MAXXFORCE®

9/10/DT 2010 EMISSION-COMPLIANT ENGINES

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.

M A IN T E N A N C E IN F O R M AT IO N G U ID E

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• 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

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NETWORK COVERAGE

2010 MAXXFORCE®

DT

ENGINE COMPONENTS COVERS 2010 EMISSIONS LEVELS

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RIGHT VIEW

1. Crankcase Breather: Maintenance-free

2. Dual Sequential Free-Wheel

Turbocharger System

3. Waste Gate Control

4. Engine Lube Filter–Part #1884508C1 (Long–std) or #1889119C91 (Short–front drive)

Numbered diamonds indicate approximate component locations.

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LEFT VIEW

5. Engine ECM

6. Fuel Filter Module - Element Part #1878042C92

7. Fuel Pump

8. Downstream Injection Metering Unit

9. EGR and Air Mixer Duct

Numbered diamonds indicate approximate component

locations.

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2010 MAXXFORCE®

DT

ENGINE COMPONENTS COVERS 2010 EMISSIONS LEVELS E

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TRUCK-MOUNTED PART PART NUMBER

FUEL/WATER SEPARATOR 2588149C1

AIR CLEANER ELEMENT 3551814C1

CENTRIFUGE 2606467C91

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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

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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 off-highway applications.

• Shift energy management technology allows for higher peak torque when used with select transmissions.

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UNMATCHED STRUCTURAL

INTERGRITY

Feature:

• Precision-machined wet sleeves

Key advantages:

• Even cylinder cooling

• Unmatched structural integrity

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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

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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

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FULL COMPLIANCE WITHOUT COMPROMISE OPTIMAL PERFORMANCE AND LOW COST OF OWNERSHIP

Features:

1. Advanced fuel injection technology

2. Proprietary combustion bowl design

3. Advanced air management

4. Electronic calibration strategies

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CYLINDER HEAD

INTAKE VALVE

FUEL INJECTOR

EXHAUST VALVE

INTAKE AIR EXHAUST GAS

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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.

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ITEMS COVERED

Non-Rescue Fire Truck/Ambulance School Bus

MONTHS MILES/KM MONTHS MILES/KM MONTHS MILES/KM

Engine* 36 150K/240K 60 100K/160K 60 Unlimited

Injection Nozzles 36 150K/240K 60 100K/160K 60 Unlimited

Federal Emissions Warranty** 60 100K/160K 60 100K/160K 60 100K/160K

Towing (Vehicles with engine failures only)

90 Days 90 Days 90 Days

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.

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2010 MAXXFORCE®

9/10/DT

(Less than 245 HP)

SERVICE INTERVALS*

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FUEL ECONOMY LIGHT = 7.0 MPG OR HIGHER (MORE THAN 3.0 KmpL)

MODERATE = 6.9 MPG – 6.0 MPG (2.9 – 2.6 KmpL)

SEVERE = LESS THAN 6.0 MPG (LESS

THAN 2.5 KmpL)

Change Engine Oil and Filter† Part #1884508C1

25,000 Miles/40,225 Km/ 825 Hrs.

20,000 Miles/32,200 Km/ 675 Hrs.

15,000 Miles/24,130Km/ 500 Hrs. **

Change Centrifuge Filter- 9/10 only Part #2606467C91

With Oil Change With Oil Change With Oil Change

Change Fuel Filter Part #1878042C92

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.

2010 MAXXFORCE®

9/10/DT

(245 – 300 HP)

SERVICE INTERVALS*

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FUEL ECONOMY LIGHT = 7.0 MPG OR HIGHER (MORE THAN 3.0 KmpL)

MODERATE = 6.9 MPG – 6.0 MPG (2.9 – 2.6 KmpL)

SEVERE = LESS THAN 6.0 MPG (LESS

THAN 2.5 KmpL)

Change Engine Oil and Filter† Part #1884508C1

20,000 Miles/32,200 Km/ 675 Hrs.

15,000 Miles/24,130Km/ 500 Hrs. **

10,000 Miles/16,100 Km/325 Hrs. **

Change Centrifuge Filter- 9/10 only Part #2606467C91

With Oil Change With Oil Change With Oil Change

Change Fuel Filter Part #1878042C92

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.

OIL MAINTENANCE &

SERVICE PROCEDURES

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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 7.0 25,000 825 3,100

Between 7.0 and 6.0 20,000 675 3,000

Less than 6.0 15,000 500 2,900

Oil Change interval for vehicles equipped with a DT-466 diesel engine (245-300 horsepower) without a Drive/Steering Axle

Miles Per Gallon Miles Hours Gallons

Over 7.0 20,000 675 2,500

Between 7.0 and 6.0 15,000 500 2,300

Less than 6.0 10,000 325 2,100

OIL MAINTENANCE &

SERVICE PROCEDURES

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RECOMMENDATIONS

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The use of CI-4 oils reduces the maintenance interval for several components by up to 25%.

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

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.

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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.

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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.

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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

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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.

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Maintenance Torque Values

Service Tip:

• Utilize the proper amount of torque when

servicing a 2010 MaxxForce® DT

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• Oil Pan Plug 68 Newton/meter or 50 ft-lbs

• Oil Filter 2/3 to 1 turn after o-ring contact

• Fuel Filter Cover 30 Newton/meter or 22 ft-lbs

• Fuel Strainer 5 Newton/meter or 44 ft-lbs

DRIVER

INDICATORS

Above are key indicator lights and their meanings

to help you understand your best course of

action, should your vehicle require maintenance.

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DRIVER INDICATORS DPF OPERATING CONDITIONS FOR 2007 AND 2010 EPA EMISSIONS EQUIPPED VEHICLES

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1. 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 emission-related 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

DRIVER INDICATORS

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1. 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.

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SOFT TOOLS THINK BEYOND THE TORQUE WRENCH.

ServiceMaxxSM

• 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

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• 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

ServiceMaxxSM Programmable Engine Features

The following features can be configured to meet the requirements of how you use your truck:

SOFT TOOLS (cont.) THINK BEYOND THE TORQUE WRENCH.

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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.