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Navistar MaxxForce 7 Operation And Maintenance Manual

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®
MaxxForce
7
Engine Operation and Maintenance Manual
Navistar, Inc.
2701 Navistar Drive, Lisle, IL 60532 USA
© 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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  • Page 1 ® MaxxForce Engine Operation and Maintenance Manual Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532 USA © 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
  • Page 2 The information, specifications, and illustrations contained in this manual are based on data that was current at the time of publication. Navistar, Inc. reserves the right to make changes and/or improvements at any time without notification, liability, or without applying those changes or improvements to vehicles previously manufactured and/or sold.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS FOREWORD..................1 SAFETY INFORMATION...............3 WARRANTY..................7 U.S. Federal Emission System Warranty..............7 Warranty Period.
  • Page 4 TABLE OF CONTENTS Engine Features................... .21 Engine Optional Features.
  • Page 5 TABLE OF CONTENTS Idle Shut Down Indicator..................40 Maintenance Lamp.
  • Page 6 TABLE OF CONTENTS Engine Shutdown...................59 Engine Warning Protection System (EWPS).
  • Page 7 TABLE OF CONTENTS Cleaning Diesel Particulate Filter (DPF)..............90 Service Cooling System.

  • Page 9: Foreword

    This manual contains information needed to correctly operate development to improve products and introduce technological and maintain your engine as recommended by Navistar, Inc. advances. Procedures, specifications, and parts defined in Numerous illustrations, symbols and feature descriptions are used to aid in understanding the meaning of the text.
  • Page 10 FOREWORD Page 2...

  • Page 11: Safety Information

    SAFETY INFORMATION Safety Information Safety Instructions Work Area This manual provides general and specific maintenance procedures essential for reliable engine operation and your • Keep work area clean, dry, and organized. safety. Since many variations in procedures, tools, and service •...
  • Page 12 SAFETY INFORMATION Vehicle 2. Type B — Flammable liquids • Make sure the vehicle is in park or neutral, the parking brake 3. Type C — Electrical equipment is set, and the wheels are blocked before servicing engine. Batteries • Clear the area before starting the engine.
  • Page 13 SAFETY INFORMATION Compressed Air • Do not refuel the tank when the engine is running. • Use an OSHA approved blow gun. Limit blow gun air Removal of Tools, Parts, and Equipment pressure to 30 psi (207 kPa). • Reinstall all safety guards, shields, and covers after •...
  • Page 14 SAFETY INFORMATION Page 6...

  • Page 15: Warranty

    Warranty repairs should be completed in a reasonable time, not than above) to exceed 30 days. Navistar, Inc. may deny warranty coverage if Your heavy-duty diesel engine conforms to U.S. Environmental your vehicle or a part has failed due to abuse, neglect, improper Protection Agency regulations for emission systems.

  • Page 16: Recommended Maintenance Or Repair Parts

    Parts other than MaxxForce service parts or ReNEWed original quality of your emission certified engine. If parts not parts recommended by Navistar. cause damage to the engine or vehicle, the warranty is invalid and maintenance and repair • Aftermarket parts or service kits costs will not be covered.

  • Page 17: Warranty Rights And Responsibilities

    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 Manual. If additional assistance is required, contact the Manager of Customer Relations.

  • Page 18: California Emission System Warranty

    Navistar, Inc. costs will not be covered. recommends that you retain all receipts covering maintenance on your truck, but Navistar, Inc. will not deny warranty solely for the lack of receipts or your failure to ensure the performance of Page 10...

  • Page 19: Emergency Repairs

    Ventilation Valve [CCV] and oil fill cap) made by Navistar to ensure that your emission control system Performance Warranty. If any emission-related part on your diesel engine is defective, the part will be repaired or replaced by Navistar. This is your Page 11...

  • Page 20: What Is Not Covered By Warranty

    Parts requiring replacement at inspection or adjustment If you have not received satisfactory service or have questions maintenance intervals for reasons other than being defective regarding your warranty rights and responsibilities, contact the Navistar, Inc. regional office for assistance. The address and Page 12...
  • Page 21 Vehicle Operator Manual. If additional assistance is required, contact the Manager of Customer Relations. Manager, Customer Relations Navistar, Inc. 2701 Navistar Drive Lisle, Illinois 60532 (Telephone 1-800-448-7825) If further questions of warranty rights and responsibilities remain, contact:...
  • Page 22 WARRANTY Page 14...

  • Page 23: Section 1 - Engine Systems

    SECTION 1 – ENGINE SYSTEMS Engine Serial Number M2 – Motor truck or U2 power unit and OEM (sold to original equipment manufacturer) Y – United States, Huntsville Alabama 7–digit suffix – Engine serial number sequence Engine Emission Label Figure 2 The U.S. Environmental Protection Agency (EPA) Figure 1 Engine Serial Number Exhaust Emission Label (Example)

  • Page 24: Engine Accessories

    SECTION 1 – ENGINE SYSTEMS Engine Emission Label (cont.) • Emission family and control systems • Year the engine was certified to meet EPA emission standards Engine Accessories The following engine parts may have manufacturers' labels or identification plates: • Air compressor •...

  • Page 25: Engine Specifications

    SECTION 1 – ENGINE SYSTEMS Engine Specifications ® MaxxForce 7 Features and Specifications Engine Configuration 4 stroke, V8 diesel Rated power @ rpm See EPA exhaust emission label. Peak torque @ rpm See EPA exhaust emission label. Displacement 6.4 L (389 in Compression ratio 16.5 : 1 Stroke...
  • Page 26 SECTION 1 – ENGINE SYSTEMS Engine Specifications (cont.) Engine lubrication oil pressure at operating temperature Low idle 12 psi (83 kPa) minimum High idle 45 psi (310 kPa) minimum Idle speed (no load) 700 rpm ± 50 (nonadjustable) Thermostat operating temperature With bypass 198°F - 205°F (92°C - 96°C) Without bypass...

  • Page 27: Engine Description

    SECTION 1 – ENGINE SYSTEMS Engine Specifications (cont.) Engine Description Cold Start Assist A relay controlled grid (duct) heater is used in the intake air ® The MaxxForce 7 is a V8 engine with a displacement of 6.4 liters stream to aid cold ambient starting. (389 cubic inches).
  • Page 28 SECTION 1 – ENGINE SYSTEMS Engine Description (cont.) The camshaft is supported by five bushings pressed into the Electronic Control System crankcase. The camshaft is crankshaft driven, and thrust is An Engine Control Module (ECM) monitors and controls engine controlled by a plate mounted behind the rear bulkhead. performance to ensure maximum performance and compliance An open crankcase breather system draws crankcase vapors with EPA emissions requirements.

  • Page 29: Engine Features

    SECTION 1 – ENGINE SYSTEMS Engine Description (cont.) 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 during cold weather startups.
  • Page 30 SECTION 1 – ENGINE SYSTEMS Engine Features (cont.) Cold Ambient Protection (CAP) CAP keeps the engine warm during cold temperatures and may provide better fuel economy, increased operator comfort, and improved engine performance. This feature should only be disabled for specialized applications. Engine damage may occur if CAP is disabled.
  • Page 31 SECTION 1 – ENGINE SYSTEMS Engine Features (cont.) Electronic Service Tool (EST) Interface Electronic Speedometer and Tachometer Vehicles are equipped with the EST interface for communication The engine control system calibrates vehicle speed. Any new between the Engine Control Module (ECM) and the EST. speed calibration information must be programmed with an EST.

  • Page 32: Engine Optional Features

    SECTION 1 – ENGINE SYSTEMS Engine Features (cont.) Fast Idle Advance It is essential that operators are trained to know the maintenance schedules and instructions regarding the operation and reset Fast idle advance increases engine idle speed for faster functionality of the service interval for the feature to be effective. warm-up to operating temperature.
  • Page 33 SECTION 1 – ENGINE SYSTEMS Engine Optional Features (cont.) Engine Exhaust Brake Vehicles that comply with the clean idle regulations will have a Certified Clean Idle label applied to the hood or door of the An exhaust brake is available to provide additional brake torque vehicle.
  • Page 34 SECTION 1 – ENGINE SYSTEMS Engine Optional Features (cont.) Radiator Shutter Enable (RSE) Road Speed Limiting (RSL) RSE provides a signal to open or close the radiator shutters. RSL is designed to regulate the maximum vehicle speed as Closing the shutters will keep the engine warm during cold controlled by the accelerator pedal.

  • Page 35: Component Location - Top

    SECTION 1 – ENGINE SYSTEMS Component Location – Top Figure 4 Top Pump cover heat shield (right) Turbocharger outlet 15. Turbocharger inlet duct assembly Right exhaust tube assembly 10. Turbocharger Outlet Temperature (TCOT) 16. Primary Freon compressor mount Exhaust turbocharger inlet manifold sensor 17.

  • Page 36: Component Location - Front

    SECTION 1 – ENGINE SYSTEMS Component Location – Front Figure 5 Front Grooved idler pulley Lifting eye (2) Vibration damper and pulleys Fan pulley Air compressor pulley 10. Heater return Flat idler pulley (2) Coolant inlet 11. Thermostat housing (coolant outlet) Belt tensioner (3) Water pump pulley Page 28...

  • Page 37: Component Location - Left

    SECTION 1 – ENGINE SYSTEMS Component Location – Left Figure 6 Left Oil fill tube cap Left valve cover 17. Power Take Off (PTO) air compressor Oil level gauge (dipstick) 10. Left exhaust tube assembly front pulley Fuel supply port (from tank) 11.

  • Page 38: Component Location - Right

    SECTION 1 – ENGINE SYSTEMS Component Location – Right Figure 7 Right Breather filter cover Front engine mounting support 12. Rear crankcase cover assembly (flywheel Engine Throttle Valve (ETV) Inner front pulley (alternator and primary housing) Primary Freon compressor mounting Freon compressor) 13.

  • Page 39: Component Location - Rear

    SECTION 1 – ENGINE SYSTEMS Component Location – Rear Figure 8 Rear Exhaust Gas Recirculation (EGR) cooler Draft tube assembly High-pressure pump cover heat shield Exhaust turbocharger inlet manifold Rear crankcase cover assembly (flywheel (right) Low-pressure turbocharger assembly housing) 10. Rear engine mounting bracket (2) Right exhaust tube assembly Flexplate 11.
  • Page 40 SECTION 1 – ENGINE SYSTEMS Page 32...

  • Page 41: Section 2 - Requirements For Fuel, Engine Oil, And Coolant

    SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT Fuel ULTRA LOW SULFUR DIESEL (ULSD) GOVERNMENT REGULATION: Diesel fuel sold for use in 2007 and later highway vehicles must be limited to a sulfur content of 15 parts per million (ppm). ®...

  • Page 42: Acceptable Fuel Blends

    If providers and customers follow correct storage and maintenance procedures for fuel and equipment, blends of B6 to Navistar, Inc. approves of blends up to B5, provided that the B20 that meet ASTM D7467 (current revision) Standard should two components satisfy current standard specifications. Quality perform satisfactorily in diesel engines.

  • Page 43: Unsafe Practices

    This creates a fire hazard and possible explosion. CAUTION: To prevent engine damage, do not mix propane with diesel fuel. Navistar, Inc. will not honor warranty claims against engines that have used propane. Figure 10 API Identification Symbol...

  • Page 44: Oil Viscosity

    SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT Engine Oil (cont.) API CJ-4 FOR HIGH PERFORMANCE DIESEL ENGINES (cont.) NOTE: Mineral and synthetic oils are acceptable for use OIL VISCOSITY provided they meet the API category recommendations and ambient temperature guidelines.

  • Page 45: Coolant

    SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT Engine Oil (cont.) OIL VISCOSITY (cont.) oils for correct flow during starting. Higher temperatures require EXTENDED LIFE COOLANT (ELC) - RED higher grade oils for satisfactory lubrication. Heavy Duty Extended Life Coolant (ELC) 50/50 Premix meeting •...

  • Page 46: Contamination Of Coolant

    SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT Coolant (cont.) EXTENDED LIFE COOLANT (ELC) - RED (cont.) For vehicles operating in extremely cold climates, coolant mixtures of 60% Concentrate and 40% water or 67% Concentrate and 33% water provide additional freeze protection as shown in table above.

  • Page 47: Section 3 - Instruments, Indicators, And Switches

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Instrument Panel Gauge Cluster Wait to Start Lamp During engine starts and engine operation, gauges and indicator lamps should be checked periodically. Gauges may vary with vehicle applications. Warning and indicator lamps show conditions not indicated by the gauges. See the Vehicle Operator Manual for description of indicator lamps for the drivetrain, chassis components, and cabin.

  • Page 48: Idle Shut Down Indicator

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Idle Shut Down Indicator Maintenance Lamp Figure 14 Maintenance Lamp Figure 13 Idle Shutdown Indicator The Maintenance lamp will illuminate in conjunction with other warning lights or general text and warning messages. It may be The Idle Shutdown indicator will illuminate Yellow when the accompanied by an audible alarm to indicate an alert condition vehicle shutdown timer will turn the engine off in 30 seconds.

  • Page 49: Amber Warning Lamp (Awl)

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Amber Warning Lamp (AWL) Red Stop Lamp (RSL) Figure 15 AWL Figure 16 RSL The Amber Warning Lamp (AWL) will illuminate YELLOW by itself, or in conjunction with other warning lights or general CAUTION: To prevent engine damage, shut down engine text and warning messages, to indicate an alert condition to immediately , if the Red Stop Lamp flashes.

  • Page 50: High Exhaust System Temperature (Hest) Lamp

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES High Exhaust System Temperature (HEST) Lamp Diesel Particulate Filter (DPF) Indicator Figure 17 HEST Lamp Figure 18 Diesel Particulate Filter Indicator The diesel particulate filter indicator operates at three different WARNING: Exhaust components are operating under levels.

  • Page 51: Malfunction Indicator Lamp (Mil)

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Diesel Particulate Filter (DPF) Indicator (cont.) Malfunction Indicator Lamp (MIL) Level Two The DPF indicator will be flashing indicating the exhaust filter is full. The vehicle should be safely pulled off the roadway and parked.

  • Page 52: Typical Water Temperature Gauge

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Typical Water Temperature Gauge CAUTION: To prevent engine damage do not operate engine above 228°F (109°C); this may cause internal damage. The indicator lamp will be activated at engine coolant temperatures above 228°F (109°C). If engine temperature suddenly rises, shut down engine and determine the cause of overheating.

  • Page 53: Oil Temperature Gauge

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Oil Temperature Gauge Oil Pressure Gauge Figure 22 Oil Pressure Gauge Figure 21 Oil Temperature Gauge The engine oil pressure gauge indicates operating oil pressure. The engine oil temperature gauge indicates the oil temperature The engine oil pressure indicator lamp and alarm will be of the engine.

  • Page 54: Engine Exhaust Brake On / Off Toggle Switch

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Oil Pressure Gauge (cont.) Engine Exhaust Brake On / Off Toggle Switch Lubrication Oil Pressure Lube Oil Pressure At normal operating temperature Low idle 12 psi (83 kPa) min. High idle 45 psi (310 kPa) CAUTION: To prevent engine damage, shut down engine immediately if the oil pressure indicator lamp and alarm are active.

  • Page 55: Air Cleaner Restriction Indicator

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Air Cleaner Restriction Indicator induction system or instrument panel depending on your specific application. Air restriction is resistance of airflow through the air cleaner. Air Restriction Indicator Calibration Accurate air restriction is measured at maximum airflow. •...
  • Page 56 SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Page 48...

  • Page 57: Section 4 - Engine Operation

    SECTION 4 – ENGINE OPERATION Preoperation Checklist 7. Check belt condition and alignment. 8. Fill the tank with recommended fuel. For further information see Acceptable Fuel Blends (page 34). WARNING: To prevent personal injury or death, provide ventilation when operating an engine in a closed 9.

  • Page 58: Priming The Fuel System

    SECTION 4 – ENGINE OPERATION Priming the Fuel System 3. There are two ways to prime the fuel system; use only one of the following two ways. PRIMING THE FUEL SYSTEM AFTER SERVICING THE FUEL FILTERS GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human 1.

  • Page 59: Priming The Fuel System After Running Out Of Fuel

    SECTION 4 – ENGINE OPERATION Priming the Fuel System (cont.) Starting the Engine PRIMING THE FUEL SYSTEM AFTER RUNNING OUT OF FUEL 1. If the vehicle has run out of fuel, turn ignition switch to OFF WARNING: To prevent personal injury or death, do not use ether, propane, gasoline or gasohol as starting aids.
  • Page 60 SECTION 4 – ENGINE OPERATION Starting the Engine (cont.) CAUTION: To prevent damage to the engine, do not depress the CAUTION: To prevent damage to the engine, if the engine fails accelerator pedal. to start within 20 seconds, do the following: 2.

  • Page 61: Emergency Starting

    SECTION 4 – ENGINE OPERATION Emergency Starting WARNING: To prevent personal injury or death, always connect jumper cable for positive battery terminals WARNING: To prevent personal injury or death, do not first. use ether starting fluid to start the engine. 4.

  • Page 62: Operation

    SECTION 4 – ENGINE OPERATION Operation EXTENDED IDLING PERIODS CAUTION: To prevent engine damage, do not extend low idle SUGGESTED WARM-UP TIME periods. NOTE: The warm up period allows lubricating oil to establish a Extended idling periods should be avoided. Diesel engine film between moving parts.

  • Page 63: Aftertreatment System

    SECTION 4 – ENGINE OPERATION Operation (cont.) AFTERTREATMENT SYSTEM • See “Safety Information” (page 3) for safety precautions. A DOC operates to oxidize the injected fuel to increase the engine vehicle exhaust piping includes exhaust gas temperature as needed for DPF Regen. Aftertreatment System to capture soot and other particulates before they exit the exhaust pipe.

  • Page 64: Engine Idle Shutdown Timer (California And All State - Optional [2012 And Newer Vehicles])

    SECTION 4 – ENGINE OPERATION Operation (cont.) ENGINE IDLE SHUTDOWN TIMER (U.S. FEDERAL-OPTIONAL [2010 AND 2011 VEHICLES]) (cont.) • Engine speed is not at idle speed (700 rpm). • If the IST is enabled, the Cold Ambient Protection (CAP) will not function.

  • Page 65: Cold Weather Operation

    SECTION 4 – ENGINE OPERATION Operation (cont.) ENGINE IDLE SHUTDOWN TIMER (CALIFORNIA AND ALL STATE - OPTIONAL [2012 AND NEWER VEHICLES]) (cont.) idle time can be programmed up to 60 minutes. The ECM will • Shift selector moved from neutral (automatic deactivate the IST when the PTO is active.

  • Page 66: Cold Ambient Protection (Cap)

    SECTION 4 – ENGINE OPERATION Operation (cont.) COLD WEATHER OPERATION (cont.) • Correct coolant and cooling system level The engine speed continues to increase or decrease to maintain a coolant temperature of 194°F (90°C) until the following occurs: • Recommended oil grade •...

  • Page 67: Hot Weather Operation

    SECTION 4 – ENGINE OPERATION Operation (cont.) HOT WEATHER OPERATION ENGINE SHUTDOWN 1. Before operating the engine above 32°F (0°C), check or Before shutting down an engine that has reached operating service the following: temperature, idle the engine for 30 seconds, allowing the hottest engine components to dissipate some of their internal heat.

  • Page 68: Hd-Obd Overview

    SECTION 4 – ENGINE OPERATION Operation (cont.) ENGINE WARNING PROTECTION SYSTEM (EWPS) (cont.) • EOT - Engine Oil Temperature overheat warning Critical - Temperature above specific threshold will shut down the engine and set a DTC. The operator has 30 seconds to •...

  • Page 69: Radiator Shuttle Enable (Rse)

    SECTION 4 – ENGINE OPERATION Operation (cont.) RADIATOR SHUTTLE ENABLE (RSE) 1. Use the lowest gear to get the vehicle moving. This allows the engine to easily move the load. RSE is an optional feature that provides a signal to open or close 2.

  • Page 70: Downhill Operation

    SECTION 4 – ENGINE OPERATION Operation (cont.) DOWNHILL OPERATION 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.

  • Page 71: Section 5 - Maintenance Schedule And Service Procedures

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Maintenance Schedule ® MaxxForce 7 Diesel Engines Service operation interval - whichever comes first: kilometers / miles, months, years, ours or liters / gallons of fuel Service Interval Service Operation See service procedures in this section for more information. Before Engine Operation Check engine oil level.
  • Page 72 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Maintenance Schedule (cont.) ® MaxxForce 7 Diesel Engines (cont.) Service operation interval - whichever comes first: kilometers / miles, months, years, ours or liters / gallons of fuel Service Interval Service Operation See service procedures in this section for more information.
  • Page 73 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Maintenance Schedule (cont.) ® MaxxForce 7 Diesel Engines (cont.) Service operation interval - whichever comes first: kilometers / miles, months, years, ours or liters / gallons of fuel Service Interval Service Operation See service procedures in this section for more information.
  • Page 74 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Maintenance Schedule (cont.) ® MaxxForce 7 Diesel Engines (cont.) Service operation interval - whichever comes first: kilometers / miles, months, years, ours or liters / gallons of fuel Service Interval Service Operation See service procedures in this section for more information.

  • Page 75: Service Procedures

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures OIL LEVEL Service Interval: Before Engine Operation 1. Park vehicle on level ground. GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human NOTE: Do not check oil level if engine is running or immediately health and the environment.

  • Page 76: Coolant Level

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) COOLANT LEVEL • If coolant level is below the ADD mark, continue with step 2. Service Interval: Before Engine Operation 2. Remove coolant tank cap and add ELC Premix 50/50 until Extended Life Coolant (ELC) Premix 50/50 is the standard the fluid level reaches the midpoint between ADD and MAX.

  • Page 77: Charge Air Cooler (Cac)

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) CHARGE AIR COOLER (CAC) EXTERNAL LEAKAGE Service Interval: Before Engine Operation Service Interval: Before Engine Operation WARNING: To prevent personal injury or death, shut WARNING: To prevent personal injury or death, shut down engine, set parking brake, and block wheels before down engine, set parking brake, and block wheels before inspecting the Charge Air Cooler.

  • Page 78: Air Cleaner Restriction

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) AIR CLEANER RESTRICTION If the yellow restriction indicator is at or near the red zone, the restriction is high and a new air filter should be installed to Service Interval: Before Engine Operation prevent reduced fuel economy, low engine power, or engine damage.

  • Page 79: Fuel Water Separator

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) FUEL WATER SEPARATOR Service Interval: With Oil Change or When Water In Fuel Sensor GOVERNMENT REGULATION: Engine fluids Light Illuminates (oil, fuel, and coolant) may be a hazard to human health and the environment.

  • Page 80: Engine Oil And Filter

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) FUEL WATER SEPARATOR (cont.) NOTE: Drain until no water or other contaminates are observed ENGINE OIL AND FILTER exiting from the drain valve. Upon opening the drain valve, a hissing sound will be heard as air fills the fuel line between the engine and the fuel tank.
  • Page 81 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) ENGINE OIL AND FILTER (cont.) Service Interval, whichever comes first: 6 months or calculation CAUTION: To prevent engine damage, do not extend from one of the following tables. recommended oil change intervals. Average fuel consumption rate in Kilometers per liter (Kmpl) vs.
  • Page 82 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) ENGINE OIL AND FILTER (cont.) 2. Run engine until operating temperature is reached, then shut 4. Inspect the oil pan drain plug and seal, if they are free of down the engine.
  • Page 83 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) ENGINE OIL AND FILTER (cont.) Schedule and Service Procedures chart (page 63). Add oil through the engine oil fill tube. Figure 32 Oil Level Gauge (Typical) 14. Check oil level gauge. Oil level must be within the crosshatched operating range on the gauge.

  • Page 84: Resetting Change Engine Oil Service Interval Message

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) ENGINE OIL AND FILTER (cont.) 18. Recheck oil level and add oil to bring oil level within the upper 8. The Change Engine Oil Service Interval message should half of the crosshatched operating range on oil level gauge. clear and reset for the next service interval.

  • Page 85: Belt, Air Intake Piping And Clamps

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) BELT, AIR INTAKE PIPING AND CLAMPS Install a new belt if any of the following conditions exist: • Excessive wear Service Interval: 10,000 miles (16,000 km), 6 months, 350 hours or 1000 gallons (3785 liters of fuel) •...
  • Page 86 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) BELT, AIR INTAKE PIPING AND CLAMPS (cont.) Removing the Belt 1. Attach a 1/2–inch drive breaker bar to square hole in auto tensioner. 2. Pull breaker bar clockwise and remove belt from auto tensioner pulley and other pulleys.

  • Page 87: Air Intake Piping And Clamps

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) AIR INTAKE PIPING AND CLAMPS Freeze Point Protection Levels Concentrate (Ethylene Glycol) and Water Mixtures For any of the following conditions, install new parts: Concentrate and Water Freeze Point Protection •...

  • Page 88: Primary Fuel Filter

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) COOLANT FREEZE POINT (cont.) 4. Adjust coolant concentration as necessary to achieve PRIMARY FUEL FILTER desired freeze point protection. Service Interval: 30,000 miles (48,280 km), 12 months, 1050 hours, or 3,000 gallons (11,360 liters) of fuel NOTE: Drain fuel filters if optional Water In Fuel (WIF) lamp is illuminated.
  • Page 89 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) PRIMARY FUEL FILTER (cont.) WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.
  • Page 90 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) PRIMARY FUEL FILTER (cont.) 1. Set parking brake and shift transmission to park or neutral. 3. Clean engine compartment components in the area of the fuel filter housing using compressed air. Before removing NOTE: Both the primary and secondary fuel filter elements the fuel filter cap, wipe the fuel filter cap and top portion of should be replaced during this service interval.
  • Page 91 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) PRIMARY FUEL FILTER (cont.) 14. Coat the new primary fuel filter element O-ring with clean 20. Secure the fuel filter cap and element to the fuel filter housing diesel fuel and install it into the groove inside the fuel filter by turning the fuel filter cap clockwise until finger-tight.

  • Page 92: Secondary Fuel Filter

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) SECONDARY FUEL FILTER WARNING: To prevent personal injury or death, store Service Interval: 30,000 miles (42,280 km), 12 months, 1050 diesel fuel properly in an approved container designed for hours or 3,000 gallons (11,360 liters) of fuel.
  • Page 93 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) SECONDARY FUEL FILTER (cont.) 2. Loosen the secondary fuel filter cover counterclockwise 3 1/2 turns to allow the secondary fuel filter housing to vent. 3. Remove fuel filter cap and fuel filter element from the secondary fuel filter housing.

  • Page 94: Crankcase Breather

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) SECONDARY FUEL FILTER (cont.) 11. Secure the fuel filter cap and element to the fuel filter housing CRANKCASE BREATHER by turning the fuel filter cap clockwise until finger-tight. NOTE: Engines built in July 2012 and later have a 12.
  • Page 95 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) CRANKCASE BREATHER (cont.) 1. For serviceable crankcase breather only: Install a new filter element per instructions in the Engine Service Manual. 2. Reset the service breather element message. Resetting Change Service Breather Element Message (page 88).

  • Page 96: Resetting Change Service Breather Element Message (Serviceable Crankcase Breather Only)

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) CRANKCASE BREATHER (cont.) RESETTING CHANGE SERVICE BREATHER ELEMENT ELECTRICAL SYSTEM MESSAGE (SERVICEABLE CRANKCASE BREATHER Service Interval: Annually ONLY) 1. Check wiring harness for cracks, rubbing, and loose Reset the Service Breather Element Message (change breather connections.

  • Page 97: Induction System

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) INDUCTION SYSTEM EXTENDED LIFE COOLANT (ELC) EXTENDER Service Interval: Annually Service Interval: 150,000 miles (240,000 km), 30 months, or 6,000 hours Have an authorized service provider pressure test the air induction system.

  • Page 98: Cleaning Diesel Particulate Filter (Dpf)

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) EXTENDED LIFE COOLANT (ELC) EXTENDER (cont.) ELC Extender 6. Install and tighten the coolant tank cap until the plastic cap clicks or the metal cap runs up against the detent. Cooling System Drain ELC Coolant Add ELC Extender...

  • Page 99: Service Cooling System

    NOTE: If using the coolant extraction service tool method, order cap: KL500NAV - Navistar Coolant Management Tool Kit. If the • Allow the engine to cool for 15 minutes or more.
  • Page 100 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) SERVICE COOLING SYSTEM (cont.) Coolant Replacement Using Gravity Method 1. Put a drain pan under the radiator. 2. Remove coolant tank pressure cap. 3. Open radiator drain cock (if present) or install a female quick-connect fitting and hose to the quick disconnect fitting installed in the radiator end tank(s) from the factory.
  • Page 101 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) SERVICE COOLING SYSTEM (cont.) 10. After coolant has drained, put a new O-ring on drain plug and install plug into crankcase. Tighten plug to 15 lb·ft (20 N·m). 11. Recycle or dispose of coolant, according to applicable regulations.
  • Page 102 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) SERVICE COOLING SYSTEM (cont.) 17. As the engine warms up, make sure coolant is flowing through coolant line – coolant will feel warm to the touch. 18. After engine reaches normal operating temperature and the thermostat has opened, shut engine off.

  • Page 103: Section 6 - Long Term Storage

    SECTION 6 – LONG TERM STORAGE General Information • Check state -of- charge eye in batteries. If any of the batteries has a dark state -of- charge indication, charge all Engines in storage 30 days or longer require the following batteries.
  • Page 104 SECTION 6 – LONG TERM STORAGE Page 96...

  • Page 105: Section 7 - Service Records

    SECTION 7 – SERVICE RECORDS Maintenance Service Record WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, put transmission in neutral or park, set parking brake, and block wheels before doing diagnostic or service procedures.
  • Page 106 SECTION 7 – SERVICE RECORDS Maintenance Service Record (cont.) Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced Page 98...
  • Page 107 SECTION 7 – SERVICE RECORDS Maintenance Service Record (cont.) Table 1 Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced Page 99...

  • Page 108: Daily Care And Report

    SECTION 7 – SERVICE RECORDS Daily Care and Report Do the following daily to prevent engine failure • Add coolant if necessary. Make sure filler cap seal is in good condition and the cap is installed tightly. WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information”...
  • Page 109 SECTION 7 – SERVICE RECORDS Daily Care and Report (cont.) Daily Care and Report Model Serial No. Date Miles Hours Fuel Lube Oil Parts Labor Service Performed Cost Parts Cost Time Cost Page 101...
  • Page 110 SECTION 7 – SERVICE RECORDS Daily Care and Report (cont.) Daily Care and Report Model Serial No. Date Miles Hours Fuel Lube Oil Parts Labor Service Performed Cost Parts Cost Time Cost Page 102...

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