Maxxforce 07 Series - EPA08-09 - Engine Operation and Maintenance Manual # (85pgs)

International® MaxxForce® 7 Diesel Engine
For
2008 Through 2009 Model Year
Truck and Derivative Vehicle Applications
Engine Operation and Maintenance Manual
© 2009 Navistar, Inc. All rights reserved.
Form No. 1171941R4

Printed in the United States of America
Form No. 1171941R4
TABLE OF CONTENTS
FOREWORD.................................................................................... 1
SAFETY INFORMATION...................................................................... 3
WARRANTY..................................................................................... 7
Federal Emission System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warranty Repairs and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Maintenance or Repair Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Emergency Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
What is not Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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
Emergency Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
What is Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
What is not Covered by Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Warranty Rights and Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
SECTION 1 – ENGINE SYSTEMS

Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Engine Specifications and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Form No. 1171941R4

TABLE OF CONTENTS
Component Location – Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Component Location – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Component Location – Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Component Location – Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Ultra Low Sulfur Diesel (ULSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Unacceptable Fuel and Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Acceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Use of Higher Biodiesel Fuel Blends (B6 to B20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Engine Oil Quality and Service Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
API CJ-4 for High Performance Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Coolant Mixtures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Shell ROTELLA® Extended Life Coolant (ELC) – red). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Contamination of Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Water Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Warning Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Odometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Form No. 1171941R4

TABLE OF CONTENTS
Air Cleaner Restriction Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
SECTION 4 – ENGINE OPERATION

Preoperation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Priming the Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Emergency Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Suggested Warm up Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Extended Idling Periods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Engine Idle Shutdown Timer (Federal-Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Engine Idle Shutdown Timer (California-Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Cold Ambient Protection (CAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Engine Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Engine Warning Protection System (EWPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Road Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Water Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Form No. 1171941R4

TABLE OF CONTENTS
Charge Air Cooler (CAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

External Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Air Cleaner Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Resetting Change Engine Oil Service Interval Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Belt, Air Intake Piping and Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Coolant Freeze Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Secondary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Extended Life Coolant (ELC) Extender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Cleaning Diesel Particulate Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Service Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
SECTION 6 – SERVICE RECORDS

Maintenance Service Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Daily Care and Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Form No. 1171941R4

FOREWORD
Foreword Technical Service Literature is revised periodically and mailed

automatically to “Revision Service” subscribers. If a technical
Navistar, Inc. is committed to continuous research and
publication is ordered, the latest revision will be supplied.
development to improve products and introduce technological
advances. Procedures, specifications, and parts defined in To order technical service literature, contact your International®
published technical service literature may be altered. dealer.
NOTE: Photo illustrations identify specific parts or assemblies All marks are trademarks of their respective owners.
that support text and procedures; other areas in a photo
illustration may not be exact.
This manual includes necessary information and specifications
for operators to service Navistar diesel engines. Contact an
International dealer for more information.
Technical Service Literature

1171941R4 International® MaxxForce® 7 Engine
Operation and Maintenance Manual
EGES-345 International® MaxxForce® 7 Service Manual
EGES-350–1 International® MaxxForce® 7 Diagnostic
Manual
EGED-355–1 International® MaxxForce® 7 Diagnostic
Form
EGED-365 International® MaxxForce® 7 Electronic
Control Systems Diagnostic Form
Form No. 1171941R4

Printed in the United States of America Page 1
FOREWORD
Form No. 1171941R4

Page 2 Printed in the United States of America
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. Vehicle
Note: A note describes actions necessary for correct, efficient • Make sure the vehicle is in neutral, the parking brake is set,
engine operation. and the wheels are blocked before servicing engine.
Form No. 1171941R4

SAFETY INFORMATION
• Clear the area before starting the engine. 3. Type C — Electrical equipment
Engine Batteries
• The engine should be operated or serviced only by qualified • Always disconnect the main negative battery cable first.
individuals.
• Always connect the main negative battery cable last.
• Provide necessary ventilation when operating engine in a
• Avoid leaning over batteries.
closed area.
• Protect your eyes.
• Keep combustible material away from engine exhaust
system and exhaust manifolds. • Do not expose batteries to open flames or sparks.
• Install all shields, guards, and access covers before • Do not smoke in workplace.
operating engine.
Compressed Air
• Do not run engine with unprotected air inlets or exhaust
• Use an OSHA approved blow gun rated at 207 kPa (30 psi).
openings. If unavoidable for service reasons, put protective
screens over all openings before servicing engine. • Limit shop air pressure to 207 kPa (30 psi).
• Shut engine off and relieve all pressure in the system before • Wear safety glasses or goggles.
removing panels, housing covers, and caps.
• Wear hearing protection.
• If an engine is not safe to operate, tag the engine and ignition
• Use shielding to protect others in the work area.
key.
• Do not direct compressed air at body or clothing.
Fire Prevention
Tools
• Make sure charged fire extinguishers are in the work area.
• Make sure all tools are in good condition.
NOTE: Check the classification of each fire extinguisher to
ensure that the following fire types can be extinguished. • Make sure all standard electrical tools are grounded.
1. Type A — Wood, paper, textiles, and rubbish
2. Type B — Flammable liquids
Form No. 1171941R4

SAFETY INFORMATION
• 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 over fill the fuel tank. Over fill creates a fire hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
• Reinstall all safety guards, shields, and covers after
servicing the engine.
• Make sure all tools, parts, and service equipment are
removed from the engine and vehicle after all work is done.
Form No. 1171941R4

SAFETY INFORMATION
Form No. 1171941R4

WARRANTY
Warranty have no record of maintenance. However, a claim may be

denied if your failure to perform proper maintenance resulted
in the failure of a warranted part and you cannot provide
Federal Emission System Warranty appropriate evidence of maintenance. Take your vehicle to an
International dealer when a problem occurs.
WARRANTY PERIOD
WARRANTY REPAIRS AND SERVICE
Navistar, Inc. warrants your light heavy-duty diesel engine for
the following warranty period (whichever comes first): All emission control system parts proven defective during
normal use will be repaired or replaced during the warranty
• 5 years period. Warranty repairs and service will be done by any
• 80,000 km (50,000 miles) authorized International dealer with no charge for parts, labor
and diagnostics. Warranty repairs should be completed in a
• Or if covered by any basic or extended warranty (if greater reasonable time, not to exceed 30 days. Navistar may deny
than above) you warranty coverage if your vehicle or a part has failed
Your light heavy-duty diesel engine conforms to U.S. due to abuse, neglect, improper maintenance or unapproved
Environmental Protection Agency regulations for emission modifications.
systems.
RECOMMENDED MAINTENANCE OR REPAIR PARTS.
The engine model year, service class, and required emission
information is on the emission label on top of the valve cover. International® service parts or International ReNEWed™ parts
This warranty is based on the engine model year, not the model are recommended for maintenance or repairs to maintain the
year of the vehicle. The warranty period begins on the date the original quality of your emission certified engine. If parts not
new vehicle is delivered to the first retail purchaser. recommended by Navistar cause damage to the engine or
vehicle, the warranty is invalid and maintenance and repair
REQUIRED MAINTENANCE costs will not be covered.
As the vehicle owner, you are responsible for all required
maintenance described in this manual. Navistar Engine Group
recommends that you retain all maintenance receipts. Navistar
will not deny an emission warranty claim solely because you
Form No. 1171941R4

WARRANTY
Federal Emission System Warranty (cont.)

EMERGENCY REPAIRS • Parts requiring replacement at inspection or adjustment
maintenance intervals for reasons other than being
Emergency repairs are recognized, if parts are not available defective.
within 30 days or repairs are not completed within 30 days. If
an International dealer is not reasonably available, the vehicle • Replacement of expendable items made in connection with
owner or any service establishment can install any replacement scheduled maintenance.
part. Vehicle, engine, and part malfunctions caused by the
Navistar will reimburse you for emergency repairs (including following:
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 an
International dealer for reimbursement of emergency repairs. • Accidents, acts of nature or other events beyond control of
Navistar.
WHAT IS NOT COVERED BY WARRANTY Conditions not covered by warranty
Unauthorized parts or expendable parts • Vehicles registered and normally operated outside the
United States.
• Parts other than International® service parts or ReNEWed™
parts. • Loss of time, inconvenience, use of vehicle/engine or
commercial loss.
• Aftermarket parts or service kits
• Vehicles with an altered or disconnected odometer or
• Nondefective parts replaced by other than International hourmeter when mileage or hours cannot be determined.
dealer.
Form No. 1171941R4

WARRANTY
Federal Emission System Warranty (cont.)

WARRANTY RIGHTS AND RESPONSIBILITIES
Navistar assures that the emission warranty is being properly

administered. If you have not received satisfactory service
or have questions regarding your warranty rights and
responsibilities, contact the Navistar regional office for
assistance. The address and phone number of each regional
office is listed in your vehicle Operator’s Manual. If additional
assistance is required, contact the Manager of Customer
Relations.
Manager, Customer Relations
Navistar, Inc.
4201 Winfield Road
Warrenville, Illinois 60555
(Telephone 1-800-448-7825)
Form No. 1171941R4

WARRANTY
California Emission System Warranty abused, neglected, or improperly maintained, and that such
abuse, neglect, or improper maintenance was the direct cause
WARRANTY PERIOD of the need for the repair or replacement of the part. Take your
vehicle to an International® dealer when a problem occurs.
Navistar, Inc. warrants your light heavy-duty diesel engine for
the following warranty period (whichever comes first): WARRANTY REPAIRS AND SERVICE
• 5 years
All emission control system parts proven defective during
• 160,000 km (100,000 miles) normal use will be repaired or replaced during the warranty
period. Warranty repairs and service will be done by any
• Or if covered by any basic or extended warranty (if greater
authorized International dealer with no charge for parts, labor
than above)
and diagnostics. Warranty repairs should be completed in a
Your light heavy-duty diesel engine conforms to applicable reasonable time, not to exceed 30 days. Navistar may deny
California Air Resources Board regulations. This vehicle is you warranty coverage if your vehicle or a part has failed
registered and certified for sale in California. due to abuse, neglect, improper maintenance or unapproved
modifications.
The engine model year, service class, and required emission
information is on the emission label on top of the valve cover.
RECOMMENDED MAINTENANCE OR REPAIR PARTS
This warranty is based on the engine model year, not the model
year of the vehicle. The warranty period begins on the date the International® service parts or International ReNEWed™ parts
new vehicle is delivered to the first retail purchaser. are recommended for maintenance or repairs to maintain the
original quality of your emission certified engine. If parts not
REQUIRED MAINTENANCE recommended by Navistar cause damage to the engine or
vehicle, the warranty is invalid and maintenance and repair
As the vehicle owner, you are responsible for all required
costs will not be covered.
maintenance described in this manual. Navistar recommends
that you retain all receipts covering maintenance on your
EMERGENCY REPAIRS
truck, but Navistar cannot deny warranty solely for the lack
of receipts or your failure to ensure the performance of all Emergency repairs are recognized, if parts are not available
scheduled maintenance. However, a claim may be denied within 30 days or repairs are not completed within 30 days. If
if Navistar demonstrates that the (engine/vehicle) has been
Form No. 1171941R4

WARRANTY
California Emission System Warranty (cont.)

EMERGENCY REPAIRS (cont.)
an International dealer is not reasonably available, the vehicle • Diesel Particulate Filter (DPF)
owner or any service establishment can install any replacement
• Hoses, clamps, fittings and tubing
part.
• Pulleys, belts and idlers
Navistar will reimburse you for emergency repairs (including
diagnostics) for the following: • Vacuum, temperature and time sensitive valves and
switches
• Replacement parts that do not exceed manufacturer’s
suggested retail price.
WHAT IS NOT COVERED BY WARRANTY
• Labor charges based on manufacturer’s recommended time
allowance and geographic hourly rate. Unauthorized parts or expendable parts
Replaced parts and paid invoices must be given to an • Parts other than International® service parts or ReNEWed™
International dealer for reimbursement of emergency repairs. parts.
• Aftermarket parts or service kits
WHAT IS COVERED BY WARRANTY
• Nondefective parts replaced by other than International
New vehicles and engines, registered and certified for sale in dealer.
California, have the following items covered by the emission
• Parts requiring replacement at inspection or adjustment
warranty when first installed on the engine as original equipment
maintenance intervals for reasons other than being
by Navistar:
defective.
• Fuel injection system
• Air induction system (includes turbocharger, exhaust
manifold, and intake manifold)
• Positive Crankcase Ventilation (PCV) system – if applicable
(includes PCV valve and oil fill cap)
Form No. 1171941R4

WARRANTY
California Emission System Warranty (cont.)

WHAT IS NOT COVERED BY WARRANTY (cont.)
• Replacement of expendable items made in connection with WARRANTY RIGHTS AND RESPONSIBILITIES
scheduled maintenance.
Navistar assures that the emission warranty is being properly
Vehicle, engine, and part malfunctions caused by the administered. If you have not received satisfactory service
following: or have questions regarding your warranty rights and
• Use of incorrect fuel, engine oil, or coolant responsibilities, contact the Navistar regional office for
assistance. The address and phone number of each regional
• Failure to maintain correct maintenance schedule office is listed in your vehicle Operator’s Manual. If additional
• Incorrect adjustments, modifications, alterations, tampering assistance is required, contact the Manager of Customer
or disconnection of vehicle components. Relations.
• Abuse or misuse of engine Manager, Customer Relations

Navistar, Inc.
• Accidents, acts of nature or other events beyond control of 4201 Winfield Road
Navistar. Warrenville, Illinois 60555
Conditions not Covered by Warranty (Telephone 1-800-448-7825)
• Vehicles registered and normally operated outside the If further questions of warranty rights and responsibilities remain,
United States. contact:
• Loss of time, inconvenience, use of vehicle/engine or The Air Resources Board

commercial loss. 9528 Telstar Avenue
El Monte, California 91731
• Vehicles with an altered or disconnected odometer or
hourmeter when mileage or hours cannot be determined.
Form No. 1171941R4

Engine Serial Number M2 – Motor truck or U2 power unit and OEM (sold to original
equipment manufacturer)
Y – United States, Huntsville
7 digit suffix – Sequence number
Engine Emission Label
Figure 1 Engine serial number

Figure 2 The U.S. Environmental Protection Agency (EPA)
exhaust emission label (Example)
The engine serial number is stamped on the crankcase pad, on
the rear left side below the cylinder head. The U.S. Environmental Protection Agency (EPA) exhaust
emission label is on top of the rear of the right valve cover,
Engine Serial Number Example under the EBP sensor mounting bracket. The label includes the
6.4HM2YXXXXXXX following:
6.4 – Engine displacement (liters) • Advertised brake horsepower ratings
H – Diesel, turbocharged, air intercooled and electronically • Engine model code
controlled
• Service applications
Form No. 1171941R4

Engine Emission Label (cont.)

• Emission family and control systems
• Year the engine was certified to meet EPA emission
standards
Engine Accessories
The following engine accessories may have manufacturers’
labels or identification plates:
• Air compressor
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• Power steering pump
• Starter motor
Labels or identification plates include information and
specifications helpful to vehicle operators and technicians.
Form No. 1171941R4

Engine Specifications and Features

International® MaxxForce® 7 Features and Specifications
Engine Configuration 4 stroke, V8 diesel
1
Rated power @ rpm 230 bhp @ 2300 rpm
Peak torque @ rpm 620 lbf•ft @ 1500 rpm 1
Displacement 6.4 L (389 in3)
Compression ratio 17.5 : 1
Stroke 105 mm (4.134 in)
Bore (sleeve diameter) 98.2 mm (3.87 in)
Firing order 1-2-7-3-4-5-6-8
Aspiration Variable Geometry Turbocharger (VGT) and Charge Air Cooled (CAC)
Combustion system Direct injection, turbocharged
Fuel system Direct injection common rail
Lube system capacity (including filter) 17.9 L (19 qts US)
Lube system capacity (overhaul only, with filter) 18.9 L (20 qts US)
Engine lubrication oil pressure at operating temperature
• Low idle 83 kPa (12 psi) minimum
• High idle 276 kPa (40 psi) minimum

Idle speed (no load) 700 rpm ± 50 (nonadjustable)
Thermostat operating temperature 88 °C - 96 °C (190 °F - 205 °F)
1
Example. See EPA emission label for other ratings.
Form No. 1171941R4

Engine Specifications and Features (cont.)

STANDARD FEATURES bearing caps machined into it for improved load retention and
alignment.
The International® MaxxForce® 7 is a V8 engine with a
displacement of 6.4 liters (389 cubic inches). The crankshaft is supported by five main bearings with fore and
aft thrust controlled at the upper half of the second main bearing.
The electronic governor controls the engine’s rpm within a safe Two connecting rods are attached to each crankshaft rod journal
and stable operating range for ideal performance. Low idle and are offset to minimize vibration. Piston pins are free floating,
governor prevents the engine rpm from dropping below a stable allowing the pins free lateral movement within the connecting rod
speed to prevent stalling when various loads are demanded on as well as the piston. Piston pins are held in place with retaining
the engine. High idle governor prevents the engine rpm from rings.
going above a safe speed that would cause internal damage to
the engine. One piece aluminum-alloy pistons are fitted with one keystone
ring, one rectangular intermediate compression ring, and a two
The cylinder heads have four valves per cylinder. Each fuel piece oil control ring. The combustion bowl is located in the
injector is centrally located between the four valves and directs piston crown to reduce emissions. All pistons are mated to
fuel over the piston bowl for improved performance and reduced fractured cap joint connecting rods.
emissions.
The Crankshaft Position (CKP) sensor and Camshaft Position
The camshaft is supported by four bushings pressed into the (CMP) sensor are used by the Electronic Control Module (ECM)
crankcase. The camshaft is crankshaft driven and thrust is to calculate rpm, fuel timing, fuel quantity, and duration of fuel
controlled by a plate mounted behind the fourth cam journal. injection.
The overhead valve train includes hydraulic roller cam followers, The Exhaust Gas Recirculating (EGR) system includes an EGR
push rods, rocker arms, and valve bridges to open the dual valve and an intake throttle valve. The EGR valve is mounted in
intake and exhaust valves. an EGR mixer elbow that is part of the EGR valve elbow housing.
The crankcase is comprised of two major matching components. The intake throttle valve is mounted on the other side of the EGR
The upper crankcase half houses the cylinders, main bearing valve elbow housing in the air stream from the CAC.
saddles, with oil and coolant passages either cast or machined. A gerotor lube oil pump is mounted in the front cover and is
The lower crankcase consists of a structural plate with the main driven by the crankshaft. Pressurized oil is supplied to engine
Form No. 1171941R4

STANDARD FEATURES (cont.)
components. All MaxxForce® 7 engines use an engine oil cooler has run out of fuel. This primes the fuel system to minimize the
and engine oil filter. amount of air injected into the system on initial startup.
A closed crankcase breather system draws crankcase vapors The Variable Geometry Turbocharger (VGT) has actuated vanes
through a breather element. The breather element removes oil in the turbine housing. These vanes modify exhaust gas flow
from the vapor and sends the vapor to the air intake and returns through the VGT. The ECM commands the VGT to control boost
the oil to the crankcase. pressure for various engine speeds and load conditions.
The low-pressure fuel pump draws fuel from the fuel tank(s) The Exhaust Gas Recirculating (EGR) system circulates cooled
through the primary fuel filter. The primary fuel filter assembly exhaust into the intake air stream in the intake manifold. This
includes a Water in Fuel (WIF) sensor and an optional fuel cools the combustion process and reduces the formation of NOX
heater. Water and solids are separated from the fuel and the engine emissions.
water is collected in the water separator bowl. The instrument
Diamond Logic® engine control is a single electronic control unit
panel WIF lamp is illuminated when water needs to be drained.
that monitors and controls the engine and chassis components.
A drain valve in the water separator bowl drains water out. Fuel
is discharged to the secondary fuel filter. The secondary fuel The glow plug relay controls the eight glow plugs, one for each
filter assembly is pressure regulated and incorporates an air cylinder. The glow plugs warm the cylinders during start-up.
bleed orifice allowing air to be automatically purged if it has
been introduced to the system.
OPTIONAL FEATURES
The high-pressure fuel system includes a High-Pressure Fuel
Pump (HPFP), high-pressure common rails, and fuel injectors. An air compressor is available for applications that require air
The ECM electronically controls the injectors allowing multiple brakes or air suspension.
injections and more precise fuel delivery to improve combustion,
A coolant heater is available to raise the temperature of the
emissions, and cold start performance.
coolant surrounding the cylinders for improved performance
A hand operated primer pump is mounted on the right valve during cold weather startups.
cover. The manual priming pump draws fuel from the fuel tank(s)
A fuel heater is available to warm the supply fuel in the primary
through the primary filter after filter replacement or when system
fuel filter. Warmed supply fuel prevents waxing, and improves
performance and fuel economy during cold weather start-up.
Form No. 1171941R4

CHASSIS MOUNTED FEATURES
A Charge Air Cooler (CAC) is an air-to-air heat exchanger which

increases the density of the air charge.
The Aftertreatment System part of the larger exhaust system,
processes engine exhaust so that it meets tailpipe emission
requirements.
• The Diesel Oxidation Catalyst (DOC) oxidizes hydrocarbons
and carbon monoxide, provides heat for exhaust system
warmup, aids in temperature management for the DPF, and
oxidizes NO into NO2 for passive DPF regeneration.
• The Diesel particulate Filter (DPF) temporarily stores
carbon-based particulates, oxidizes stored particulates,
stores non-combustible ash, and provides required exhaust
back pressure drop for engine performance.
Form No. 1171941R4

Component Location – Front
Figure 3 Front
1. Fan drive pulley 3. Water pump 5. Water drain valve
2. Air compressor belt tensioner 4. Vibration damper 6. Belt tensioner
Form No. 1171941R4

Component Location – Left
Figure 4 Left
1. Oil level gauge 2. Electronic Control Module (ECM) 3. Oil level gauge and tube assembly
Form No. 1171941R4

Component Location – Right
Figure 5 Right
1. Exhaust Back Pressure (EBP) sensor 3. Fuel priming pump operating handle 5. Low-pressure fuel pump
2. Fuel priming pump 4. Primary fuel filter
Form No. 1171941R4

Component Location – Top
Figure 6 Top
1. Exhaust Gas Recirculation (EGR) cooler 3. Oil fill cap 5. Exhaust Gas Recirculation (EGR) valve
2. Turbocharger 4. Secondary fuel filter 6. Engine oil filter
Form No. 1171941R4

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

International® 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 7 American Petroleum Institute (API) Diesel Pump
Label • Off road diesel fuel
• Low Sulfur Diesel (LSD) fuel 0.05% (500 ppm)
The API Diesel Pump Label is compliant with EPA CFR 80.570. • Commercial Jet A or JP8 aviation fuel
• Heating or furnace oil
• Biodiesel B100 (neat biodiesel)
• Biodiesel blends higher than 20%
Form No. 1171941R4

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 A new standard ASTM D7467-08 covers the specifications for
have key properties that are comparable to those in diesel fuel. blends between 6% and 20% (B6 to B20). These blends may be
used in vehicles that operate in populated areas or in fleets which
ACCEPTABLE FUEL BLENDS are required to use alternative fuels to reduce urban pollution.
Use of B6 to B20 blends is at the discretion of the
• Ultra low sulfur kerosene (No. 1-D S15 diesel fuel) blended
customer/operator and will not automatically void an engine
with No. 2-D S15 fuel to improve cold weather performance.
warranty. However, if engine component failure can be directly
Blend rate would depend upon regional low temperatures.
attributable to use of a B6 to B20 blend not provided by
• Lower biodiesel blends up to B5 (a blend of 5% neat a BQ9000 certified fuel supplier or not meeting the ASTM
biodiesel with 95% diesel fuel). D7467-08 Standard, Navistar may, at its option, deny warranty
on the affected engine or engine component.
Such blends have characteristics indistinguishable from
diesel fuel, if the two components meet the requirements of Navistar recommends that users of B20 select a BQ9000
their respective standards: ASTM D6751 current revision, certified fuel supplier and request proof from the supplier
for neat biodiesel and ASTM D975 current revision, for ultra that the fuel meets the ASTM D7467-08 Standard. Fuels not
low sulfur diesel fuel. meeting the specification may cause fuel system deposits,
plugged filters, contaminated engine oil, and fuel degradation.
As of October 1, 2008 blends of up to 5% biodiesel are
included in the diesel fuel standard ASTM D975-08a. If providers and customers follow correct storage and
(D975-08a designates the 2008 revision of the standard.) maintenance procedures for fuel and equipment, blends
of B6 to B20 that meet the ASTM D7467-08 Standard
Navistar, Inc. approves of blends up to B5, provided that the
should perform satisfactorily in diesel engines. Contact your
two components satisfy current specifications. Quality biodiesel
International® dealer for further information on ASTM standards
blends up to B5 should not cause engine or fuel system
and recommendations for correct storage and maintenance
problems.
procedures.
Form No. 1171941R4

Fuel (cont.)
USE OF HIGHER BIODIESEL FUEL BLENDS (B6 TO B20)
(cont.)
Navistar, Inc. follows the official position of the Engine

Manufacturers Association (EMA) on biodiesel fuel. See
www.enginemanufacturers.org for more information.
UNSAFE PRACTICES
WARNING: To prevent personal injury or death, do

not mix gasoline, gasohol, or alcohol with diesel fuel. An
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 will not honor warranty claims against
engines that have used propane.
Form No. 1171941R4

Engine Oil API CJ-4 oils provide protection against the following:
• Catalyst poisoning and particulate blockage
ENGINE OIL QUALITY AND SERVICE CATEGORIES
• Engine wear
The American Petroleum Institute (API) defines engine oil quality
by service categories that define oil performance measured in • Piston deposits
standardized engine tests. • Soot related viscosity increase, deposits, and wear
API CJ-4 FOR HIGH PERFORMANCE DIESEL ENGINES • Viscosity loss due to shear
• Oxidative thickening
• Oil foaming and aeration
API CJ-4 oil, in combination with Ultra Low Sulfur Diesel
(ULSD) fuel [0.0015% (15 ppm) maximum sulfur content],
is recommended to maintain performance and durability
of aftertreatment systems meeting 2007 diesel emission
regulations.
API CI-4 oils are allowed in diesel engines that meet these
regulations. Use of the CI-4 engine oil shortens Diesel
Particulate Filter (DPF) cleaning service intervals.
Figure 8 API Identification Symbol
API CJ-4 oils are recommended for high speed diesel engines
with advanced, exhaust aftertreatment systems that meet 2007
on-highway exhaust emission standards.
Form No. 1171941R4

Engine Oil (cont.)

OIL VISCOSITY oils for correct flow during starting. Higher temperatures require
higher grade oils for satisfactory lubrication.
• A block heater is required, if temperatures are below -23 °C
(-10 °F).
• For heavy duty driving or trailer towing, higher oil grades
15W-40 and 5W-40 oils are required, if temperatures are
over 10 °C (50 °F).
For oil system capacity and service, see Section 5 - Maintenance
Schedule and Service Procedures.
Figure 9 SAE viscosity grades and temperature ranges
The Society of Automotive Engineers (SAE) defines oil viscosity

(thickness) by grade. Colder temperatures require lower grade
Form No. 1171941R4

Coolant wishes to use a different coolant, it should minimally meet ASTM

D6210, Standard Specification for fully - Formulated Glycol Base
COOLANT MIXTURES Engine Coolant for Heavy Duty Engines.
Engine coolant mixtures include water, glycol (ethylene or ROTELLA® ELC 50/50 Premix provides freeze protection to -36
propylene), and inhibitors. Conventional and fully formulated °C (-34 °F) and maximum corrosion protection. ROTELLA® ELC
coolants require regular testing of inhibitor levels to maintain 50/50 Premix is used to replenish coolant loss and ensure that
safe levels of protection. Testing of conventional coolant glycol/water concentrations stay in balance.
determines levels of nitrite, nitrite/molybdate, and freeze point ROTELLA® ELC 50/50 Extender is added at the designated
protection. If necessary, Supplemental Coolant Additives service interval. See Section 5 - Maintenance Schedule and
(SCAs) are added to replenish inhibitors. Service Procedures.
Extended life coolant mixtures (water and ethylene glycol) do not
require regular testing of inhibitor levels or addition of SCAs. Freeze Point Protection Levels Provided by ROTELLA®
Concentrate and Water Mixtures
SHELL ROTELLA® EXTENDED LIFE COOLANT (ELC) – Concentrate and Water Freeze Point Protection
RED) Mixtures
40% ROTELLA® Concentrate -24.4 °C (-12 °F)
Part Numbers for ROTELLA® Extended Life Coolant
and 60% water
(premix, concentrate, and extender)
2000 gal (50/50 Premix) 55 gal (Concentrate) ROTELLA®
and 50% water
ROTELLA® 9404200001 940410055
55 gal (50/50 Premix) 1 gal (Concentrate)
and 40% water
ROTELLA® 94042000055 ROTELLA® 9404106021
1 gal (6/pack 50/50 Premix) 1 qt. US (6/pack 50/50 Extender)
and 33% water
ROTELLA® 9404206021 ROTELLA® 9404306031
For vehicles operating in extremely cold climates, a coolant
Shell ROTELLA® Extended Life Coolant (ELC) 50/50 Premix is
mixture of 60% ROTELLA® Concentrate and 40% water or 67%
the standard factory fill for the cooling system. If a customer
ROTELLA® Concentrate and 33% water provide additional
Form No. 1171941R4

Coolant (cont.)
SHELL ROTELLA® EXTENDED LIFE COOLANT (ELC) –
RED) (cont.)
freeze protection as shown in the table above. Mixtures having

more than 67% ROTELLA® Concentrate are not recommended.
For cooling system service, see Section 5 - Maintenance
Schedule and Service Procedures.
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 ROTELLA® ELC with other coolant products
will not be obvious.
To verify coolant quality, contact an International® service parts
dealer and request coolant test kit ZSH297400001KIT.
Form No. 1171941R4

Form No. 1171941R4

Instrument Panel Gauge Cluster
Figure 10 Typical instrument panel gauge cluster
Gauges may vary with vehicle applications. Warning and

indicator lamps show conditions not indicated by the gauges.
Form No. 1171941R4

Water Temperature Gauge Oil Pressure Gauge
Figure 11 Water temperature gauge Figure 12 Oil pressure gauge
The water temperature gauge indicates the temperature of The engine oil pressure gauge indicates operating oil pressure.
coolant in the cooling system. The gauge operates only when The engine oil pressure indicator lamp will be activated at
the ignition switch is turned to ON. Normal engine operating pressure less than 35 kPa (5 psi) when engine is over 325 rpm.
temperature is 89 °C to 104 °C (192 °F to 219 °F).
CAUTION: To prevent engine damage, shut down engine
CAUTION: To prevent engine damage – do not operate engine immediately, if the gauge fluctuates or drops to 241 kPa (35 psi)
above 109 °C (228 °F); this may cause internal damage. or less under load. Correct the problem.
The amber indicator lamp will be activated at engine coolant
temperatures above 109 °C (228 °F). If engine temperature
suddenly rises, shut down engine and determine the cause of
overheating.
Form No. 1171941R4

Oil Pressure Gauge (cont.)

Lubrication Oil Pressure Oil Temperature Gauge
Lube Oil Pressure
At normal operating temperature
Low idle 83 kPa (12 psi) min.
High idle 276 kPa (40 psi)
Figure 13 Oil temperature gauge
The engine oil temperature gauge indicates the operating oil

temperature of the engine.
Form No. 1171941R4

Warning Lights The change oil indicator can be programmed for kilometers,
miles, hours or calculated fuel consumption. These service
Warning lights signal when a gauge reading is outside preset interval limits may be adjusted at the owners discretion. Consult
limits. your International dealer.
• Red warning lamps indicate situations that must be The change engine oil message below the odometer illuminates
inspected before operating the vehicle. after a preselected parameter is reached. This feature remains
• Amber warning lamps indicate situations that should be inactive until ordered active.
reviewed by the operator. NOTE: If this feature is active, the system must be reset
• An audible alarm is activated when a warning lamp is lit. This after each oil change. See Resetting Change Engine Oil
alerts the operator that an active fault exists. Service Interval in Section 5 “MAINTENANCE SCHEDULE
AND SERVICE PROCEDURES”.
Odometer
Figure 14 Odometer and Change engine oil message

1. Odometer
2. Illuminated change oil message
Form No. 1171941R4

Air Cleaner Restriction Indicators Air cleaner restriction is measured by an air restriction indicator,
mounted on the air cleaner or instrument panel.
Air restriction is resistance of airflow through the air cleaner.
Accurate air restriction is measured at maximum airflow. Air Restriction Indicator Calibration
• Both indicators are calibrated in inches of water.
• Both 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.
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 as soon as possible.
Air Restriction Indicator Reset
Figure 15 Air cleaner restriction indicators • The air restriction indicator should be reset, when the
indicator is checked to determine air filter restriction.
1. Mounted on air cleaner
2. Mounted on instrument panel If the air filter was not changed, the yellow indicator will
maintain the same reading when the vehicle is driven under
normal driving conditions.
• If a new air filter is installed, the air restriction indicator
should be reset.
Form No. 1171941R4

Form No. 1171941R4

Preoperation Checklist
WARNING: To prevent personal injury or death,

provide ventilation when operating an engine in a closed Figure 16 Oil level gauge
area. Inhalation of exhaust gas can be fatal.
This engine has been given predelivery and delivery service by 2. Check for correct oil level.
your International dealer and is ready for operation. The operator
should fully understand the use and function of all controls and CAUTION: To prevent engine damage, do not overfill with
instruments. oil.
NOTE: See Service Procedures in Section 5 for the following 3. Inspect for coolant, fuel or oil leaks.
steps. 4. Inspect air cleaner and piping for tightness and correct
1. Check cooling system level. installation of filter element.
5. Check for loose or hanging electrical connections.
6. Check belt condition and alignment.
7. Fill the tank with recommended fuel.
8. Inspect exhaust system for obstruction or damage.
9. Drain water from fuel system.
Form No. 1171941R4

Priming the Fuel System
WARNING: To prevent personal injury or death, shift

transmission to park or neutral, set parking brake, and block
wheels before doing diagnostic or service procedures.
WARNING: To prevent personal injury or death, make

sure that the engine has cooled before priming the fuel
system.
WARNING: To prevent personal injury or death, do not

smoke and keep fuel away from open flames and sparks.
CAUTION: To prevent engine damage, do not add fuel to the
fuel filter header. This can contaminate the fuel.
Figure 17 Fuel priming pump
1. Fuel priming pump
2. Fuel priming pump knob
If engine runs out of fuel or the fuel filter header has been
drained, do the following:
1. Set parking brake and shift transmission to Park or Neutral.
2. Fill fuel filter header with fuel by pumping the fuel primer
pump.
Form No. 1171941R4

Starting the Engine CAUTION: To prevent damage to the engine, do not depress the
accelerator pedal.
WARNING: To prevent personal injury or death, do not 2. Depress clutch pedal if equipped.
use ether, propane, gasoline or gasohol as starting aids. 3. Turn ignition key to ON to preheat glow plugs
NOTE: The ECM normally does not energize glow plugs
WARNING: To prevent personal injury or death, do not during hot starts. However, the ECM senses reduced
install ether start equipment, if an engine has an intake air atmospheric pressure at high altitude and could energize
heater or other cold climate starting aid. the glow plugs during hot starts.
4. Watch for the WAIT TO START lamp on the instrument panel
WARNING: To prevent personal injury or death, do not to go off. Do not crank engine until the lamp is off.
use ether starting fluid to start engine.
5. When the WAIT TO START lamp goes off, turn ignition key
to START. If the vehicle has push button starting, press and
hold starter button.
6. When the engine starts, release the ignition key or starter
button. The ignition key will return to ON and the engine will
continue to run.
7. Release clutch pedal if equipped.
Figure 18 Ignition key positions
Form No. 1171941R4

Starting the Engine (cont.)

CAUTION: To prevent damage to the engine, if the engine fails NOTE: If engine starts and then stops, repeat engine starting
to start within 20 seconds, do the following: procedure. If more than three attempts are required, correct
cause of no-start.
• Turn ignition key to OFF and wait 2-3 minutes.
• Repeat steps 1 through 5. Emergency Starting
• If after three attempts the engine does not start, determine
the cause. WARNING: To prevent personal injury or death, do the
following when jump starting an engine:
• If starting attempts are continued, the starter motor can be
damaged. • Wear eye protection.
8. Low idle speed is 700 rpm (nonadjustable). Extended idling • Do not smoke
periods should be avoided. See Extended Idling Periods in
• Keep flames or sparks away from battery vent openings.
this section. Check all gauges during warm-up.
• Protect against inhaling hydrogen gas fumes from battery
9. Within seconds after engine start, engine oil pressure should
vent openings.
exceed 83 kPa (12 psi).
• Use a 12 volt system with a negative ground.
CAUTION: To prevent engine damage – do not increase engine
speed until oil pressure gauge indicates normal. If oil pressure • Do not exceed 16.0 volts, if the ignition switch is turned to
does not reach the minimum limit within 20 to 30 seconds, OFF, ACC or ON during engine cranking.
shutdown engine.
CAUTION: To prevent engine damage, do not allow metal tools
10. If oil pressure does not meet the minimum limit 276 kPa (40 to contact positive terminal of battery.
psi), stop the engine and correct the problem.
11. After the engine has reached operating temperature and
2. Shut off lights, heater, air conditioner, and other electrical
rated speed, the oil pressure should be 276 kPa (40 psi)
loads in both vehicles.
minimum. If oil pressure does not meet the minimum limit,
stop the engine and correct the problem. 3. Make sure vehicles are not touching.
Form No. 1171941R4

Emergency Starting (cont.)

9. Disconnect jumper cable from positive battery terminals or
WARNING: To prevent personal injury or death, one terminal and jump start stud.
always connect jumper cable for positive battery terminals
first.
4. Connect one end of the first jumper cable to the positive (+) Operation
terminal of the dead battery or to the positive (+) terminal of
the jump start stud. Connect the other end to the positive (+) SUGGESTED WARM UP TIME
terminal of the booster battery.
NOTE: Before applying a load or increasing speed above 1000
rpm, warm up engine for a minimum of 5 minutes at or below
WARNING: To prevent personal injury or death, do not 1000 rpm. The warm up period allows lubricating oil to establish
attach jumper cable to the negative (-) terminal of the dead a film between moving parts.
battery and the negative (-) terminal of the booster battery.
This can cause sparks and an explosion. Cold ambient engine warm up time can be reduced by operating
5. Connect one end of the second jumper cable to the the vehicle under load at reduced engine speed. Begin normal
negative (-) terminal of the booster battery and the other operation when engine systems reach operating temperature.
end to chassis frame of the vehicle with the dead battery. The Cold Ambient Protection (CAP) system aids in engine warm
up and maintains engine heat during extended idling periods.
6. Start engine in vehicle that has the charged battery. See Extended Idling Periods, in this section.
7. Start engine in vehicle that has the dead battery.
IDLE SPEED

always disconnect jumper cable from negative contacts WARNING: To prevent personal injury or death,
first. provide ventilation when operating an engine in a closed
area.
8. Disconnect jumper cable from negative terminal and chassis
frame.
Form No. 1171941R4

Operation (cont.)
IDLE SPEED (cont.)
Extended idling periods should be avoided. Diesel engine

efficiency is improved when the cylinder temperature remains
high. Low temperature in cylinders may cause the following:
• Unburned fuel may seep from exhaust manifold gaskets and
vehicle exhaust system connections. This seepage has the
dark colored appearance of lubricating oil.
• Incomplete combustion and unburned fuel will wash
lubricating oil from cylinder sleeves. Unburned fuel will be
carried into the lubricating oil, dilute the oil, and change oil
viscosity.
• Carbon will form on internal components of turbocharger and
EGR, reducing engine efficiency.
Figure 19 Idle speed
• Carbon will clog and damage the Diesel Particulate Filter
(DPF)
Low idle speed for the International® MaxxForce® 7 Diesel
Engines is 700 rpm (nonadjustable). ENGINE IDLE SHUTDOWN TIMER (FEDERAL-OPTIONAL)
EXTENDED IDLING PERIODS
CAUTION: To prevent engine damage, do not extend low idle GOVERNMENT REGULATION: State and local
periods. regulations may limit engine idle time. The vehicle
owner or operator is responsible for compliance with
these regulations.
Form No. 1171941R4

Operation (cont.)
ENGINE IDLE SHUTDOWN TIMER (FEDERAL-OPTIONAL)
(cont.)
The optional Idle Shutdown Timer (IST) allows the Engine • Brake pedal movement is detected or a brake switch fault is
Control Module (ECM) to shutdown the engine during extended detected.
idle. Idle time can be programmed from 5 to 120 minutes. The
• Parking brake transition is detected.
ECM can be programmed to deactivate the IST when the PTO
is active. • Clutch pedal is pressed or clutch pedal switch fault is
detected (manual transmissions, if equipped with a clutch
Thirty seconds before engine shutdown, the amber IDLE
switch).
SHUTDOWN indicator in the instrument panel gauge cluster
illuminates. This continues until the engine shuts down or the • Shift selector is moved from neutral (automatic
low idle shutdown timer is reset. The engine must be out of transmissions).
gear for the IST to work. Engine shutdown timer will deactivate
• If the IST is enabled, the Cold Ambient Protection (CAP) will
for one or more of the following conditions:
not function.
• Engine speed is not at idle speed (700 rpm).
ENGINE IDLE SHUTDOWN TIMER
• Vehicle movement or a Vehicle Speed Sensor (VSS) fault is
(CALIFORNIA-STANDARD)
detected.
• Manual DPF Regeneration is enabled.
• Accelerator pedal movement or an Accelerator Position
GOVERNMENT REGULATION: State and local
sensor (APS) fault is detected.
regulations may limit engine idle time. The vehicle
• Engine coolant operating temperature is below 60 °C (140 owner or operator is responsible for compliance with
°F). these regulations.
• Ambient temperature below 16 °C (60 °F) or above 44 °C
(110 °F).
Form No. 1171941R4

Operation (cont.)
ENGINE IDLE SHUTDOWN TIMER
(CALIFORNIA-STANDARD) (cont.)
Your heavy duty diesel engine conforms to applicable California • Accelerator pedal movement or an Accelerator Pedal
Air Resources Board (CARB) Engine Shutdown System (ESS) Sensor (APS) fault is detected.
regulations. This vehicle is registered and certified for sale in
• Engine coolant operating temperature is below 16°C (60°F).
California.
• Brake pedal movement or a brake switch fault is detected.
The CARB Idle Shutdown Timer (IST) allows the Engine Control
Module (ECM) to shutdown the engine during extended idle. • Parking brake transition is detected.
When parking brake is set, the idle time can be programmed
• Clutch pedal is pressed or clutch pedal switch fault is
up to 5 minutes. When parking brake is released, the idle time
detected (manual transmissions, if equipped with a clutch
can be programmed up to 15 minutes. No parking brake, the
switch).
idle time can be programmed up to 15 minutes. During service,
the idle time can be programmed up to 60 minutes. The ECM • Shift selector is moved from neutral (automatic
will deactivate the IST when the PTO is active. transmissions).
Thirty seconds before engine shutdown, the amber IDLE • If the IST is enabled, the Cold Ambient Protection (CAP) will
SHUTDOWN indicator in the instrument panel gauge cluster not function.
illuminates. This continues until the engine shuts down or the
low idle shutdown timer is reset. The engine must be out of COLD WEATHER OPERATION
gear for the IST to work. Engine shutdown timer will deactivate
for one or more of the following conditions: NOTE: If operating in temperatures below -29 °C (-20 °F),
contact an International dealer for information about special
• Engine speed is not at idle speed (700 rpm). cold weather equipment and precautions.
• Vehicle movement or a Vehicle Speed Sensor (VSS) fault is NOTE: At temperatures below -20 °C (-4 °F), a crankcase
detected. mounted cup plug coolant heater is recommended to improve
• Manual DPF regeneration is enabled. cold starting.
Form No. 1171941R4

Operation (cont.)
COLD WEATHER OPERATION (cont.)
1. Before operating the engine at 0 °C (32 °F) or lower, check CAP maintains engine coolant temperature by increasing engine
or service the following: rpm to a programmed value when ambient air temperature is
below 20 °C (68 °F), coolant temperature is below 70 °C (158
• Correct battery size
°F), and engine has been idling at no load for over five minutes.
• Correct amount of electrolyte, if not a maintenance free
CAP is standard on all trucks without an idle shutdown timer, with
battery.
a clutch switch (manual transmissions) or a neutral safety switch
• Full battery charge (automatic transmission).
• Condition of other electrical equipment The engine speed will continue to increase or decrease to
maintain a coolant temperature of 80 °C (176 °F) until the
• Cooling system hoses for leaks
following occurs:
• Correct coolant and cooling system level
• Engine load is greater than 45%.
2. At the end of each daily operation do the following:
• Brake pedal is applied or brake switch fault is detected.
• Fill the fuel tank with correct fuel.
• Clutch pedal is depressed or clutch pedal switch fault is
• Drain water from the fuel filter housing. detected (manual transmissions, if equipped with a clutch
switch).
• Check oil level.
• Shift selector is moved from neutral (automatic
• Clean external surfaces of the engine, radiator, and
transmissions). Shift selector must be in neutral for CAP
accessories to prevent dirt or snow build up.
to work.
COLD AMBIENT PROTECTION (CAP) • Power Takeoff (PTO) switch, also used for electronic hand
throttle, is turned on and actively controls engine speed.
CAP safeguards the engine from damage caused by prolonged
idle at no load during cold weather. CAP also improves cab • Accelerator pedal is depressed or accelerator pedal sensor
warm-up. fault is detected.
Form No. 1171941R4

Operation (cont.)
COLD AMBIENT PROTECTION (CAP) (cont.)
• Idle Shutdown Timer (IST) is enabled. • Clean external surfaces of the engine, radiator, and
accessories 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.
At the end of each day, idle the engine for several minutes before
HOT WEATHER OPERATION shutdown.
• Idling is recommended, if an engine has been running at
1. Before operating the engine above 0 °C (32 °F), check or
maximum horsepower.
service the following:
• Idling dissipates heat.
• Correct battery size
• Correct amount of electrolyte, if not a maintenance free ENGINE WARNING PROTECTION SYSTEM (EWPS)
battery.
The Engine Warning Protection System (EWPS) warns the
• Full battery charge operator of engine conditions that can damage the engine.
• Condition of other electrical equipment EWPS has two modes of operation: warning mode (standard)
and protection mode (optional)
Warning mode (standard)
• Correct coolant and cooling system level
• The warning mode is the standard calibration for EWPS.
2. At the end of each daily operation do the following:
• The warning mode monitors engine rpm, Engine Coolant
• Fill the fuel tank with correct fuel. Temperature (ECT), Engine Oil Pressure (EOP), and Engine
• Drain water from the fuel filter housing. Coolant Level (ECL) optional.
• Check oil level
Form No. 1171941R4

Operation (cont.)
ENGINE WARNING PROTECTION SYSTEM (EWPS) (cont.)
• When a condition meets or exceeds a programmed warning PARKING

limit, the red engine lamp will illuminate and an alarm will
sound.
WARNING: To prevent personal injury or death, do the
• The engine will not shut down. following after parking vehicle:
Protection mode (optional) • Set transmission to park or neutral.
• The protection mode is an optional calibration that can • Set parking brake.
be added to the EWPS by the dealer, if requested by the
customer. • Block wheels or turn wheels toward curb.
• The protection mode monitors critical engine conditions: ROAD OPERATION

ECT, ECL, and EOP.
• When a condition meets or exceeds a programmed (warning
critical) limit, the red engine lamp will flash and an alarm will
sound.
• The engine will shut down, after 30 seconds of operation
past critical threshold values for coolant temperature,
coolant level or oil pressure. The operator has 30 seconds
to safely pull the vehicle off the road. If the critical engine
condition remains, the ECM allows the engine to be
restarted and run for 30 second periods.
NOTE: The protection mode is not offered for school buses or
emergency vehicles.
Figure 20 Road operation
Form No. 1171941R4

Operation (cont.)
ROAD OPERATION (cont.)
Correct road operation of your vehicle will provide the following: DOWNHILL OPERATION
• Satisfactory engine performance
• Maximum fuel economy
• Long service life
General guidelines for correct road operation
1. Use the lowest gear to start vehicle. This allows the engine
to easily start the load.
2. Accelerate smoothly and evenly to engine rated speed.
Rapid acceleration causes high fuel consumption.
3. To prevent lugging, do not let engine speed drop below peak
torque rpm during full throttle.
4. When approaching a hill, depress accelerator smoothly
Figure 21 Downhill operation
to start the upgrade at full power. Shift down to maintain
maximum vehicle speed.
CAUTION: To prevent engine damage when driving downhill, 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 allows a lower rpm.
Form No. 1171941R4

Maintenance Schedule
International® MaxxForce® 7 Diesel Engines

Service operation interval - which ever comes first: kilometers/miles, months, years, hours or liters/gallons of fuel
Service Interval Service Operation
See service procedures in this section for more information.

Daily Check engine oil level.
Check coolant level.
Drain water separator.
Check for external leaks.
Check air restriction indicator.
16,000 km (10,000 miles) Change engine oil and oil filter.

6 months, 350 hours Inspect belt, air intake piping, and clamps.
3785 liters (1000 gallons) of fuel Check coolant freeze point.
32,600 km (20,000 miles) Change primary and secondary fuel filters

12 months, 700 hours
7570 liters (2000 gallons) of fuel
Yearly Inspect electrical system.
Pressurize air induction system.
CONTINUED ON NEXT PAGE
Form No. 1171941R4

Maintenance Schedule (cont.)

International® MaxxForce® 7 Diesel Engines (cont.)
Service operation interval - which ever comes first: kilometers/miles, months, years, hours or liters/gallons of fuel
Service Interval Service Operation
See service procedures in this section for more information.

240,000 km (150,000 miles) Add Extended Life Coolant (ECL) Extender
30 months, 6,000 hours
1
322,000 km (200,000 miles) Cleaning Diesel Particulate Filter (DPF)
30 months, 6,000 hours
483,000 km (300,000 miles) Service cooling system.

5 years
1
Reduced service interval required if allowed CI-4 engine lubrication oil is used. If using CI-4 oil, reduce DPF cleaning interval to 241,000 km
(150,000 miles) 22 months, or 4,500 hours.
Form No. 1171941R4

Service Procedures NOTE: Do not check oil level if engine is running or immediately
after engine shutdown.
WARNING: To prevent personal injury or death, put 2. Shut down engine and wait 15 minutes.
transmission in neutral or park, set parking brake, and block 3. Remove oil level gauge from fill tube.
wheels before doing diagnostic or service procedures on
the engine or vehicle.
GOVERNMENT REGULATION: Dispose of fuel Figure 22 Oil level gauge

according to applicable regulations in a correct
container clearly marked DIESEL FUEL.
CAUTION: To prevent engine damage do the following:
• Assure oil level readings are within the crosshatched
operating range on the oil level gauge.
GOVERNMENT REGULATION: Engine fluids (oil, • Do not overfill the engine with oil.
fuel, and coolant) may be a threat to the environment. • Do not operate engine if oil level is above or below the
Recycle or dispose of engine fluids according to operating range.
applicable regulations. Never put engine fluids in the
trash, on the ground, in sewers or bodies of water. 4. If oil level is below operating range, fill with recommended
oil for operating climate. The ADD mark indicates 0.95 liters
(2 quarts US) of oil should be added. See Engine Oil Quality
OIL LEVEL and service categories, in Section 4.
Service Interval: Daily

1. Park vehicle on level ground.
Form No. 1171941R4

Service Procedures (cont.)

COOLANT LEVEL

Shell ROTELLA® Extended Life Coolant (ELC) 50/50 Premix
is the standard factory fill for the cooling system. If a customer
wishes to use a different coolant, it should minimally meet ASTM
D6210, Standard Specification for fully - Formulated Glycol
Base Engine Coolant for Heavy Duty Engines. ROTELLA®
ELC 50/50 Premix is used to replenish coolant loss and ensure
that glycol/water concentrations stay in balance.
Figure 23 Deaeration tank

1. Deaeration tank
2. Deaeration tank cap
3. MAX coolant level
4. ADD coolant level
Form No. 1171941R4


COOLANT LEVEL (cont.)
WATER DRAIN VALVE

following when removing the radiator cap or deaeration tank Service Interval: Daily
cap:
• Allow the engine to cool for 15 minutes or more.
• Wrap a thick cloth around the radiator cap or deaeration tank
cap.
• Loosen cap slowly a quarter to half turn to vent pressure.
• Pause for a moment to avoid being scalded by steam.
• Continue to turn cap counterclockwise to remove.
1. Check coolant level in the deaeration tank.

• Coolant level should be at midpoint of ADD and MAX.
• If coolant level is below the ADD mark, continue with
step 2.
Figure 24 Water drain valve
2. Add ROTELLA® ELC Premix 50/50 to the correct coolant
level (midpoint of ADD and MAX).
3. Install and tighten the deaeration cap until the plastic cap
clicks or the metal cap runs up against the detent.
Form No. 1171941R4


WATER DRAIN VALVE (cont.)

comply with the following:
• When draining fuel, dispose of fuel in a container marked
DIESEL FUEL, according to applicable regulations.
• Do not smoke.
• Keep vehicle away from open flames and sparks.
NOTE: If necessary, connect a hose to the end of the water drain
valve.
1. Put a suitable container under water drain valve.
2. Open water drain valve and drain water/fuel mixture.
Figure 25 Fuel primer pump assembly

1. Fuel primer pump assembly
2. Fuel primer pump knob
NOTE: If the fuel/water mixture does not flow out of drain, unlock
the fuel primer pump by turning the knob counterclockwise. Push
once on the fuel primer pump to displace fuel in the filter. This
will eliminate contaminants in the filter. Turn fuel primer pump
knob clockwise to lock.
Form No. 1171941R4


WATER DRAIN VALVE (cont.)
EXTERNAL LEAKAGE
dispose of fuel in a container marked DIESEL FUEL, Service Interval: Daily
according to applicable regulations.
3. Close water drain valve. WARNING: To prevent personal injury or death, shut
down engine, set parking brake, and block wheels before
4. Dispose of fuel in a correct container. inspecting for external leakage.
CHARGE AIR COOLER (CAC) 1. Check for the following conditions:

• Cracked hoses
• Loose clamps
WARNING: To prevent personal injury or death, shut • Water stains
down engine, set parking brake, and block wheels before
• Oil stains
inspecting the Charge Air Cooler.
• Fuel stains
1. Inspect Charge Air Cooler (CAC) core for debris and clogged
external fins. • Leakage at water pump (wetness from the weep hole is
normal)
2. Before starting engine remove debris blocking the core.
2. Correct problems.
Form No. 1171941R4


AIR CLEANER RESTRICTION same reading when the vehicle is driven under normal driving
conditions.
If the yellow position indicator has locked in the red zone, a
new air filter should be installed to prevent low engine power
or engine damage.
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. Install a new air filter element.
5. Push reset button on air restriction indicator. The yellow
indicator will return to zero.
Figure 26 Air cleaner restriction indicators

1. Mounted on air cleaner
2. Mounted on instrument panel
Push reset button to check air restriction indicator. If the air

filter was not changed, the yellow indicator will return to the
Form No. 1171941R4


ENGINE OIL AND FILTER
Service Interval: 16,000 km (10,000 miles), 6 months, 350 hours

or 3785 liters (1000 gallons of fuel)
CAUTION: To prevent engine damage, do not extend
recommended oil change intervals.
1. Park vehicle on level ground. Set parking brake and shift
transmission to Park or Neutral.
2. Run engine until operating temperature is reached, then shut
engine down.
WARNING: To prevent personal injury or death, wear

protective clothing when draining hot oil.
Figure 27 Oil filter removal and installation

WARNING: To prevent personal injury or death, do not
let engine fluids stay on your skin. Clean skin and nails 1. Oil filter cap
using hand cleaner and wash with soap and water. Wash or 2. O-ring seal
discard clothing and rags contaminated with engine fluids. 3. Oil filter element
4. Oil filter housing
3. Remove oil filter cap.

4. Remove and dispose of O-ring seal on oil filter cap.
5. Remove and dispose of old oil filter element.
6. Install new oil filter element.
Form No. 1171941R4


ENGINE OIL AND FILTER (cont.)
7. Install new O-ring seal on oil filter cap.

CAUTION: To prevent engine damage, do not over overtighten
oil filter cap.
Figure 28 Oil level gauge
8. Install oil filter cap and tighten to the special torque 25 N·m
(18 lbf-ft).
9. Put drain pan under the oil pan drain plug, remove oil pan 14. Check oil level gauge. Oil level must be within the
drain plug, and drain oil. crosshatched operating range on the gauge.
10. Install new O-ring on oil pan drain plug and install drain plug. 15. Start engine and run at low idle.
11. Tighten oil pan drain plug to 68 N·m (50 lbf·ft). 16. Check reading on oil pressure gauge.
• Minimum lube oil pressure is 83 kPa (12 psi) @ 700 rpm.
• If there is no gauge reading, shut engine off immediately.
dispose of oil or discard components, according to
Check for oil filter leaks.
applicable regulations.
• Let engine run until operating temperature is reached.
12. Dispose of oil according to applicable regulations.
Check for leaks.
CAUTION: To prevent engine damage, do not overfill with oil.
17. Shut down engine for 15 minutes.
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 oils will reduce DPF cleaning
interval, see Maintenance Schedule (page 49). Add oil 18. Recheck oil level and add oil (if needed) to bring oil level
through the engine oil fill tube. within the crosshatched operating range on gauge.
Form No. 1171941R4


RESETTING CHANGE ENGINE OIL SERVICE INTERVAL BELT, AIR INTAKE PIPING AND CLAMPS
MESSAGE
Service Interval: 16,000 km (10,000 miles), 6 months, 350 hours
Reset the Service Interval Message (change engine oil) per the or 3785 liters (1000 gallons of fuel)
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
down on the fifth time for four seconds.
7. The Change Oil message should clear.
8. The operation from the time the cruise is turned On for Figure 29 Cracks in belt ribs
the second time to the fifth activation of the resume switch 1. Belt in good condition
must take place within six seconds. If you fail to reset the 2. Belt ready for replacement
message, repeat the process. 3. Belt ribs
4. Cracks in belt
Form No. 1171941R4


BELT, AIR INTAKE PIPING AND CLAMPS (cont.)
For any of the following conditions install a new belt:

• Excessive wear
• Missing material
• Grease or oil contamination
• Over three cracks per inch in a belt rib
Figure 30 Square hole in auto tensioner (typical)
1. Attach a 1/2 inch breaker bar to square hole in auto

tensioner.
Form No. 1171941R4


BELT, AIR INTAKE PIPING AND CLAMPS (cont.)
2. Pull breaker bar away from belt and install belt over auto ROTELLA® ELC 50/50 Extender is added at the designated
tensioner pulley and other pulleys. service interval.
3. Release auto tensioner. Tensioner will automatically adjust.
Freeze Point Protection Levels Provided by ROTELLA®
4. Remove breaker bar. Concentrate and Water Mixtures
For any of the following conditions, install new parts: Concentrate and Water Freeze Point Protection
Mixtures
• Loose hoses or clamps
• Ruptured hoses and 60% water
• Cracked air cleaner housing 50% ROTELLA® Concentrate -36.7 °C (-34 °F)
• Damaged Charge Air Cooler (CAC) and 50% water
COOLANT FREEZE POINT and 40% water
Service Interval: 24,000 km (15,000 miles), 6 months, or 550 67% ROTELLA® Concentrate -70.6 °C (-95 °F)
hours and 40% water
ROTELLA® ELC 50/50 Premix provides freeze protection to -36 For vehicles operating in extremely cold climates, a coolant
°C (-34 °F) and maximum corrosion protection. If a customer mixture of 60% ROTELLA® Concentrate and 40% water or 67%
wishes to use a different coolant, it should minimally meet ASTM ROTELLA® Concentrate and 33% water provide additional
D6210, Standard Specification for fully - Formulated Glycol freeze protection as shown in the table above. Mixtures having
Base Engine Coolant for Heavy Duty Engines. ROTELLA® more than 67% ROTELLA® Concentrate are not recommended.
ELC 50/50 Premix is used to replenish coolant loss and ensure
that glycol/water concentrations stay in balance. Check freeze point with a refractometer.
1. Put drop of coolant on refractometer window.
Form No. 1171941R4


COOLANT FREEZE POINT (cont.)
2. Look through eyepiece and focus.

3. Record freeze point.
PRIMARY FUEL FILTER
Service Interval: 32,000 km (20,000 miles), 12 months, 700

hours or 7570 liters (2,000 gallons) of fuel
NOTE: Change fuel filter if optional fuel filter lamp is illuminated.
NOTE: If fuel used has more than average impurities, shorter
service intervals may be required.

comply with the following:
• Make sure the transmission is in neutral, parking brake
is set, and wheels are blocked before doing diagnostic or Figure 31 Primary fuel element assembly
service procedures on engine or vehicle.
1. Fuel drain valve
• When draining fuel, dispose of fuel in a container marked 2. Fuel heater electrical connector
DIESEL FUEL, according to applicable regulations. 3. Water In Fuel (WIF) sensor electrical connector
• Do not smoke.
• Keep vehicle away from open flames and sparks. 1. Set parking brake and shift transmission to Park or Neutral.
2. Put a suitable container under the water drain valve.
3. Open water drain valve and drain the fuel filter assembly.
Form No. 1171941R4


PRIMARY FUEL FILTER (cont.)

dispose of fuel in a container marked DIESEL FUEL,
according to applicable regulations.
4. Dispose of fuel in a correct container.
5. Disconnect electrical connector from fuel heater.
6. Disconnect electrical connector from WIF sensor.
Figure 32 Primary fuel element assembly

1. Primary filter element assembly
2. Element and bowl primary seal
3. Bowl assembly with fuel heater/probe
7. Remove bowl assembly. Use an oil filter wrench, if

necessary.
8. Remove seal from bowl assembly.
Form No. 1171941R4


PRIMARY FUEL FILTER (cont.)
9. Remove primary filter element assembly. SECONDARY FUEL FILTER

10. Install a new primary filter element assembly. Service Interval: 32,000 km (20,000 miles), 12 months, 700
11. Install new seal in bowl assembly. hours or 7570 liters (2,000 gallons) of fuel
12. Install bowl assembly and hand tighten.

13. Close fuel drain valve by turning it clockwise.
14. Connect fuel heater electrical connector.
15. Connect WIF sensor electrical connector.
Figure 33 Fuel filter removal and installation

1. Fuel filter cap
2. O-ring
3. Fuel filter element
4. Fuel filter housing
Form No. 1171941R4


SECONDARY FUEL FILTER (cont.)
1. Remove fuel filter cap.

2. Remove O-ring from fuel filter cap and discard O-ring.
3. Remove fuel filter element from fuel filter housing.
CAUTION: To prevent engine damage, the fuel filter element
must be installed in the fuel filter housing.
NOTE: The engine will not run if the filter element is not installed.
The installed filter element opens a check valve in the center of
the stand pipe, allowing fuel to flow.
4. Install new fuel filter element.
CAUTION: To prevent engine damage, do not add fuel to the
fuel filter housing; this can add contaminants to the fuel.
5. Install new O-ring fuel on filter cap.
CAUTION: To prevent engine damage, the fuel filter cap must
Figure 34 Fuel priming pump
be tightened on the fuel filter housing.
1. Fuel priming pump
6. Install fuel filter cap and tighten to the special torque 27 N·m
2. Fuel priming pump knob
(20 lbf-ft).
7. Fill fuel filter header with fuel by pumping the fuel primer
pump.
Form No. 1171941R4


ELECTRICAL SYSTEM INDUCTION SYSTEM
Service Interval: Yearly Service Interval: Yearly

1. Check wiring harness for cracks, rubbing and loose Pressure test the air induction system as follows:
connections.
• For inspection procedures, see International® MaxxForce®
2. Check sensors for loose connections, corrosion or cracks. 7 Engine Diagnostic Manual.
3. Check battery cables for the following conditions: • Have your International dealer pressure test the air induction
system.
• Broken insulation.
• Rubbing or chaffing.
• Corroded or loose connections.
Electronics
Periodically check that all fault codes are cleared out and
do not reappear. For correct procedures, see International®
MaxxForce® 7 Engine Diagnostic Manual or contact your
International dealer.
Form No. 1171941R4


EXTENDED LIFE COOLANT (ELC) EXTENDER
Service Interval: 240,000 km (150,000 miles), 30 months or following when removing the radiator cap or deaeration tank
6,000 hours cap:
cap.
1. Remove deaeration tank cap.
ROTELLA® ELC Extender

Cooling System Drain ELC Coolant Add ROTELLA®
Capacity ELC Extender
22-30 liters (6-8 0.2 liter (0.5 quart 0.2 liter (0.5 quart
Figure 35 Deaeration tank ADD and MAX level marks gallons) US) US)
1. Deaeration tank 30-49 liters (8-13 0.5 liter (1.0 quart 0.5 liter (1.0 quart
2. Deaeration tank cap gallons) US) US)
49-83 liters (13-22 0.7 liter (1.5 quart 0.7 liter (1.5 quart
gallons) US) US)
Form No. 1171941R4


EXTENDED LIFE COOLANT (ELC) EXTENDER (cont.)
2. Confirm coolant system capacity. CLEANING DIESEL PARTICULATE FILTER

3. According to Cooling System Capacity in the table, drain the For Engines Using CJ-4 Engine Oil
correct volume of coolant from the cooling system.
Service Interval: 322,000 km (200,000 miles) 30 months or
NOTE: Shell ROTELLA® ELC 50/50 Premix is the standard 6,000 hours
factory fill for the cooling system. ROTELLA® ELC 50/50 Premix
is used to replenish coolant loss and ensure that glycol/water Clean DPF at designated service interval. Take vehicle to your
concentrations stay in balance. If a customer wishes to use International® dealer for cleaning.
a different coolant, it should minimally meet ASTM D6210, For Engines Using CI-4 Engine Oil
Standard Specification for fully - Formulated Glycol Base
Engine Coolant for Heavy Duty Engines. Service Interval: 241,000 km (150,000 miles) 22 months or
4,500 hours
4. Add the same volume of ROTELLA® ELC Extender to the
cooling system. Clean DPF at designated service interval. Take vehicle to your
International® dealer for cleaning.
5. Check coolant level. If necessary, add ROTELLA® ELC
50/50 Premix to bring coolant level to mid point (between
ADD and MAX) of deaeration tank.
6. Install and tighten the deaeration tank cap until the plastic
cap clicks or the metal cap runs up against the detent.
Form No. 1171941R4


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

following when removing the radiator cap or deaeration tank
cap:
cap.
Figure 36 Deaeration tank
1. Deaeration tank
1. Park vehicle so the engine is level.

3. Put a drain pan under the radiator.
4. Remove deaeration tank pressure cap.
Form No. 1171941R4


SERVICE COOLING SYSTEM (cont.)
5. Open radiator drain valve. 8. After coolant has drained, install right side coolant drain plug.
6. After radiator has drained, close the drain valve and move
the drain pan under right side coolant drain plug.
Figure 38 Left side coolant drain plug
9. Move the drain pan under left side coolant drain plug.
Figure 37 Right side coolant drain plug
10. Remove left side coolant drain plug.
11. After coolant has drained, install left side coolant drain plug.
7. Remove right side coolant drain plug.
Form No. 1171941R4


NOTE: Shell ROTELLA® ELC 50/50 Premix is the standard

factory fill for the cooling system. ROTELLA® ELC 50/50 Premix
is used to replenish coolant loss and ensure that glycol/water
concentrations stay in balance. If a customer wishes to use
a different coolant, it should minimally meet ASTM D6210,
Standard Specification for fully - Formulated Glycol Base
Engine Coolant for Heavy Duty Engines.
12. Slowly fill cooling system with new ROTELLA® ELC 50/50
Premix or ROTELLA® Concentrate and water mixture until
coolant is at the mid point between the ADD and FULL level
in the deaeration tank.
13. Install and tighten the deaeration tank cap until the plastic
cap clicks or the metal cap runs up against the detent.
14. Start the engine.
Figure 39 ADD and MAX level marks on deaeration tank 15. Allow the engine to operate at a fast idle until the engine
1. Deaeration tank reaches normal operating temperature.
2. Deaeration tank cap 16. As the engine warms up, make sure coolant is flowing
3. MAX coolant level through deaeration line – coolant will feel warm to the touch.
17. After engine reaches normal operating temperature and the
thermostat has opened, shut engine off.
Form No. 1171941R4


Figure 40 ADD and MAX level marks on deaeration tank

1. Deaeration tank
18. If necessary, add coolant to the deaeration tank to bring the

level up to the MAX mark.
Form No. 1171941R4


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 block
wheels 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.
Form No. 1171941R4

Maintenance Service Record (cont.)

Maintenance Service Record
Date Service Month Service Hours km (Miles) Item Serviced
Form No. 1171941R4

Maintenance Service Record (cont.)

Table 1 Maintenance Service Record
Date Service Month Service Hours km (Miles) Item Serviced
Form No. 1171941R4

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 block
wheels before doing diagnostic or service procedures. • Drain water from the fuel filter housing.
Check the following daily to prevent engine failure. Report all • Clean external surfaces of the engine, radiator, and
problems for immediate service. accessories to prevent dirt or snow build up.
• Oil level.
• Oil, air, fuel or coolant 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
Form No. 1171941R4

Daily Care and Report (cont.)

Daily Care and Report
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost
Form No. 1171941R4

Daily Care and Report (cont.)

Table 2 Daily Care and Report
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost
Form No. 1171941R4

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects and
other reproductive harm.

Maxxforce 07 Series - EPA08-09 - Engine Operation and Maintenance Manual # (85pgs)

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International® MaxxForce® 7 Diesel Engine

Engine Operation and Maintenance Manual

© 2009 Navistar, Inc. All rights reserved.

Form No. 1171941R4

SECTION 1 – ENGINE SYSTEMS

Form No. 1171941R4

Component Location – Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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

SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES

Form No. 1171941R4

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

SECTION 4 – ENGINE OPERATION

SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Form No. 1171941R4

Charge Air Cooler (CAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

SECTION 6 – SERVICE RECORDS

Form No. 1171941R4

Foreword Technical Service Literature is revised periodically and mailed

Technical Service Literature

Form No. 1171941R4

Form No. 1171941R4

Safety Information Safety Instructions

This manual provides general and specific maintenance Work Area

Form No. 1171941R4

Form No. 1171941R4

• Check for frayed power cords before using power tools.

Form No. 1171941R4

Form No. 1171941R4

Warranty have no record of maintenance. However, a claim may be

Form No. 1171941R4

Federal Emission System Warranty (cont.)

Form No. 1171941R4

Federal Emission System Warranty (cont.)

Navistar assures that the emission warranty is being properly

Form No. 1171941R4

Form No. 1171941R4

California Emission System Warranty (cont.)

Form No. 1171941R4

California Emission System Warranty (cont.)

• Abuse or misuse of engine Manager, Customer Relations

• Loss of time, inconvenience, use of vehicle/engine or The Air Resources Board

Form No. 1171941R4

Engine Emission Label

Figure 1 Engine serial number

Form No. 1171941R4

Engine Emission Label (cont.)

Form No. 1171941R4

Engine Specifications and Features

• High idle 276 kPa (40 psi) minimum

Form No. 1171941R4

Engine Specifications and Features (cont.)

Form No. 1171941R4

STANDARD FEATURES (cont.)

Form No. 1171941R4

CHASSIS MOUNTED FEATURES

A Charge Air Cooler (CAC) is an air-to-air heat exchanger which

Form No. 1171941R4

Component Location – Front

Form No. 1171941R4

Component Location – Left

Form No. 1171941R4

Component Location – Right

Form No. 1171941R4