International® MaxxForce® 7 Diesel Engine

1 international maxxforce 7 Diesel EngineFor2008 Through 2009 Model YearTruck and Derivative Vehicle ApplicationsEngine Operation and Maintenance Manual 2009 Navistar, Inc. All rights No. 1171941R4 Printed in the United States of AmericaForm No. 1171941R4 Printed in the United States of AmericaTABLE OF 1 SAFETY 7 Federal Emission System 7 Warranty 7 Required 7 Warranty Repairs and 7 Recommended Maintenance or Repair Parts.. 7 Emergency 8 What is not Covered by 8 Warranty Rights and 9 California Emission System Repairs and Maintenance or Repair is Covered by is not Covered by Rights and 1 Engine SYSTEMSE ngine Serial Emission Specifications and No. 1171941R4 Printed in the United States of AmericaTABLE OF CONTENTSC omponent Location Location Location Location 2 REQUIREMENTS FOR FUEL, Engine OIL, AND Low Sulfur Diesel (ULSD).

2 23 Unacceptable Fuel and Fuel of Higher Biodiesel Fuel Blends (B6 to B20)..24 Unsafe Oil Quality and Service CJ-4 for High Performance Diesel ROTELLA Extended Life Coolant (ELC) red)..28 Contamination of 3 INSTRUMENTS, INDICATORS, AND SWITCHESI nstrument Panel Gauge Temperature Pressure Temperature No. 1171941R4 Printed in the United States of AmericaTABLE OF CONTENTSAir Cleaner Restriction 4 Engine OPERATIONP reoperation 37 Priming the Fuel the Warm up Idling Idle Shutdown Timer (Federal-Optional)..42 Engine Idle Shutdown Timer (California-Standard)..43 Cold Weather Ambient Protection (CAP)..45 Hot Weather Warning Protection System (EWPS).. 5 MAINTENANCE SCHEDULE AND SERVICE PROCEDURESM aintenance Drain No.

3 1171941R4 Printed in the United States of AmericaTABLE OF CONTENTSC harge Air Cooler (CAC)..55 External Cleaner Restriction ..56 Engine Oil and Change Engine Oil Service Interval , Air Intake Piping and Freeze Fuel Filter ..62 Secondary Fuel Life Coolant (ELC) Diesel Particulate Cooling 6 SERVICE RECORDSM aintenance Service Care and No. 1171941R4 Printed in the United States of AmericaFOREWORDF orewordNavistar, Inc. is committed to continuous research anddevelopment to improve products and introduce technologicaladvances. Procedures, specifications, and parts defined inpublished technical service literature may be :Photo illustrations identify specific parts or assembliesthat support text and procedures; other areas in a photoillustration may not be manual includes necessary information and specificationsfor operators to service Navistar Diesel engines.

4 Contact anInternational dealer for more Service Literature1171941R4 international maxxforce 7 EngineOperation and Maintenance ManualEGES-345 international maxxforce 7 Service ManualEGES-350 1 international maxxforce 7 DiagnosticManualEGED-355 1 international maxxforce 7 DiagnosticFormEGED-365 international maxxforce 7 ElectronicControl Systems Diagnostic FormTechnical Service Literature isrevised periodically and mailedautomatically to Revision Service subscribers. If a technicalpublication is ordered, the latest revision will be order technical service literature, contact your international marks are trademarks of their respective No. 1171941R4 Printed in the United States of AmericaPage 1 FOREWORDForm No.

5 1171941R4 Page 2 Printed in the United States of AmericaSAFETY INFORMATIONS afety InformationThis manual provides general and specific maintenanceprocedures essential for reliable Engine operation and yoursafety. Since many variations in procedures, tools, and serviceparts are involved, advice for all possible safety conditions andhazards cannot be safety instructions before doing any service and testprocedures for the Engine or vehicle. See related applicationmanuals for more for Safety Instructions, Warnings, Cautions, andNotes in this manual can lead to injury, death or damage to theengine or TerminologyThree terms are used to stress your safety and safe operation ofthe Engine : Warning, Caution, and NoteWarning: A warning describes actions necessary to preventor eliminate conditions, hazards, and unsafe practices that cancause personal injury or : A caution describes actions necessary to prevent oreliminate conditions that can cause damage to the Engine : A note describes actions necessary for correct, efficientengine InstructionsWork Area Keep work area clean, dry, and organized.

6 Keep tools and parts off thefloor. Make sure the work area is ventilated and well lit. Make sure a First Aid Kit is Equipment Use correct lifting devices. Use safety blocks and Measures Wear protective safety glasses and shoes. Wear correct hearing protection. Wear cotton work clothing. Wear sleeved heat protective gloves. Do not wear rings, watches or other jewelry. Restrain long Make sure the vehicle is in neutral, the parking brake is set,and the wheels are blocked before servicing No. 1171941R4 Printed in the United States of AmericaPage 3 SAFETY INFORMATION Clear the area before starting the The Engine should be operated or serviced only by qualifiedindividuals.

7 Provide necessary ventilation when operating Engine in aclosed area. Keep combustible material away from Engine exhaustsystem and exhaust manifolds. Install all shields, guards, and access covers beforeoperating Engine . Do not run Engine with unprotected air inlets or exhaustopenings. If unavoidable for service reasons, put protectivescreens over all openings before servicing Engine . Shut Engine off and relieve all pressure in the system beforeremoving panels, housing covers, and caps. If an Engine is not safe to operate, tag the Engine and Prevention Makesurechargedfire extinguishers are in the work :Check the classification of eachfire extinguisher toensure that the followingfire types can be Type A Wood, paper, textiles, and rubbish2.

8 Type B Flammable liquids3. Type C Electrical equipmentBatteries Always disconnect the main negative battery cablefirst. Always connect the main negative battery cable last. Avoid leaning over batteries. Protect your eyes. Do not expose batteries to openflames or sparks. Air Use an OSHA approved blow gun rated at 207 kPa (30 psi). Limit shop air pressure to 207 kPa (30 psi). Wear safety glasses or goggles. Wear hearing protection. Use shielding to protect others in the work area. Do not direct compressed air at body or Make sure all tools are in good condition. Make sure all standard electrical tools are No. 1171941R4 Page 4 Printed in the United States of AmericaSAFETY INFORMATION Check for frayed power cords before using power Under Pressure Use extreme caution when working on systems underpressure.

9 Follow approved procedures Do not overfill the fuel tank. Overfill creates afire hazard. Do not smoke in the work area. Do not refuel the tank when the Engine is of Tools, Parts, and Equipment Reinstall all safety guards, shields, and covers afterservicing the Engine . Make sure all tools, parts, and service equipment areremoved from the Engine and vehicle after all work is No. 1171941R4 Printed in the United States of AmericaPage 5 SAFETY INFORMATIONForm No. 1171941R4 Page 6 Printed in the United States of AmericaWARRANTYW arrantyFederal Emission System WarrantyWARRANTY PERIODN avistar, Inc. warrants your light heavy-duty Diesel Engine forthe following warranty period (whichever comesfirst): 5years 80,000 km (50,000 miles) Or if covered by any basic or extended warranty (if greaterthan above)Your light heavy-duty Diesel Engine conforms to Protection Agency regulations for Engine model year, service class, and required emissioninformation is on the emission label on top of the valve warranty is based on the Engine model year, not the modelyear of the vehicle.

10 The warranty period begins on the date thenew vehicle is delivered to thefirst retail MAINTENANCEAs the vehicle owner, you are responsible for all requiredmaintenance described in this manual. Navistar Engine Grouprecommends that you retain all maintenance receipts. Navistarwill not deny an emission warranty claim solely because youhave no record of maintenance. However, a claim may bedenied if your failure to perform proper maintenance resultedin the failure of a warranted part and you cannot provideappropriate evidence of maintenance. Take your vehicle to anInternational dealer when a problem REPAIRS AND SERVICEAll emission control system parts proven defective duringnormal use will be repaired or replaced during the warrantyperiod.