MAXXFORCE 9/10/DT 2010 EMISSION-COMPLIANT ENGINES

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1 MAXXFORCE 9/10/DT 2010 EMISSION-COMPLIANT ENGINES

2 M A I N T E N A N C E I N F O R M AT I O N G U I D E MAKING THE MOST OF YOUR INTERNATIONAL VEHICLE BACKED BY THE INDUSTRY S LARGEST NETWORK, INTERNATIONAL TRUCKS EQUIPPED WITH MAXXFORCE 9/10/DT ENGINES ARE BUILT FOR THE LONG HAUL. 2 - MAXXFORCE 9/10/DT

3 N E T W O R K C O V E R A G E NETWORK COVERAGE Largest North American truck dealer network Over 9,000 technicians 9 North American Parts Distribution Centers Top-quality parts and expert service Unmatched 24/7 parts availability The latest diagnostic tools 3 - MAXXFORCE 9/10/DT

4 E N G I N E C O M P O N E N T S E N G I N E C O M P O N E N T S 2010 MAXXFORCE DT ENGINE COMPONENTS COVERS 2010 EMISSIONS LEVELS RIGHT VIEW 1. Crankcase Breather: Maintenance-free 2. Dual Sequential Free-Wheel Turbocharger System 3. Waste Gate Control 4. Engine Lube Filter Part # C1 (Long std) or # C91 (Short front drive) Numbered diamonds indicate approximate component locations MAXXFORCE 9/10/DT

5 E N G I N E C O M P O N E N T S 2010 MAXXFORCE DT ENGINE COMPONENTS COVERS 2010 EMISSIONS LEVELS LEFT VIEW 5. Engine ECM 6. Fuel Filter Module - Element Part # C92 7. Fuel Pump 8. Downstream Injection Metering Unit 9. EGR and Air Mixer Duct Numbered diamonds indicate approximate component locations. TRUCK-MOUNTED PART FUEL/WATER SEPARATOR AIR CLEANER ELEMENT CENTRIFUGE PART NUMBER C C C MAXXFORCE 9/10/DT

6 E N G I N E C O M P O N E N T S DURABILITY & RELIABILITY ROCK-SOLID RELIABILITY MADE LEGENDARY Features: Premium plateau-honed cylinder design Premium machined wet-sleeve design Durable roller cam followers Key advantages: Heavy-duty engine durability Increased head gasket integrity 6 - MAXXFORCE 9/10/DT

7 E N G I N E C O M P O N E N T S WIDE VOCATIONAL CAPABILITY PURPOSE-BUILT TO THE NEEDS OF INTERNATIONAL CUSTOMERS Key advantages: Compatible with a full range of automatic and manual driveline options, plus thousands of potential build configurations. Serves the broadest range of on and offhighway applications. Shift energy management technology allows for higher peak torque when used with select transmissions. 7 - MAXXFORCE 9/10/DT

8 E N G I N E C O M P O N E N T S UNMATCHED STRUCTURAL INTERGRITY Feature: Precision-machined wet sleeves Key advantages: Even cylinder cooling Unmatched structural integrity 8 - MAXXFORCE 9/10/DT

9 E N G I N E C O M P O N E N T S PREMIUM VALVE TRAIN Features: Roller cam followers Replaceable valve seats Four valves per cylinder Key advantages: Increased durability Longer valve and camshaft life Easy cylinder head rebuild Better breathing, performance & lower emissions 9 - MAXXFORCE 9/10/DT

10 E N G I N E C O M P O N E N T S OUTSTANDING FUEL ECONOMY VIA ADVANCED HIGH-PRESSURE FUEL SYSTEM Feature: Electro-hydraulic, high-pressure fuel system features new high-efficiency injector nozzles and advanced electronic control strategies. Key advantages: Exceptional gains in fuel economy 10 - MAXXFORCE 9/10/DT

11 E N G I N E C O M P O N E N T S FULL COMPLIANCE WITHOUT COMPROMISE OPTIMAL PERFORMANCE AND LOW COST OF OWNERSHIP Features: 1. Advanced fuel injection technology CYLINDER HEAD INTAKE AIR 3 INTAKE VALVE FUEL INJECTOR EXHAUST VALVE EXHAUST GAS 2. Proprietary combustion bowl design 3. Advanced air management Electronic calibration strategies 11 - MAXXFORCE 9/10/DT

12 B A S I C W A R R A N T Y MAXXFORCE 9/10/DT BASIC ENGINE WARRANTY With an unsurpassed B-50 rating of 550,000 miles (885,000 KM) engine life that helps your business go on without interruption you can count on your MaxxForce engine to show up for work every day. ITEMS COVERED Non-Rescue Fire Truck/Ambulance School Bus MONTHS MILES/KM MONTHS MILES/KM MONTHS MILES/KM Engine * K/240K K/160K 60 Unlimited Injection Nozzles K/240K K/160K 60 Unlimited Federal Emissions Warranty ** K/160K K/160K K/160K Towing (Vehicles with engine failures only) 90 Days 90 Days 90 Days 12 - MAXXFORCE 9/10/DT

13 B A S I C W A R R A N T Y LOCK IN COSTS WITH A SERVICE CONTRACT FROM INTERNATIONAL Reduce your overall operating costs by predetermining your operating costs per mile. Improve the resale and residual value of your MaxxForce engine(s) through consistent and proper maintenance, upkeep and repairs. Target high-cost areas of repair so that your extended coverage improves your bottom line MAXXFORCE 9/10/DT

14 I N T E R V A L & O P E R A T I O N S 2010 MAXXFORCE 9/10/DT (Less than 245 HP) SERVICE INTERVALS * FUEL ECONOMY LIGHT = 7.0 MPG OR HIGHER (MORE THAN 3.0 KmpL) Change Engine Oil and Filter Part # C1 25,000 Miles/40,225 Km/ 825 Hrs. MODERATE = 6.9 MPG 6.0 MPG ( KmpL) 20,000 Miles/32,200 Km/ 675 Hrs. SEVERE = LESS THAN 6.0 MPG (LESS THAN 2.5 KmpL) 15,000 Miles/24,130Km/ 500 Hrs. ** Change Centrifuge Filter- 9/10 only Part # C91 With Oil Change With Oil Change With Oil Change Change Fuel Filter Part # C92 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. Clean or Change Fuel Strainer 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. Adjust Engine Valve Lash 120,000 Miles/193,000 km/ 5,000 Hrs. 120,000 Miles/193,000 km/ 5,000 Hrs. 120,000 Miles/193,000 km/ 5,000 Hrs. Clean Diesel Particulate Filter (DPF) 200,000 Miles/322,000 km/6,000 Hrs. 200,000 Miles/322,000 km/6,000 Hrs. 200,000 Miles/322,000 km/6,000 Hrs. Add Extended Life Coolant (ELC) Extender 150,000 Miles/240,000 km/6,000 Hrs. 150,000 Miles/240,000 km/6,000 Hrs. 150,000 Miles/240,000 km/6,000 Hrs. Replace Engine Coolant 300,000 Miles/500,000 km/12,000 Hrs. 300,000 Miles/500,000 km/12,000 Hrs. 300,000 Miles/500,000 km/12,000 Hrs MAXXFORCE 9/10/DT

15 I N T E R V A L & O P E R A T I O N S 2010 MAXXFORCE 9/10/DT ( HP) SERVICE INTERVALS * FUEL ECONOMY LIGHT = 7.0 MPG OR HIGHER (MORE THAN 3.0 KmpL) Change Engine Oil and Filter Part # C1 Change Centrifuge Filter- 9/10 only Part # C91 Change Fuel Filter Part # C92 20,000 Miles/32,200 Km/ 675 Hrs. MODERATE = 6.9 MPG 6.0 MPG ( KmpL) 15,000 Miles/24,130Km/ 500 Hrs. ** SEVERE = LESS THAN 6.0 MPG (LESS THAN 2.5 KmpL) 10,000 Miles/16,100 Km/325 Hrs. ** With Oil Change With Oil Change With Oil Change 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. Clean or Change Fuel Strainer 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. 30,000 Miles/43,300km/1,100 Hrs. Adjust Engine Valve Lash 120,000 Miles/193,000 km/ 5,000 Hrs. 120,000 Miles/193,000 km/ 5,000 Hrs. 120,000 Miles/193,000 km/ 5,000 Hrs. Clean Diesel Particulate Filter (DPF) 200,000 Miles/322,000 km/6,000 Hrs. 200,000 Miles/322,000 km/6,000 Hrs. 200,000 Miles/322,000 km/6,000 Hrs. Add Extended Life Coolant (ELC) Extender 150,000 Miles/240,000 km/6,000 Hrs. 150,000 Miles/240,000 km/6,000 Hrs. 150,000 Miles/240,000 km/6,000 Hrs. Replace Engine Coolant 300,000 Miles/500,000 km/12,000 Hrs. 300,000 Miles/500,000 km/12,000 Hrs. 300,000 Miles/500,000 km/12,000 Hrs MAXXFORCE 9/10/DT

16 F L U I D I N F O R M A T I O N OIL MAINTENANCE & SERVICE PROCEDURES Oil Change interval for vehicles equipped with a DT-466 diesel engine (less than 245 horsepower) without a Drive/Steering Axle Miles Per Gallon Miles Hours Gallons Over , ,100 Between 7.0 and , ,000 Less than , ,900 Oil Change interval for vehicles equipped with a DT-466 diesel engine ( horsepower) without a Drive/Steering Axle Miles Per Gallon Miles Hours Gallons Over , ,500 Between 7.0 and , ,300 Less than , , MAXXFORCE 9/10/DT

17 F L U I D I N F O R M A T I O N OIL MAINTENANCE & SERVICE PROCEDURES 17 - MAXXFORCE 9/10/DT

18 F L U I D I N F O R M A T I O N OIL RECOMMENDATIONS The use of CJ-4 oils brings the following benefits: Reduced catalyst poisoning and reduced particulate blockage Decreased engine wear Fewer piston deposits Reduced soot-related viscosity increases, deposits and wear Minimized viscosity loss due to shear Prevention of oxidative thickening and oil aeration The use of CI-4 oils reduces the maintenance interval for several components by up to 25% MAXXFORCE 9/10/DT

19 S E R V I C E T I P S SERVICE TIPS MaxxForce engines are built to deliver maximum durability and reliability year after year. The following are some service tips designed to help keep your MaxxForce 9/10/DT engine performing mile after mile MAXXFORCE 9/10/DT

20 S E R V I C E T I P S SUGGESTED WARM-UP TIME Service Tip: Before applying a load or increasing speed above 1000 rpm, warm up the engine for a minimum of 5 minutes at or below 1000 rpm. The warm-up period allows lubricating oil to establish a film between moving parts MAXXFORCE 9/10/DT

21 S E R V I C E T I P S DIESEL FUEL SYSTEM CLEANER Situation: Federal requirements mandate the use of Ultra Low Sulfur Diesel (ULSD) for on-highway applications. With ULSD, deposits can form in diesel engines. Service Tip: MaxxForce Diesel Fuel Additive is the solution. Use of this additive will clean fuel injector deposits and prevent new ones from forming. Available in a variety of sizes MAXXFORCE 9/10/DT

22 S E R V I C E T I P S REFILLING COOLANT Service Tip: Use the Navistar Coolant Management Tool for these important benefits: Speeds drain/refill times Eliminates air pockets in the system Allows system to be psi tested before coolant added 22 - MAXXFORCE 9/10/DT

23 S E R V I C E T I P S RADIATOR CAPS Service Tip: Your radiator cap is a crucial part of your engine and needs to be inspected and pressure tested. A weak or defective radiator cap can lead to severe cooling system component damage MAXXFORCE 9/10/DT

24 S E R V I C E T I P S Maintenance Torque Values Service Tip: Utilize the proper amount of torque when servicing a 2010 MaxxForce DT Oil Pan Plug Oil Filter Fuel Filter Cover Fuel Strainer 68 Newton/meter or 50 ft-lbs 2/3 to 1 turn after o-ring contact 30 Newton/meter or 22 ft-lbs 5 Newton/meter or 44 ft-lbs 24 - MAXXFORCE 9/10/DT

25 S E R V I C E T I P S DRIVER INDICATORS Above are key indicator lights and their meanings to help you understand your best course of action, should your vehicle require maintenance MAXXFORCE 9/10/DT

26 S E R V I C E T I P S DRIVER INDICATORS DPF OPERATING CONDITIONS FOR 2007 AND 2010 EPA EMISSIONS EQUIPPED VEHICLES HEST (High Exhaust System Temperature) Lamp Warns drivers that the exhaust temperature is high 2. DPF Status Lamp Indicates the need to regenerate the DPF Stops blinking and turns off during a regen 3. Malfunction Indicator Lamp (MIL) Engine Emissions Control System Indicates DPF sensor faults or other emissionrelated faults 4. General Warning Lamp Used in conjunction with other warning lights or general text and warning Indicates an alert condition to the operator 5. Stop Alert Lamp Used in conjunction with other warning lights or general text and warning messages to indicate a red STOP alert 26 - MAXXFORCE 9/10/DT

27 S E R V I C E T I P S DRIVER INDICATORS Wait-to-Start Lamp Turn ignition switch to ON to activate the cold start assist system. The Wait-to-Start lamp will illuminate continuously. Do not crank engine while lamp is on continuously. When the Wait-to-Start lamp begins flashing, turn ignition switch to START. If the vehicle has pushbutton starting, press and hold the starter button. Temperature is high. 2. Shift Indicator Illuminates green to assist operators in determining when it is appropriate to shift the transmission to a higher gear in order to maximize driving fuel economy. 3. Maintenance Lamp The amber Maintenance lamp will illuminate in conjunction with other warning lights or general text and warning messages. It may be accompanied by an audible alarm to indicate an alert condition to the operator MAXXFORCE 9/10/DT

28 S P E C I A L T O O L S SOFT TOOLS THINK BEYOND THE TORQUE WRENCH. ServiceMaxx SM Performs engine off and engine running diagnostic tests Records snapshots of your engine Displays active and inactive Diagnostic Trouble Codes (DTCs) and operating data Gives you the ability to specify your programmable engine features 28 - MAXXFORCE 9/10/DT

29 S P E C I A L T O O L S SOFT TOOLS (cont.) THINK BEYOND THE TORQUE WRENCH. ServiceMaxx SM Programmable Engine Features The following features can be configured to meet the requirements of how you use your truck: Cruise control data Progressive shift PTO Engine retarder Traction control Fan control Password protection Engine warning and protection Vehicle setup Timer gear down-protection Remote service interval trip reporting Plate engine In-cab PTO Idle shutdown Vehicle speed 29 - MAXXFORCE 9/10/DT

30 S P E C I A L T O O L S HARD TOOLS POWERED PRECISION. Your International or IC Bus dealer is equipped with the industry s best repair tools, developed and produced by Navistar product experts. When your vehicle is being serviced by one of our dealers you can be confident that the best available technical information and services, specialty tools and equipment, and sophisticated diagnostic products are being utilized. For a comprehensive list of available tools for your MaxxForce engines, visit your International or IC Bus dealer. Support for those who equip their own shops with our industry-leading tools and equipment is available through your International or IC Bus dealer MAXXFORCE 9/10/DT

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