MAXXFORCE®

7 2010 EMISSION-COMPLIANT ENGINES

MAKING THE MOST OF YOUR INTERNATIONAL

®

VEHICLE

BACKED BY THE INDUSTRY’S LARGEST

NETWORK, INTERNATIONAL® TRUCKS

EQUIPPED WITH MAXXFORCE® 7 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

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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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2010 MAXXFORCE®

7

ENGINE COMPONENTS COVERS 2010 EMISSIONS LEVELS

RIGHT VIEW

1. Open crankcase breather

2. Dual sequential free-wheel

turbocharger system

3. Inlet air heater

4. Road draft tube

Numbered diamonds indicate approximate component locations.

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LEFT VIEW

5. Fuel filter module — Element part #1884207C92

6. Fuel cooler

7. Pan mounted oil filter —

Element part #1899332C91

8. EGR mixer

Numbered diamonds indicate approximate component locations.

2010 MAXXFORCE®

7

ENGINE COMPONENTS COVERS 2010 EMISSIONS LEVELS E

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TRUCK-MOUNTED PART PART NUMBER

AIR CLEANER ELEMENT 2602212C1

5 6 8

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DURABILITY & RELIABILITY ROCK-SOLID RELIABILITY MADE LEGENDARY

Features:

• High-pressure common rail fuel system

• Compacted graphite iron (CGI) block

• Dual sequential turbo and advanced

air management

Key advantages:

• Heavy-duty engine durability

• Designed for maximum reliability and serviceability

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ADVANCED FUEL SYSTEM EFFICIENCY AND PERFORMANCE

Feature:

• High-pressure common rail fuel system

Key advantages:

• Improved fuel efficiency

• In-cylinder reduction of emissions

• One of the quietest running diesels

in the industry

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PREMIUM VALVE TRAIN LESS MAINTENANCE AND NOISE

Feature:

• Roller cam followers

Key advantages:

• Reduced maintenance

• Reduced noise

• Rolling element bearings reduce friction

and camshaft stress

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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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3

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MAXXFORCE® 7

BASIC ENGINE WARRANTY WE TRAVEL THE LONG ROAD WITH YOU.

With an unsurpassed B-50 rating of 500,000 miles (805,627 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/160K 60 100K/160K 60 Unlimited

Interior 36 150K/160K 60 100K/160K 60 Unlimited

Federal Emissions Warranty** 60 50K/160K 60 50K/160K 60 50K/160K

Towing 90 Days 90 Days 90 Days

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LOCK IN COSTS WITH

A SERVICE CONTRACT

FROM INTERNATIONAL®

ESSENTIAL PEACE OF MIND.

• 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®

7

SERVICE INTERVALS*

ON SCHEDULE. AHEAD OF THE GAME. INT

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FUEL ECONOMY LIGHT = >10.0 MPG/AVG SPEED OF >15 MPH (>4.25 KMPL/AVG; SPEED OF >24 KMPH)

MODERATE = 8.0 MPG – 10.0 MPG/AVG SPEED OF 15 – 25 MPH (3.4 – 4.25 KMPL/AVG; SPEED 24 – 40 KMPH)

SEVERE = <8.0 MPG/AVG SPEED OF >15 MPH (<2.5 KMPL/AVG SPEED OF >24 KMPH)

Change engine oil and filter† Part # 1899332C91

15,000 mi/24,000 km/500 hr 12,500 mi/20,000 km/500 hr

10,000 mi/16,000 km/500 hr**

Change fuel filter Part # 1884207C92

30,000 mi/43,300 km/1500 hr/2,000 gal (7,570 L) fuel/12 mo

30,000 mi/43,300 km/1500 hr/2,000 gal (7,570 L) fuel/12 mo

30,000 mi/43,300 km/1500 hr/2,000 gal (7,570 L) fuel/12 mo

Drain water from fuel separator With oil change or when water- in-fuel sensor light illuminates

With oil change or when water- in-fuel sensor light illuminates

With oil change or when water- in-fuel sensor light illuminates

Clean diesel particulate filter (DPF)††

200,000 mi/322,000 km/6,000 hr/30 mo.

200,000 mi/322,000 km/6,000 hr/30 mo.

200,000 mi/322,000 km/6,000 hr/30 mo.

Add extended life coolant (ELC) extender

150,000 mi/240,000 km/6,000 hr/30 mo.

150,000 mi/240,000 km/6,000 hr/30 mo.

150,000 mi/240,000 km/6,000 hr/30 mo.

Replace engine coolant 300,000 mi/483,000 km/12,000 hr/60 mo/5 yr

300,000 mi/483,000 km/12,000 hr/60 mo/5 yr

300,000 mi/483,000 km/12,000 hr./60 mo/5 yr .

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OIL MAINTENANCE &

SERVICE PROCEDURES MAXIMIZE YOUR ENGINE’S LIFESPAN.

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2010 Emission Level MaxxForce® 7

Oil Change Intervals

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Average KmpL Average KmpL

<24 24–40 40–80 >80

>4.25 500 hr 24,000 km 16,000 km 16,000 km

3.4–4.25 500 hr 20,000 km 16,000 km 12,000 km

<3.4 500 hr 16,000 km 12,000 km 12,000 km

Average mpg Average mph

<15 15–25 25–50 >50

>10 500 hr 15,000 mi 10,000 mi 10,000 mi

8–10 500 hr 12,500 mi 10,000 mi 7,500 mi

<10 500 hr 10,000 mi 7,500 mi 7,500 mi

OIL

RECOMMENDATIONS PERFORMANCE IN EVERY DROP.

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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 increases in soot-related viscosity, deposits and wear

• Minimized viscosity loss due to shear

• Prevention of oxidative thickening and oil aeration

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SERVICE TIPS OPTIMIZED FOR UPTIME.

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

®

7 engine performing mile after mile.

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SUGGESTED WARM-UP TIME PREPARE FOR THE PERFECT START.

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 PROTECTION AGAINST DEPOSITS.

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 PROVEN PERFORMANCE.

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 ADDED PROTECTION, AT YOUR FINGERTIPS.

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 PERFORMING MILE AFTER MILE.

Service Tip:

• Utilize the proper amount of torque when

servicing a 2010 MaxxForce® 7.

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• Oil pan plug 25 Newton's/meter or 18 lbs/ft

• Oil filter 3/4 to 1 turn after O-ring contact

• Primary fuel filter 50 Newton's/meter or 37 lbs/ft

• Secondary fuel filter 40 Newton's/meter or 29 lbs/ft

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DRIVER INDICATORS HELPING YOU GO THE DISTANCE.

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 (cont.) OPERATING CONDITIONS FOR 2010 AND 2007 EPA EMISSIONS EQUIPPED VEHICLES

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1. Diesel Particulate Filter temperature lamp

– Illuminates when the exhaust system is hot and regeneration is in progress

2. Diesel Particulate Filter indicator

– Indicates the need to regenerate the DPF

– Stops blinking and turns off during a regen

3. Malfunction Indicator lamp (MIL)

– Indicates DPF sensor faults or other emission-related faults

4. Warn Engine lamp

– Used in conjunction with other warning lights or general text and warning

– Indicates an alert condition to the operator

5. Stop Engine lamp

– Used in conjunction with other warning lights or general text and warning messages to indicate a red STOP alert

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DRIVER INDICATORS (cont.) OPERATING CONDITIONS FOR 2010 AND 2007 EPA EMISSIONS EQUIPPED VEHICLES

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6. 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 push-button starting, press and hold the starter button.

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

• 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:

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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.

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