank cap Allow the engine to cool for 15 minutes or more Wrap a thick cloth around the radiator cap or coolant tank cap Loosen cap slowly a q...

Page 77: ...Air Cooler CAC core for debris and clogged external fins 2 Before starting engine remove debris blocking the core EXTERNAL LEAKAGE Service Interval Before Engine Operation WARNING To prevent personal...

Page 78: ...tion 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 Remo...

Page 79: ...er 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 WA...

Page 80: ...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 Cl...

Page 81: ...ine Control Module ECM will notify you when the appropriate interval is reached based on the mileage hours and fuel consumption calculation For further information see Resetting Change Engine Oil Serv...

Page 82: ...ash with soap and water Wash or discard clothing and rags contaminated with engine fluids 3 Place a drain pan under the oil pan drain plug remove oil pan drain plug and drain oil 4 Inspect the oil pan...

Page 83: ...ation see Maintenance 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 cro...

Page 84: ...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...

Page 85: ...000 km 6 months 350 hours or 1000 gallons 3785 liters of fuel Figure 33 Cracks In Belt Ribs 1 Belt in good condition 2 Belt ready for replacement 3 Belt ribs 4 Cracks in belt Install a new belt if an...

Page 86: ...quare hole in auto tensioner 2 Pull breaker bar clockwise and remove belt from auto tensioner pulley and other pulleys 3 Slowly release breaker bar auto tensioner automatically adjusts 4 Remove breake...

Page 87: ...50 50 Premix is used to replenish coolant loss and ensure that glycol water concentrations stay in balance ELC 50 50 Extender is added at the designated service interval Freeze Point Protection Level...

Page 88: ...If fuel used has more than average impurities shorter service intervals may be required GOVERNMENT REGULATION Engine fluids oil fuel and coolant may be a hazard to human health and the environment Han...

Page 89: ...igned for and clearly marked DIESEL FUEL WARNING To prevent personal injury or death do not mix gasoline gasohol or alcohol with diesel fuel A heat source spark or electronic device can ignite these f...

Page 90: ...essure fuel system components may cause component failure 3 Clean engine compartment components in the area of the fuel filter housing using compressed air Before removing the fuel filter cap wipe the...

Page 91: ...re it 17 Coat the threads of the primary fuel filter cap with clean diesel fuel 18 Verify a small O ring is installed at the bottom of the primary fuel filter If the O ring is loose not installed in t...

Page 92: ...NING 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...

Page 93: ...d 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 r...

Page 94: ...ck 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 see Starting the Engine page 51 16 If leaks are found...

Page 95: ...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 1 For serviceable...

Page 96: ...time the cruise is turned ON for the second time to the fifth activation of the SET CRUISE switch must take place within 6 seconds If you fail to reset the message repeat the process 8 The Change Brea...

Page 97: ...death do the following when removing the radiator cap or coolant tank cap Allow the engine to cool for 15 minutes or more Wrap a thick cloth around the radiator cap or coolant tank cap Loosen cap slo...

Page 98: ...fully Formulated Glycol Base Engine Coolant for Heavy Duty Engines 4 Add the same volume of ELC Extender to the cooling system 5 Check coolant level If necessary add ELC 50 50 Premix to bring coolant...

Page 99: ...are 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 tank...

Page 100: ...uick disconnect fitting installed in the radiator end tank s from the factory 4 After one radiator has drained close the drain valve remove female quick connect and repeat steps 3 through 5 for the ot...

Page 101: ...lenish coolant loss and ensure that glycol water concentrations stay in balance If a customer wishes to use a conventional non OAT ELC coolant it should minimally meet ASTM D6210 Standard Specificatio...

Page 102: ...e reaches normal operating temperature and the thermostat has opened shut engine off NOTE Use of a Coolant Extraction Fill Service Tool will provide faster and more complete filling Gravity filling wi...

Page 103: ...rns 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 experie...

Page 104: ...SECTION 6 LONG TERM STORAGE Page 96...

Page 105: ...ction of this manual WARNING To prevent personal injury or death put transmission in neutral or park set parking brake and block wheels before doing diagnostic or service procedures Save scheduled mai...

Page 106: ...SECTION 7 SERVICE RECORDS Maintenance Service Record cont Maintenance Service Record Date Service Month Service Hours Miles Km Item Serviced Page 98...

Page 107: ...SECTION 7 SERVICE RECORDS Maintenance Service Record cont Table 1 Maintenance Service Record Date Service Month Service Hours Miles Km Item Serviced Page 99...

Page 108: ...nt 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 e...

Page 109: ...SECTION 7 SERVICE RECORDS Daily Care and Report cont Daily Care and Report Model Serial No Fuel Parts Labor Date Miles Hours Qty Cost Lube Oil Parts Cost Time Cost Service Performed Page 101...

Page 110: ...SECTION 7 SERVICE RECORDS Daily Care and Report cont Daily Care and Report Model Serial No Fuel Parts Labor Date Miles Hours Qty Cost Lube Oil Parts Cost Time Cost Service Performed Page 102...