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Bob NeitzelVocational Marketing
Manager
August 2011
Western States Highway Equipment Managers Association
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Navistar 2010: Taking a Different Path
• MaxxForce 13 Heavy Duty Diesel Engine –
summary
• Why isn’t Navistar going with SCR?
• How have Navistar Advanced EGR engines been
tested?
• What happens when the credits run out?
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MaxxForce DT/9/10 - I6
MaxxForce 7 - V8
Built for fuel economy, power, reliability, durability
MaxxForce 11/13
6.4 Liter
220 HP – 300 HP
15 Liter
435 HP – 550 HPAvailable 2012
MaxxForce15
7.6/9.3 Liter
215 HP – 350 HP
10.5/12.4 Liter
330 HP – 475 HP
Navistar MaxxForce Engines
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• Reduce customer operating costs
• Meet 2010 standards with minimal customer burden
• Achieve EPA / CARB compliance and
certification– CARB Best Available Control
Technology
Our 2010 Commitment
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Navistar Strategy
Observations and conclusions• One or more viable alternatives to liquid urea based SCR will be
available within a few years– Leading industry suppliers and smaller research oriented companies
• Navistar never made SCR investment that Europe did– Gives us a timing advantage on future technology
Customer perspective• What happens to vehicles with liquid urea based SCR when other
alternatives mature?
Navistar perspective• Decision to go with Advanced EGR prime path, monitor developing
technologies– Most security for customers, provides differentiation for Navistar
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COMBU
STION TEM
PERA
TURE
Low
High
COMBUSTION CYCLE
Too Hot: • Excess NOX• Lambda > 1.0
Too Cool: • Excess fuel • Excess soot• Lambda < 1.0
Optimum• Low Nox• Low Soot
EGR Technical FormulaAdvanced EGR goalsAir fuel ratio control, thru the complete
transient cycle Lambda > 1.0 => Excess Air (Lean) Lambda = 1.0 = Stoichiometry Diesel 14.5Lambda < 1.0 =< Excess Fuel (Rich)
Thermal control, thru the complete transient cycleCooled exhaust molecules surround the nitrogen molecules acting like insulation which protects the nitrogen from super heated combustion temperatures, therefore keeping the nitrogen molecules from converting to Nox.
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MaxxForce Advanced EGR Enablers
1.) Engine Calibration
2.) Air Management
3.) Exhaust Management
4.) Fuel Management
5.) Mixing Management
Desired EGR Mass Flow Rate
EGR =
φ
(A, density,
flow coef.)
Flow Models
Commanded EGR Valve Position
2010
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MaxxForce 7 Product Improvements
9
CGI Engine Block
Integrated Fuel Filter & Cooler After treatment
Can size increases by ¾ in, (=33%)Emitec to Corning
1225 to 1160 LB.B50 500,000 Miles
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MaxxForce DT, 9, 10 Product Improvements
10
Electronic Fuel Pump
Downstream Injection
After treatment
HC Doser / DSI
MetallicDOC
AT DPF12”
X 12”Metallicpre DOCEngine
Multi‐position
Exhaust device
Can size increases by ¾ in, (=33%)Emitec to Corning
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MaxxForce 11 & 13 Product Improvements
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Jacobs Engine Brake
Relocated Fuel Filer Assembly Integrated Oil Filter & Crank Case Breather
Bosch DSI Injector
Service Interval Reduced to 0MaxxForce 11 398 Ft. LB. at 2100 RPMMaxxForce 13 470 Ft. LB. At 2100 RPM
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NOxg/bhp‐hr
MaxxForce Advanced EGR: An Evolution
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Myths about EGR
10/31/2011
Myth: Engines run hot with EGR
Truth:
Enhanced cooling system and lower combustion
temperatures
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2010 Heavy Cooling Systems
2010 Cooling System
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Myths about EGR
10/31/2011
Myth: Engines with EGR lose fuel
economy Truth:
Vehicle, fuel system, combustion chamber design
and electronic control enhancements match—and
even improve—fuel economy
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WorkStar ® 7600 “Slope-nose” Exterior
1.
The new sloped hood of
the WorkStar provides
best‐in‐class visibility for
the driver
2.
Strong vocational
“mega‐bracket”
design
(similar to the PayStar
5900SBA) provides a
strong support for the
radiator and front end
3.
Heavy‐duty 150,000 lb
tow‐hooks
1
3
2
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10/31/2011
WorkStar ® 7600 “Slope-nose” Mega-Bracket
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WorkStar ® 7600 “Slope-nose” Exterior
Additional Features:• Common radiator with PayStar
5900SBA (1,564 in²)
• Designed for REPTO and transmission
mounted PTO applications
• Front frame extensions and FEPTO
accommodation available in standard
WorkStar hood configuration
• Available in Set‐Back (46”) 4x2 / 6x4 /
8x6 axle configurations
• Set‐Forward axle (29.5”) is available in
standard WorkStar hood configuration
• Available December
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WorkStar ® 7600 with Eagle Interior
12
5
3
1.
LoneStar inspired
instrument panel
features easy to read
ivory gauges
2.
Easy to clean vinyl
interior panels provide
durability
3.
Ergonomic center
panel allows easy
access to auxiliary
truck and body
switches
4.
Steering wheel
controls allow the
driver to keep his/her
hands on the steering
wheel
5.
Easy to clean
vocational floor mat
4
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WorkStar ® 7600 with Eagle Interior
Additional Features:• Premium seats provide an
abundance of adjustment to fit any
driver resulting in superior comfort
• Rosewood trim with gauges
available in either easy to read ivory
or black with chrome bezels
• Back wall pocket for additional
storage
• Door mounted speakers & grab
handle
• Available December 2011
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Snow Plow Extended Frame Rails Reinforcement
•Moved all 315HP and lower engines back to mid-cab position (~70% of WorkStar MDD)•Investigating a non‐notched high cab cooling
solution for the remainder of 7400 and 7500.
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• New Model 7600 SBA Tridem – Hendrickson Primaax Suspension – 69k
• Vocational air ride
– Meritor 53k axles– Available now
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New Model 7600 SFA 6x6
• In Production– Fabco SDA-1800 18k front drive axle– Fabco TC270 2 speed transfer case– 46k Hendrickson HMX rear suspension
• Expand offering to include: – Fabco SDA-2100 21k front drive axle
• w/20k springs– Fabco TC-180 transfer case
• Single speed• 15,000 lb-ft input torque
– Fabco TC-142 transfer case• 2 speed• 20,000 lb-ft input torque
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• E-Coated Frame Rails (Pictures after 1000 hrs in salt spray booth)– 0010021 CHASSIS COATING Corrosion Resistant Primer Coating for Single Frame Rails– 0010022 CHASSIS COATING Corrosion Resistant Primer Coating for Reinforced Frame Rails
Single Rail Powder Coat Only
Single Rail E‐Coat & Powder Coat
Inside Reinforced Rail Powder Coat
OnlyOutside Reinforced Rail Powder Coat
Only
Outside Reinforced Rail E‐Coat &
Powder CoatInside Reinforced Rail E‐Coat & Powder
Coat
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Corrosion Resistance Features• Huck Spin II Bolt and Collars
– These corrosion resistant bolts are thoroughly cleaned, then coated with Geomet® 321, a non- electrolytically applied thin-film coating of metallic grey color for corrosion protection.
– Collars are zinc electroplated with a black-dyed trivalent chromate. The collars then lubed with cetyl alcohol flake.
• Aluminum Battery Boxes
• Aluminum Fuel Tanks
• Stainless Steel Fuel Tank Straps– 15924 – Bright finish stainless steel fuel tank straps
• Aluminum Steps– 16XTK – Two bright aluminum steps per door– 16ZBB – Two, aluminum, self-cleaning steps (Bustin) per door
• RPM/TCM Mounted Inside Cab
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Corrosion Resistance Features
• Brake System Improvements– Bendix ATR-6 – virtually eliminates corrosion issues
with internal valve system
• New MPM Composite Oil Pan with Heater (12WTH)– The MPM composite further prolongs the life of the oil pan in two ways
1. The plastic absorbs and dissipates energy when small road debris hits the finish a . It takes longer for the little rocks to chew through the finish and expose the metal leading to rust on the outer steel layer.
2. The inside plastic layer acts as a protective barrier for the layer of steel outside of it in the event that the steel layer rusts
a. Until the plastic layer is removed the second layer of steel will remain intact preventing oil leakage
•Metal – Plastic – Metal oil pan design•E‐coat /powder coat on outer layer
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7600 REPTO Service Hatch– Add stamped hole in transmission cover plate, cutout in floor mat
• Provide a 6x6 inch opening in transmission cover• Production Date – Fall 2011
Fire Piece Frame reinforcement behind the cab, designed for wing plow support (recommended with right or left wing plows-SQ)
28
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Dual Hood Hatches• Hood hatches – dual for checking and filling all fluids
– Production Fall 2011
29
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High Visibility Mid-Range Diesel (MaxxForce DT, 9, 10) Truck
Description:This program will release the DuraStar hood and cooling module onto the WorkStar Mid-Range Diesel (MRD) chassis. This product provides our customers, who are not needing front PTO, an option for better visibility with the feature set of our Severe Service WorkStar
Update:• Program Approved• Coming Fall 2011
High Visibility Mid-Range Diesel (MaxxForce DT, 9, 10) Truck
Description:This program will release the DuraStar hood and cooling module onto the WorkStar Mid-Range Diesel (MRD) chassis. This product provides our customers, who are not needing front PTO, an option for better visibility with the feature set of our Severe Service WorkStar
Update:• Program Approved• Coming Fall 2011
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WorkStar Compressed Natural Gas (CNG)• 7300/7400 Garland
Production• 210-300 HP MF-DT• 4 – Tank/Step
combinations
• Garland Truck Specialty Center (TSC) Installation:
• CNG Fuel Tanks• Natural gas fueling• Road Test Validation
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WorkStar Latest product features releasesLatest product features releases01MSP BUMPER, FRONT Full Width, Aerodynamic, Chrome Plated Steel; 0.189" Material Thickness,
Includes Mounting Holes for 2 CPI Bumper Mounted Sirens01SBJ CROSSMEMBER, INTERMEDIATE 1st Located 3.78" to the Rear04AZV AIR BRAKE ABS {Bendix AntiLock Brake System} Full Vehicle Wheel Control System (6-Channel; 6
Sensor/6 Module) With Automatic Traction Control04AZY AIR BRAKE ABS {Bendix AntiLock Brake System} With Electronic Stability Program (6-Channel; 6
Sensor/6 Modulator) With Automatic Traction Control08WKU BATTERY DISCONNECT SWITCH 200 Amp; Lever Operated, Locks with Padlock, Battery Box
Mounted, Does Not Disconnect Charging Circuits, Disconnects Power to PDC08TKJ STOP, TURN, TAIL & B/U LIGHTS {Truck Lite} Super 44, With LED Bulbs for Stop, Turn & Tail Lights
and License Plate Light and Backup lights, With Power Module, "International" Termination and Less Junction Box
08TKG STOP, TURN, TAIL & B/U LIGHTS {Truck Lite} Super 44, With LED Bulbs for Stop, Turn & Tail Lights and License Plate Light, Truck Lite Super 40 for Backup lights, With Power Module, "International" Termination and Less Junction Box
08THK STOP, TURN, TAIL & B/U LIGHTS {Truck Lite Super 40}, With Power Module, "International" Termination and Less Junction Box
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WorkStar Latest product features releasesLatest product features releases14GVM AXLE, REAR, TANDEM {Meritor MT-40-14X-5DCR-P} Single Reduction, 0.500"(12.7mm) Wall
Housing Thickness, 40,000-lb Capacity, R Wheel Ends, Lube Pump, With Driver Controlled Locking Differential in Forward Rear and Rear Rear Axle
14WMM AXLE, PUSHER, LIFT TYPE {Watson & Chalin SL-2055 Tru Track} 20,000-lb Capacity; Includes One Self-Steer Axle
14UPP SUSPENSION, REAR, AIR, TRIDEM {Hendrickson PAX-690-55} 55" Axle Spacing; 69,000-lb Capacity, 12.5" Ride Height, With Shock Absorbers Mounted in Standard Location
15DRX FUEL TANK, CNG (2) 80 U.S. Gal. Diesel Equivalent, Frame Mounted Left & Right Side Back of Cab
15SUV FUEL TANK, CNG 40 U.S. Gal. Diesel Equivalent, Frame Mounted Right Side Back of Cab
15SUW FUEL TANK, CNG 40 U.S. Gal. Diesel Equivalent, Frame Mounted Left Side Back of Cab
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Fuel Saving Idle Reduction Options
• Auto Therm code 60ADA– Engine “off” cab heating, save fuel, reduce emissions– Available on TerraStar, DuraStar or WorkStar engine/cab combination– Reduce engine idling to maintain cab heat.– 70° F cab heat for 11/2 hours with 32° F outside ambient temperature
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2010 Emissions MaxxForce 11 in PayStar 5500/ & 5600 models • Release 2010 compliant MaxxForce 11
engines in the 5500 and 5600 6x4 models
• Retain aluminum cab offering for heavy duty construction customers
• Retain Tridem offering for heavy duty construction customers
• Utilize Garland Engineering resources to lead the activity with expert support from Power Train and Vehicle Engineering functional teams as needed for guidance and reviews
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Horizontal / Vertical Exhaust• Available on 5500, 5600, and 5900
SBA w/MaxxForce 11 and13 engines
• Clean CA• Manual or Automatic transmissions
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• All Wheel Drive (4x4)• Available Mid 2012
• Premium appearance package
• Chrome Grille (all chrome)
• Painted fender extensions (paint grain)
• Painted modesty panels
(paint grain)
• Headlight surround ‐
chrome
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