Navistar ProStar+ Operation And Maintenance Manual
  1. Manuals
  2. Brands
  3. Navistar Manuals
  4. Trucks
  5. ProStar+
  6. Operation and maintenance manual

Navistar ProStar+ Operation And Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
ProStar
+
®
Operation and Maintenance Manual
Navistar, Inc.
2701 Navistar Drive, Lisle, IL 60532 USA
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ProStar+ and is the answer not in the manual?

Questions and answers

Related Manuals for Navistar ProStar+

Summary of Contents for Navistar ProStar+

  • Page 1 ProStar ® Operation and Maintenance Manual Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532 USA © 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
  • Page 2 The information, specifications, and illustrations contained in this manual are based on data that was current at the time of publication. Navistar, Inc. reserves the right to make changes and/or improvements at any time without notification, liability, or without applying those changes or improvements to vehicles previously manufactured and/or sold.
  • Page 3 These numbers are required to obtain pertinent information for this vehicle or engine. VEHICLE IDENTIFICATION NUMBER (VIN) CUSTOMER ASSISTANCE CENTER 1-800-44-TRUCK (1-800-448-7825) ENGINE Navistar, Inc. Feature Code: Serial Number: 2701 Navistar Drive Lisle, IL 60532 USA www.navistar.com FRONT AXLE Feature Code: Serial Number: REAR AXLE Feature Code:...

  • Page 5: Table Of Contents

    Table of Contents Section 1 – Foreword Engine Serial Number........16 Line Set Ticket.
  • Page 6 Table of Contents Front of Tractor..........34 Headlights.
  • Page 7 Table of Contents ® ® ® Bendix Wingman Fusion System......102 Restraint Webbing System........117 Bendix ®...
  • Page 8 Table of Contents General Information.........133 Charge Air Cooler.
  • Page 9 Indicator............183 Eaton ® Navistar ® Alliance Transmissions....163 Reservoir Moisture Draining.
  • Page 10 Table of Contents Connecting / Disconnecting a Trailer to a Vehicle Inspection and Adjustment....... . .208 with Air Suspension.
  • Page 11 Table of Contents Troubleshooting..........223 General Information.
  • Page 12 Table of Contents Maintenance Intervals........245 Fuse Charts.

  • Page 13: Section 1 - Foreword

    Foreword SECTION 1 — FOREWORD Preface Cautions and Warnings Your vehicle has been engineered and manufactured so that it Throughout this manual, you will find Cautions and Warnings: can provide economical and trouble-free service. However, it is the owner's responsibility to see that the vehicle receives proper WARNING care and maintenance.

  • Page 14: Assistance Guide

    Foreword Assistance Guide Contact Closest Navistar, Inc. Regional Sales Office. Addresses of Regional Sales Offices are found in the front When parts are required, always provide the unit code number, of this manual. Should you desire to contact any of these vehicle model, and vehicle serial number.

  • Page 15: Line Set Ticket

    Foreword Line Set Ticket NOTE: Washing Instructions - Wash the vehicle with warm water and mild soap, then wipe wet surfaces with a chamois Each vehicle is provided with a Line Set Ticket (code sheet), or soft cloth. DO NOT use hot water or strong soaps or which lists identification code numbers of component units used detergents.

  • Page 16: Storage Duration - Over One Month

    Foreword 7. Lubricate all exposed transmission, auxiliary transmission 5. Perform the procedure for Storage Duration - One Month and PTO shift rails. or Less, if returning the vehicle to storage. 8. Check state of charge eye in batteries and recharge if NOTE: After every 30 additional days of storage, perform open circuit voltage is below 12.6 volts.

  • Page 17: Diesel Exhaust Fluid (Def) Storage

    Protection Agency Noise Control Regulations. This warranty covers this vehicle as designed, built, and equipped by Navistar and is not limited to any particular part, component, or system of the vehicle manufactured by Navistar. Defects in design, assembly, or in any part, component, or system of the vehicle as manufactured by Navistar at the time the vehicle left Navistar’s control, which cause noise emissions...

  • Page 18: Tampering With Noise Control System Prohibited

    Foreword Tampering with Noise Control System Prohibited operating speed or horsepower other than those provided by Navistar, Inc. Federal law prohibits the following acts or the causing thereof: 6. Exhaust System: Removing or rendering inoperative 1. Removing or rendering inoperative by any person,...

  • Page 19: Warranty

    Foreword and the MIL will go out after certain operating conditions have The period of coverage is the greater of the base mechanical been met. This may take several times operating the vehicle. warranty or: • Five (5) years or 50,000 miles, whichever comes first, Supplemental Federal Emission Control System Warranty for spark-ignition and light heavy-duty diesel vehicles with GVWR below 19,500 pounds.

  • Page 20: Supplemental Federal Emission Control System

    National Highway Traffic Safety Administration The GHG emission-related warranty covers components (NHTSA) in addition to notifying Navistar, Inc. To notify Navistar certified as innovative technologies which are part of the certified see the contact information listed in the front of the manual.

  • Page 21: Safety Recalls And Authorized Field Changes

    Foreword ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa, You can make the free call anonymously, and you might Ontario K1A 0N5. be eligible for a reward. To learn more about vehicle theft and how you can protect yourself, visit the NICB's Web site, www.nicb.org.
  • Page 22 Foreword • Permanently mount your CB radio or remove it when you Layer 3: Vehicle Immobilizer will be away from your truck. A. Fuse cutoffs • Do not discuss where your vehicle is located when you B. Kill switches are not on the road. C.

  • Page 23: Optional Diamond Logic Electronic Application Solutions

    Foreword ® Optional Diamond Logic Electronic Application NOTE: This vehicle may be equipped with electronic application-specific options not described in this operator’s Solutions manual. Many of these features are supplied with rocker switches that have custom labels applied. The presence of WARNING these options as factory installed can be verified from the Line Set Ticket included with the vehicle.
  • Page 24 Foreword...

  • Page 25: Section 2 - Model Description

    Model Description SECTION 2 — MODEL DESCRIPTION Introduction The International ® ProStar + Series Truck is available in two ® models, the International ® ProStar + Series and International ® ® ® ProStar + Eagle Series. ® This operator's manual covers all versions. Illustrations in this manual are used for reference only and may differ slightly from the actual vehicle.
  • Page 26 Model Description 6 x 4 Day Cab with Full Aero Package 4 x 2 Short Sleeper (56-Inch) with Full Aero Package 4 x 2 Short Sleeper (56-Inch) 6 x 4 Short Sleeper (56-Inch)
  • Page 27 Model Description 6 x 4 Short Sleeper (56-Inch) with Full Aero Package 4 x 2 Long Sleeper (73-Inch) with Full Aero Package 4 x 2 Long Sleeper (73-Inch) 6 x 4 Long Sleeper (73-Inch)

  • Page 28: Vehicle Identification

    Model Description The Vehicle Identification Number (VIN) is located on the driver-side door. The VIN and model description are necessary when ordering replacement parts or service manuals. Feature Codes Feature Codes are the basis for identifying the components used on International ®...

  • Page 29: Line Set Ticket

    Model Description Line Set Ticket One copy of the Line Set Ticket is included in the literature provided with the vehicle. When replacement parts are required, NOTE: Be sure to return Line Set Ticket to vehicle after take this copy with you to positively identify vehicle components obtaining parts.

  • Page 30: Exterior Components

    Model Description Exterior Components Front View: ProStar + Not Equipped with Selective ® Catalytic Reduction (SCR) System Sunshade Chassis Skirt (Front) 13. Collision Warning / Safety System Camera (Optional) Fuel Cap (Optional) Luggage Door External Hook-Up for Block Heater 14. Bumper External Hook-Ups for Telephone and TV 10.

  • Page 31: Front View: Prostar

    Model Description Front View: ProStar + Equipped with Selective Catalytic ® Reduction (SCR) System Sunshade Chassis Skirt (Rear) 14. Radar (Optional) Camera (Optional) Chassis Skirt (Front) 15. Collision Warning / Safety System Luggage Door Diesel Exhaust Fluid (DEF) Tank Cap (Optional) External Hook-Ups for Telephone and TV 10.

  • Page 32: Back View: Identical For All Prostar + Models

    Model Description Back View: Identical for All ProStar + Models ® Grab Handle Work Lights Fuel Cap Gladhand Storage Bracket Luggage Door In-Transit Heat (Optional)

  • Page 33: Cab Entry And Exit

    Model Description Cab Entry and Exit Hood Raising the Hood WARNING To prevent property damage, personal injury, and / or death, do not step or climb upon any vehicle surface unless it is slip resistant and a handhold is provided. WARNING To prevent property damage, personal injury, and / or death, a three-point stance should be used...

  • Page 34: Lowering The Hood

    Model Description without pinning or pinching yourself between the hood and WARNING any other structures. To prevent property damage, personal injury, 2. Release the latches on both sides of the cowl. and / or death, never put any part of your body 3.

  • Page 35: Luggage Box Access

    Model Description Luggage Box Access Chassis Skirts The optional chassis skirts on the International ® ProStar + Series Driver and Passenger Side ® trucks are available to provide improved aerodynamics. NOTE: If your vehicle is equipped with the new style, “bolted-on”...

  • Page 36: Chassis Skirt Removal

    Model Description If your vehicle is equipped with the traditional style, removable 1. Locate the locking handle at the rear inside of the chassis skirts, you can remove the rear driver-side chassis skirt chassis skirt. on sleeper models without tools to gain access to the battery 2.

  • Page 37: Chassis Skirt Installation

    Model Description Chassis Skirt Installation NOTE: If vehicle is ordered with the optional No Idle Solution, the rear passenger side chassis skirt that covers NOTE: There are two hooks on the back side of the chassis additional batteries will remove and install the same as the skirt that must be fully engaged on the mounting bar to be rear driver-side chassis skirt.
  • Page 38 Model Description...

  • Page 39: Section 3 - Inspection Guide

    Inspection Guide SECTION 3 — INSPECTION GUIDE Introduction WARNING To prevent property damage, personal injury, and General Information / or death, if vehicle is equipped with an automatic transmission, have qualified technician WARNING regularly check operation of transmission neutral start switch. If unit starts in gear, the vehicle may To prevent property damage, personal injury, and inadvertently move.

  • Page 40: Tractor Inspection

    Inspection Guide Tractor Inspection Exterior Lights Check Perform an automatic check of all exterior lights by doing the Preparation following steps: NOTE: Perform following procedures prior 1. Place the ignition key in the ON or ACC position, place conducting the pre-trip inspection. the transmission in Neutral, and set the parking brake.

  • Page 41: Left Side Cab Area (For Vehicles Not Equipped With Selective Catalytic Reduction (Scr) System)

    Inspection Guide Left Side Cab Area (for Vehicles Not Equipped with NOTE: If the vehicle is equipped with side skirts, it will be Selective Catalytic Reduction (SCR) System) necessary to remove the left rear skirt to gain access to the battery box.

  • Page 42: Left Side Cab Area (For Vehicles Equipped With Selective Catalytic Reduction (Scr) System)

    Inspection Guide Left Side Cab Area (for Vehicles Equipped with Selective NOTE: To access the battery box, find the plastic panel Catalytic Reduction (SCR) System) (battery door) behind the upper step under the left side cab, release the latches, and lift up the battery door. Inspection Items 1.

  • Page 43: Left Engine Compartment

    Inspection Guide Left Engine Compartment 2. Air Cleaner: Check air cleaner element, housing, and hoses for loose connections or damage. Check air filter restriction gauge for restriction reading. For element replacement, see Air Cleaner Element Service in the Maintenance Instructions section. 3.

  • Page 44: Left Front Of Tractor

    Inspection Guide Left Front of Tractor WARNING To prevent property damage, personal injury, and / or death, do not operate vehicle if there is a loss of steering or suspension, which could cause loss of vehicle control. WARNING To prevent property damage, personal injury, and / or death, if wheels or tires must be changed, obtain expert tire service help.
  • Page 45 Inspection Guide 5. Air Suspension (if equipped): Check for air leaks, loose 9. Tire: Check tread depth, tire inflation and note if tread components, and damage to air bag. Inspect stabilizer is evenly worn. Minimum tread depth is 4/32 inch on bar for worn, loose, or damaged components.

  • Page 46: Front Of Tractor

    Inspection Guide Front of Tractor 1. Camera: Inspect for damage and secure mounting. 2. Lighting System: Lower hood and inspect parking, clearance, identification lights, turn signals, fog lights, and reflectors on hood, bumper, and cab. They should be clean, operational, and the proper color. 3.

  • Page 47: Right Front Of Tractor

    Inspection Guide Right Front of Tractor WARNING To prevent property damage, personal injury, and / or death, if wheels or tires must be changed, obtain expert tire service help. Mounting and demounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment.
  • Page 48 Inspection Guide 4. Wheel and Lug Nuts: Check for damaged or bent wheel. securely mounted. Check for broken, loose or missing Check to see that all lug nuts are present and not loose parts. Check for cracked, worn or frayed hoses, and for (look for rust trails around nuts).

  • Page 49: Right Engine Compartment

    Inspection Guide Right Engine Compartment 1. Coolant Level: Do not remove pressure cap unless coolant is cool. Ensure fluid level is between the minimum and maximum fluid level range as marked on the plastic translucent reservoir. 2. Radiator and Charge Air Cooler: Check for loose mounting and damage.

  • Page 50: Right Side Of Cab

    Inspection Guide Right Side of Cab WARNING To prevent property damage, personal injury, and / or death, maintain adequate clearance between all parts of the exhaust system and all hoses, wires and lines for engine cooling, brake system, fuel system, power steering system and electrical system.

  • Page 51: Right Side Under Vehicle

    Inspection Guide Right Side Under Vehicle WARNING To prevent property damage, personal injury, and / or death, maintain adequate clearance between all parts of the exhaust system and all hoses, wires and lines for engine cooling, brake system, fuel system, power steering system and electrical system.

  • Page 52: Right Rear Of Tractor

    Inspection Guide Right Rear of Tractor WARNING To prevent property damage, personal injury, and / or death, if wheels or tires must be changed, obtain expert tire service help. Mounting and demounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment.
  • Page 53 Inspection Guide 5. Tires: Check tread depth, tire inflation and note if tread 8. Torque Rods and Shock Absorbers: Check to see that is evenly worn. Minimum tread depth is 2/32 inch on all torque rods are not cracked, broken, or missing. Check drive tires.

  • Page 54: Rear Of Tractor

    Inspection Guide Rear of Tractor 1. Lights and Reflectors: Check to see that reflectors and lights are clean. Make sure none are missing or broken. Rear running lights should be clean, not broken and RED in color. 2. Frame: Check for cracks or bends in frame. Make sure there are no loose, cracked, bent, broken, or missing crossmembers or crossmember fasteners.

  • Page 55: Left Rear Of Tractor

    Inspection Guide Left Rear of Tractor 1. Brake Chamber and Hoses: Check for cracked, worn or frayed hoses, and for secure couplings. Check to see that the brake chambers are not cracked or dented and that they are securely mounted. Check for broken, loose or missing parts.

  • Page 56: Fifth Wheel And Coupling Area

    Inspection Guide 7. Hub: Check for obvious leaking on outside or inside of Fifth Wheel and Coupling Area wheel. Inspect axle flanges and wheel seals for leaks and loose mounting hardware or broken items. Check lube level, if equipped with sight glass. 8.

  • Page 57: Cab Interior Inspection

    Inspection Guide 3. Mounting Bolts and Release Handle: Look for loose 5. Low Air Alarm: The low air pressure alarm may sound or missing mounting brackets, clamps, bolts or nuts. immediately after the engine starts but before the air All locking pins must be in place and free of damage. compressor has built up minimum 55 psi (379 kPa) Ensure that release handle is in the engaged position pressure.
  • Page 58 Inspection Guide 12. Doors: Ensure windows are clean and operate properly 16. Air Brake Check: Check the air brakes in the following and smoothly in both doors. manner: 13. Windshield and Wipers: Check windshield for cracks, a. Install wheel chocks if necessary. Push in parking dirt, illegal stickers or other obstructions to view.

  • Page 59: Section 4 - Controls / Features

    Controls / Features SECTION 4 — CONTROLS / FEATURES Introduction NOTE: This vehicle may be equipped with electronic, application-specific options not described in this operator’s General Information manual. Many of these features are supplied with rocker switches that have custom labels applied. The presence of The controls / features enable the driver to monitor and manage these options as factory installed can be verified from the the operation of the majority of the vehicle's functions.

  • Page 60: Dash Components

    Controls / Features Dash Components Overhead Console The overhead console contains storage area for the operator, and other items for driver comfort. Overhead Storage CB Radio Mount City Horn Pad Storage Compartment Instrument Panel Gauge Cluster Sun Visors Center Dash Panel / Wing Panel Map Lights Electronic Touchscreen (optional) Cab Dome Lighting...

  • Page 61: Instrument Panel Gauge Cluster

    Controls / Features Instrument Panel Gauge Cluster functions of the vehicle. The following are descriptions and illustrations of the gauges, warning indicators, and integral The instrument panel gauge cluster includes the instrument digital display options. gauges, warning indicators, and an Integral Digital Display, For Vehicles Not Equipped with Selective Catalytic which provide odometer, transmission gear indication, and Reduction (SCR) System:...

  • Page 62: Warning Indicators

    Controls / Features For Vehicles Equipped with Selective Catalytic Reduction (SCR) System: Warning Indicators warning indicators are driven by the software in the instrument panel gauge cluster. At ignition, the warning indicators will The instrument panel gauge cluster contains 25 individual LED illuminate for 8 to 10 seconds, as part of the vehicle power-up warning indicators.
  • Page 63 Controls / Features Item Item Description AWL - The AMBER Warning Lamp (AWL) illuminates when the vehicle needs to be serviced at the first Optional Wait to Start Lamp available opportunity. This lamp may • Illuminates YELLOW when intake be associated with information found in air heaters and glow plugs Exhaust Aftertreatment section.
  • Page 64 Controls / Features Illuminates YELLOW when a trailer Diesel Particulate Filter (DPF) status antilock brake system malfunction has indicator: Illuminates YELLOW (Solid been detected. If the ABS indicator stays or Flashing) to indicate the need to illuminated or continues to flash, have regenerate the Diesel Particulate the system serviced immediately.

  • Page 65: Gauges

    Controls / Features Not used. Gauges Illuminates YELLOW when the PTO There are 10 gauges in the instrument panel gauge cluster to function (if installed) is activated. help monitor the vehicle while in service. Most gauges have Illuminates YELLOW when an antilock in-gauge warning indicators that turn on if the gauge pointer brake system malfunction has been moves into an out-of-acceptable-range condition.
  • Page 66 Controls / Features For vehicles not equipped with The speedometer indicates the vehicle Selective Catalytic Reduction (SCR) speed in miles per hour (MPH) and system: Indicates the engine lubricant kilometers per hour (Km/h). temperature in degrees Fahrenheit (°F) (optional). Indicates the battery voltage (VOLTS) For vehicles equipped with Selective when the ignition switch is in the ON Catalytic Reduction (SCR) system:...

  • Page 67: Instrument Panel Gauge Cluster Alarms

    Controls / Features Instrument Panel Gauge Cluster Alarms The instrument panel gauge cluster will sound an audible alarm that accompanies out-of-range gauge readings along with the particular gauge warning lamps. The instrument panel gauge WARNING cluster alarms will also sound when any sensor (sender) unit fails;...
  • Page 68 Controls / Features Alarm Conditions Audible Alarm Pattern Additional Comments Rear-Rear Axle oil temperature gauge 5 BEEPS Instrument panel gauge cluster warning indicator out-of-range reading illuminates. Forward-Rear Axle oil temperature gauge 5 BEEPS Instrument panel gauge cluster warning indicator out-of-range reading illuminates.

  • Page 69: Direct Drive Warning Indicators

    Controls / Features Direct Drive Warning Indicators Item Item Color Description The direct drive warning indicators give information to the YELLOW Luggage door is ajar. operator of various conditions of the vehicle. Eight spaces are available for the direct drive warning indicators. Blank cover plates will be used in spaces that do not have direct drive BLANK Not used...

  • Page 70: Integral Digital Display

    Controls / Features Integral Digital Display clockwise or counterclockwise. To select the screens within a quadrant, press and release the control. Pressing and holding The Integral Digital Display is located below the speedometer the control for more than 3 seconds to reset the value of the and the tachometer.
  • Page 71 Controls / Features Item No. Quadrant Number and Message Function Message Description Quadrant 1: Informational Messages Informational Display Screens: • Odometer • Trip Odometer • Total Engine Hours • Trip Hours • Machine PTO A or B Hours • Machine Trip PTO A or B Hours •...

  • Page 72: General Text And Warning Messages

    Controls / Features Item No. Quadrant Number and Message Function Message Description Quadrant 4: Transmission Gear Indication Transmission gears for the Allison P-R-N-D-L gear selection display, or the Eaton ® Transmission display. Quadrant 3: Compass Heading / Outside (Optional) Displays compass heading when vehicle is equipped with a compass Temperature module.

  • Page 73: Optional Instrument Panel Gauge Cluster Compass

    Controls / Features Optional Instrument Panel Gauge Cluster Compass Compass Declination Zone Set Procedure Calibration Procedure The Declination Zone number is used to account for the All new vehicles with an optional compass must have an initial errors between magnetic North and true North in the vehicle’s compass calibration performed.
  • Page 74 Controls / Features Declination Zone Map...
  • Page 75 Controls / Features Step Procedure Displayed Message Select Quadrant 2 (lower right) on the display by turning the display control knob either clockwise or counterclockwise. Select the Compass Declination message by pressing and releasing the display control knob until this message appears. Press and HOLD the display control knob until any Declination Zone number (0 –...

  • Page 76: Compass Directional Calibration Procedure

    Controls / Features Compass Directional Calibration Procedure To begin the Compass Directional Calibration Procedure, stop the vehicle in an area large enough to permit driving in complete circles and perform the following steps: Step Procedure Displayed Message Select Quadrant 2 (lower right) on the instrument panel gauge cluster display by turning the display control knob either clockwise or counterclockwise.
  • Page 77 Controls / Features Stop the vehicle and wait shortly. The End Calibration message should reappear on the display. Push and HOLD the display control knob until the End Calibration command disappears. The calibration should now be complete. IMPORTANT!: Just pressing and failing to hold the display control knob inward until the End Calibration command disappears will cancel the calibration procedure and you must start over at Step 1.

  • Page 78: Integral Digital Display Detailed Information

    Controls / Features Integral Digital Display Detailed Information Quadrant 1: Informational Displays NOTE: The available display screens are dependent on the configuration of the vehicle. Quadrant 1 – Display Messages Description Odometer The odometer displays the total distance traveled. Display Format: 100,000.0 TRIP MILES TRIP KM...
  • Page 79 Controls / Features Quadrant 1 – Display Messages Description Trip Hours The Trip Hour display provides a record of elapsed engine hours since the last reset. NOTE: The trip hours and trip miles are independently reset. Display Format: 100,000.0 TRIP HOURS Machine PTO A or B Hours This display will provide a record of the total accumulated Machine PTO hours, while PTO function A or B is engaged.
  • Page 80 Controls / Features Quadrant 1 – Display Messages Description Engine PTO Trip Hours This display will provide a record of the Engine PTO Trip hours sent from engine. Display Format: 100,000.0 ENG PTO TRP HOURS Instantaneous Fuel Economy This display provides a record of the instantaneous fuel economy sent from the engine. The display shall be in miles per gallon or liters per 100 kilometers, corresponding to the units selected while in the odometer mode.
  • Page 81 Controls / Features Quadrant 1 – Display Messages Description Machine PTO Fuel Used A and B The display value shall be the calculated Machine PTO Fuel Used. Display Format: 100,000.0 PTO GAL A PTO GAL B PTO L A PTO L B Machine PTO Trip Fuel Used A and B The display value shall be the calculated Machine PTO Trip Fuel Used.
  • Page 82 Controls / Features Quadrant 1 – Display Messages Description Engine PTO Trip Fuel Used The display value shall be the calculated Engine PTO Trip Fuel Used. Display Format: 100,000.0 ENG PTO TRP GAL ENG PTO TRP L Trip Idle Fuel Used The display value shall be the calculated Trip Idle Fuel Used.
  • Page 83 Controls / Features Quadrant 1 – Display Messages Description Diesel Particulate Filter Level The instrument panel gauge cluster shall display the relative Diesel Particulate Filter (DPF) Level. The instrument panel gauge cluster displays the following graphic: With L (low) on the left and H (high) on the right, the graph is shown by bars each representing a 10% increase / decrease in soot level.
  • Page 84 Controls / Features Quadrant 2: Text and Warning Messages an asterisk (*), indicating multiple messages. To view additional messages, press and release the Display Control button to These messages inform the driver of vehicle conditions. If the proceed to the next message. message flashes, it will flash for 3 –...
  • Page 85 Controls / Features Quadrant 2 – Display Description Message Flashes (Yes Warning Indicator Messages / No) Association Activate HVAC Front Blower Bar graph displayed show blower speed setting in Off and low to high increments. HVAC Sleeper Blower Speed Bar graph displayed show blower speed setting in Off and low to high increments.
  • Page 86 Controls / Features Quadrant 2 – Display Description Message Flashes (Yes Warning Indicator Messages / No) Association Warn Engine (Priority 1 or 2) (1) Message is displayed when the Red Stop Lamp goes (1) Red Stop Lamp (2) Amber Warning Lamp (2) Message is displayed when the Amber Warning Lamp goes on and the Red Stop Lamp does not.
  • Page 87 Controls / Features Quadrant 2 – Display Description Message Flashes (Yes Warning Indicator Messages / No) Association Check Trans Message is displayed when transmission needs to be Amber Warning Lamp serviced. Trans Temp Message is displayed when transmission turns on the Amber Warning Lamp Amber Warning Lamp.
  • Page 88 Controls / Features Quadrant 2 – Display Description Message Flashes (Yes Warning Indicator Messages / No) Association ECM, TCM, Shift Selector, ABS, Message is displayed when a module other than the Amber Warning Lamp Retarder – Driveline, EGC, engine requests the Amber Warning Lamp. Compass Module, ESC, VSM, SD, AGSP, TPMS, Exhaust Module, Telematics, AGSP 2,...
  • Page 89 Controls / Features Quadrant 2 – Display Description Message Flashes (Yes Warning Indicator Messages / No) Association Blank screen, available only when engine RPM is less than or equal to 325 RPM, or vehicle speed is less than 2 mph (3 km/h). Calibrate Compass Message is displayed when vehicle speed is less than 2 mph (3 km/h) and the operator has not requested...
  • Page 90 Controls / Features Quadrant 2 – Display Description Message Flashes (Yes Warning Indicator Messages / No) Association DEF Quality Derated Diesel Exhaust Fluid (DEF) quality problem has been Amber Warning Lamp present for 1 hour or longer. Engine performance is limited. DEF Quality Derated 5mph Diesel Exhaust Fluid (DEF) quality problem has been Amber Warning Lamp;...
  • Page 91 Controls / Features Warning Messages Quadrant 3 – Description Display Messages In addition to the Diagnostic Trouble Codes (DTC), the digital display will display a warning message whenever a fault indicator Outside Display Format: is illuminated. This warning message will be toggled with the Temperature and normal DTC as follows: Compass Heading...

  • Page 92: Switches

    Controls / Features Quadrant 4: Transmission Gear Displays is closed. It also sounds when headlight switch is on, ignition switch is in OFF position, and the drivers door is open. Quadrant 4 – Transmission Gear Indications The headlights are operated in a variety of modes: Allison P-R-N-D-L gear display Daytime Running Lights (DRL)

  • Page 93: Dome Lighting

    Controls / Features Dome Lighting Item Item Description The overhead dome light is used for reading and for illumination Used to either turn on the sleeper dome when entering and exiting the vehicle. The dome light on / off or floor light. is also controlled by pushing on the lamp lens.

  • Page 94: Steering Wheel Controls

    Controls / Features Steering Wheel Controls SET / COAST - Used to set the speed desired on the cruise control or coast to a lower desired speed. When parked, used to decrease idle RPM. HEADLIGHT INT - Used to momentarily turn off (interrupt) the headlights when pressed.

  • Page 95: Cruise Control

    Controls / Features a. Press the ON position of the ON / OFF steering wheel MARKER INT - Used to toggle the park control. lights and markers on or off, depending on park light switch position. If the park b. Bring the vehicle to the desired operating speed (above lights are on, it will toggle them off.

  • Page 96: Steering Column And Switches

    Controls / Features Steering Column and Switches Stop Override Hazard (Optional) - When hazard lights are activated and the brake pedal is depressed, all hazard / turn signal lights on the front, side lights of the truck, and the side trailer lights will continue to flash.
  • Page 97 Controls / Features Automatic Intermittent Interval Control (Optional) – This Keep the fluid reservoir filled with Fleetrite Windshield Washer feature automatically changes the wiper speed from HIGH or Solvent or equivalent. LOW to the slowest intermittent speed when the parking brake 6.

  • Page 98: Center Dash Panel / Wing Panel

    Controls / Features Center Dash Panel / Wing Panel...

  • Page 99: Gauges

    Controls / Features Gauges Switches There are four spaces for optional gauges in the instrument Up to 23 optional switches can be located in the center and panel gauge cluster of the center instrument panel. There are lower right side of the center instrument panel. Location of these five optional gauges to choose from.
  • Page 100 Controls / Features FOG LIGHT / ON SUSP / DUMP Turns on Fog Lamps when This switch allows the headlight switch is on, and operator to release the high beams are off. air from the air bags in a rear air suspension system ®...
  • Page 101 Controls / Features FIFTH WHEEL JAW DIFF / LOCK UNLOCK Used when vehicle has Press and hold this single locking differential momentary switch to for improved traction unlock the fifth wheel jaw. on poor surfaces at low Vehicle must be stationary, speeds.
  • Page 102 Controls / Features INHIBIT REGEN / ON ENAB / DATA LOG The Regeneration Inhibit When enabled, allows the switch is used to prevent driver to log the last 5 the Normal Regeneration seconds of data group's or Parked Regeneration operational parameter processes.
  • Page 103 Controls / Features The center instrument panel also consists of console 33. Dash Electronic Touchscreen (optional) components for driver comfort and use, as well as the 34. Air Brake Valve Controls transmission controls and Electronic Touchscreen. a. Trailer Air Supply 27.

  • Page 104: Climate Control

    Controls / Features Climate Control WARNING To prevent property damage, personal injury, and / or death, never drive the vehicle unless the windshield and all other windows are clear. A fogged, ice / snow covered, or dirty windshield or window limits vision, which could cause an accident. To improve defroster efficiency, remove ice and / or snow by hand from the windshield and windows with a non-metallic scraper.
  • Page 105 Controls / Features MAX Air Conditioning Mode In this mode, all airflow is directed to the panel air outlets and the air is recirculated inside the vehicle. Use this mode to block out any outside odors, smoke, or dust and to cool the interior rapidly upon initial startup in very hot or humid weather.
  • Page 106 Controls / Features Mix Mode In this mode 50% of the airflow is directed to the defrost and side de-mist air outlets and 50% of the airflow is directed to the floor air outlets, while fresh (outside) air is circulated inside the vehicle. The A/C compressor turns on and off automatically as needed when in this mode to reduce humidity levels and help reduce moisture buildup on the windshield.

  • Page 107: Air Conditioning

    Controls / Features Air Conditioning Dehumidification The heater-defroster systems can be operated simultaneously CAUTION with the air conditioner during mild weather and high humidity prevent property damage, follow conditions to dehumidify the cab air. Turn the mode button to recommended service procedures and maintain one of the A/C positions and position the temperature knob at adequate air flow through air exchange devices.

  • Page 108: Smartwave ® Display

    USB or SD Cards, and automatic software updates over the internet. The Premium Door and Window Controls System will also support the installation of Navistar approved Applications (also known as Apps). Refer to the Vehicle...

  • Page 109: Remote Keyless Entry Operation (Optional)

    Controls / Features NOTE: The vehicle is delivered with two identical keys. If more keys are needed, order them through your authorized International Truck dealer. Record the key code and keep it in a secure place. A new key can be made if the keys are lost.

  • Page 110: Lock / Unlock From Interior

    Controls / Features Lock / Unlock From Interior Locking the Door To lock, push the lock / unlock button on the lock symbol in the WARNING door control panel located by the vent window. Pressing the lock / unlock button on the lock symbol once locks both cab doors. To prevent property damage, personal injury, and / or death, and to reduce the risk of personal Unlocking the Door...

  • Page 111: Driver / Passenger Windows

    Controls / Features Driver / Passenger Windows Mirror Controls Manual Operation To lower door glass (driver door), turn window regulator handle clockwise. To raise glass, turn handle counterclockwise. Reverse this procedure for the passenger door. Power Operation Trucks may have optional electrically operated driver and passenger windows.

  • Page 112: Bendix Wingman Advanced ® Collision Warning System

    Controls / Features ® ® ® Bendix Wingman Advanced Collision Warning WARNING System To prevent property damage, personal injury, and / or death, the Bendix ® Wingman ® Advanced ® WARNING Collision Warning System is not to be used or relied upon to operate a vehicle.
  • Page 113 Controls / Features ® ® ® The optional Bendix Wingman Advanced Collision Warning • Adaptive Cruise Control with Braking – When cruise System combines adaptive cruise control with braking feature control is on with the speed set, the adaptive cruise along with collision mitigation technology to assist the driver in control helps the driver maintain a set following distance various conditions.

  • Page 114: Bendix Wingman Fusion

    Controls / Features ® ® ® Bendix Wingman Fusion System WARNING To prevent property damage, personal injury, WARNING and / or death, be aware that the Bendix ® Wingman ® Fusion ® System may provide little To prevent property damage, personal injury, and / or death, before using this feature, read and to no warning or stationary vehicle braking for some hazards, such as pedestrians, animals,...

  • Page 115: Driver Interface Unit

    Controls / Features ® Bendix Driver Interface Unit ® ® ® The optional Bendix Wingman Fusion system is an advanced safety system that integrates radar, camera and brakes into Bendix ® Driver Interface Unit a comprehensive driver assistance system that includes the following features not offered with the Bendix ®...

  • Page 116: Meritor Wabco Onguard™ Collision Safety System

    Controls / Features OnGuard™ ™ ™ Collision Safety ® Meritor Wabco OnGuard™ ™ ™ Display ® Meritor Wabco System WARNING To prevent property damage, personal injury, and / or death, before using this feature, read and thoroughly understand the Meritor Wabco ®...

  • Page 117: Driver Reward

    Controls / Features Three Levels of OnGuard™ ™ ™ defense: fuel economy, time at idle, or both. Rewards include higher maximum vehicle speed and higher cruise control speed limit. • Collision Warning System generates audible and visual Lower maximum vehicle speed or cruise control speed limits alerts when the vehicle's following distance may result in may result as a penalty for failing to meet the standards.
  • Page 118 Controls / Features...

  • Page 119: Section 5 - Sleeper Features

    Sleeper Features SECTION 5 — SLEEPER FEATURES Introduction Common features on the International ® ProStar + Series 56-in ® (142 cm) short sleeper model. General Information There are three trim versions of sleepers available: • ProStar + Series ® • ProStar + Eagle Series ®...
  • Page 120 Sleeper Features ® ® Common features on the International ProStar + Series 73-in Common features on the International ProStar + Series 73-in ® ® (185 cm) long sleeper model with lower bunk: (185 cm) long sleeper model with lower and upper bunks: Duct Work Vents Rear Wardrobe Cabinet NOTE: Although not illustrated, the long sleeper models...

  • Page 121: Lighting

    Sleeper Features Lighting Floor Lights There are two red floor lights located under the lower bunk Dome Light included with all sleeper cabs. These floor lights are controlled The sleeper dome light is a large fluorescent light located on by the same two-switch arrangement as the sleeper dome light. the headliner of the sleeper compartment.

  • Page 122: Sleeper Control Panel

    Sleeper Features Sleeper Control Panel The sleeper control panel comes with several optional features, but the main components are the switch pack, sleeper climate General Information controls, and inverter control panel. Sleeper Control Panel Item Component Description Switch Pack The sleeper control panel is equipped with locations for up to six switches.

  • Page 123: Accent Light Dimmer Switch

    Sleeper Features Accent Light Dimmer Switch Engine Control Switch This switch is used for adjusting the brightness and WARNING dimness of the sleeper compartment accent lights. To prevent property damage, personal injury, and • Up position brightens the accent lights. / or death, never start the engine unless you're •...

  • Page 124: Auto Start / Stop System

    Sleeper Features the engine will begin cranking. Release the switch as soon as • If the LED is steady on, the system has been enabled and the engine starts. the automatic start / stop of the engine will occur when the conditions are met (bunk switch is pressed, voltage is low, To stop the engine, press the ENGINE CNTL switch again.
  • Page 125 Sleeper Features Auto Start / Stop Mode Manual Start / Stop Mode 1. To enable, set all safety interlocks (Neutral, parking 1. To enable, perform Steps 1 - 6 as previously stated in brake set, clutch not depressed, hood closed). the auto start / stop mode.

  • Page 126: Manual Climate Controls

    Sleeper Features Manual Climate Controls Electronic Climate Controller NOTE: If sleeper air conditioning is desired and the main NOTE: If sleeper air conditioning is desired and the main cab blower is not enabled, the air conditioner will not cab blower is not enabled, the air conditioner will not function and the message Activate Front Blower will appear function and the message Activate Front Blower will appear on the instrument panel gauge cluster.

  • Page 127: No-Idle Heating

    Sleeper Features NOTE: The temperature display is a representation of Power Receptacle the current temperature set point, not actual sleeper temperature. A 12-volt power socket is located to the right of the sleeper climate controls. This power source provides No-Idle Heating a location to operate accessories.

  • Page 128: Windows

    Sleeper Features 2. Power Indicator Light: The power inverter light will illuminate solid GREEN when the power inverter is powered on or in Float Charge State. A blinking GREEN light (one blink per second) indicates that the power inverter is in Bulk or Absorption Charging State. blinking GREEN light (two blinks per second) indicates that the power inverter is in Load Demand Mode.

  • Page 129: Bunk Restraint System

    Two types of sleeper bunk occupant restraint systems are bunk with seven buckles. The only restraint system provided available with sleeper bunks supplied by Navistar, Inc. If the with the optional upper bunk is the restraint webbing system. To sleeper berth is not provided with one of these two types of...
  • Page 130 Sleeper Features 2. Insert two rear latches on the rear wall into two mating buckles (4) that are sewn to the restraint webbing system, making sure that both buckles are fully latched. 3. Insert three front latches that are sewn to the front of the restraint webbing system into the front buckles mounted at the front of the bunk.

  • Page 131: Lower Bunk

    Sleeper Features Lower Bunk Item Component Description General Information Release To open, press upward on the latch mechanism Latch and lift the front edge of the bunk platform. To close, lower the bunk until the latch mechanism is locked in place. Gas Shocks The lower bunk is fitted with two gas shocks to aid in opening, closing, and supporting the...

  • Page 132: Upper Bunk

    Sleeper Features Sleeper Allows air to enter sleeper HVAC unit. Do not HVAC block HVAC air intake. Intake Sleeper Replaceable / cleanable filter cleans air and HVAC Air protects heat exchanger from becoming Intake Filter plugged with lint and debris. Upper Bunk General Information The optional upper bunk is hinged and can be raised and locked...

  • Page 133: Entering The Upper Bunk

    Sleeper Features Entering the Upper Bunk 1. Begin by facing the bottom step, placing your right foot on the bottom step. Grasp the front edge of the airline cabinet with your right hand and grasp the front bunk rail with your left hand. (The bunk area is designed for your head to be at the driver’s side of the bunk.) 2.

  • Page 134: Exiting The Upper Bunk

    Sleeper Features Exiting the Upper Bunk 1. While keeping a firm grip with both hands on the front edge of the upper bunk, sit up on the upper bunk positioning your body above the top step and your legs over the front of the upper bunk. 2.

  • Page 135: Cabinets / Storage

    Sleeper Features Cabinets / Storage General Information WARNING To prevent property damage, personal injury, and / or death, always remove all loose items from the interior and store appropriately when vehicle is in motion. Falling items can be a distraction to the driver, or a projectile can cause an accident.

  • Page 136: Cabinets

    Sleeper Features Cabinets 3. Lift Release Handle: The drawer is equipped with a lift release handle. To open the drawer, lift the handle Refrigerator Cabinet from the bottom and slide the drawer open. To close, push the drawer shut until the lift release handle locks the drawer shut.

  • Page 137: Horizontal Refrigerator

    Sleeper Features Horizontal Refrigerator Dresser Cabinet Control Knob / Thermostat Power Indicator Drawer Refrigerator Cabinet Lift Release Handle An optional horizontal refrigerator is available on select 1. Dresser Top: The top of the dresser cabinet serves as International ® ProStar + Series sleeper models and is located a desktop.
  • Page 138 Sleeper Features 3. Lift Release Handle: All drawers are equipped with lift 6. Dresser Cabinet: The dresser cabinet is available release handles. To open the drawers, lift the handle on select International ® ProStar + Series long sleeper ® from the bottom and slide the drawer open. To close, models and is located behind the passenger's seat.

  • Page 139: Tower Wardrobe Cabinet

    Sleeper Features Tower Wardrobe Cabinet 1. Tower Wardrobe: The tower wardrobe cabinet is available on select International ® ProStar + Series long ® sleeper models and is located behind the driver's seat. The tower wardrobe cabinet provides hanging clothes storage. When equipped with the upper bunk option, the tower wardrobe cabinet provides steps for access to the upper bunk.

  • Page 140: Rear Wardrobe Cabinet

    Sleeper Features Rear Wardrobe Cabinet 1. Rear Wardrobe: The rear wardrobe cabinet is mounted on the rear wall of International ® ProStar + Series ® sleeper models and provides storage for hanging clothes. When an upper bunk is installed in the sleeper compartment, the rear wardrobe cabinet is not installed.

  • Page 141: Airline Cabinets

    Sleeper Features Airline Cabinets 1. Airline Cabinets: These airline-style cabinets are mounted at the top of the side walls and can come in configurations of one, two, or three cabinets on each side of select International ® ProStar + Series sleeper ®...

  • Page 142: Convenience Features

    Sleeper Features Convenience Features Power Sockets Several 120-volt AC power sockets, for using electrical General Information appliances within the sleeper, are distributed throughout the The sleeper cab is equipped with additional features that make sleeper compartment. living on the road easier and more convenient. Speakers Sleeper Curtain There are two standard coaxial speakers mounted on the rear...

  • Page 143: Section 6 - Operation

    Operation SECTION 6 — OPERATION Operation Safety WARNING To prevent property damage, personal injury, General Information and / or death, do not operate the truck in the possible presence of flammable vapors unless WARNING both a complete hazard analysis is performed and necessary additional safety processes and To prevent property damage, personal injury, and / or equipment such as vapor testing, air intake...
  • Page 144 Operation WARNING WARNING To prevent property damage, personal injury, and To prevent property damage, personal injury, / or death, always use occupant restraint system and / or death, when parking your vehicle, do when vehicle is moving. Any location in the not leave transmission in gear.

  • Page 145: Cab Controls

    Operation This section contains information concerning the safe operation WARNING of your vehicle. It is extremely important that this information is read and understood before the vehicle is operated. To prevent property damage, personal injury, and or death, properly inspect and maintain seat Cab Controls belts.

  • Page 146: General Information

    Operation General Information Tether straps are installed on all suspension-type seats. Tether straps help secure the seat to the floor and are intended to Safety belts must be worn by the driver and all passengers at restrain the seat and safety belt in case of an accident or all times.

  • Page 147: Operation

    Operation Operation To operate the seat belt follow these steps: 1. Slowly pull the three-point seat belt out of the retractor and slowly pull it across your lap far enough to engage the buckle. If the retractor locks too soon, allow the seat belt to retract slightly, then slowly pull it out again.

  • Page 148: Care Of Seat Belts

    Operation Care of Seat Belts Clean the belts occasionally with mild soap; do not use cleaning solvents or abrasives. WARNING The entire seat belt assembly should be inspected periodically for corrosion, wear, fraying, or weak spots. The retractor, latch, To prevent property damage, personal injury, and buckle should be checked for proper function, and all seat and / or death, do not bleach or re-dye seat belt belt mounting bolts should be tight at all times.

  • Page 149: Seats

    Operation Seats There are several seat options that can be used in the International ® ProStar + Series vehicle. If a different seat ® General Information assembly than the one listed below is installed in your vehicle, see your authorized International Truck dealer. WARNING The air suspension seats for the driver and passenger are equipped with features that adjust for maximum comfort and...
  • Page 150 Operation Seat Controls and Adjustments Item No. Item Description Backrest Tilt By rotating the handle, the backrest recline angle can be adjusted. Chugger Snubber Moving the handle down isolates the seat from the fore and aft movement of the cab. Armrests Armrests can be adjusted by lowering / raising to desired angle.

  • Page 151: Starting Procedures

    Operation Starting Procedures NOTE: Some automated transmissions will delay engine cranking until the transmission power-up is complete. General Information Engine Starting WARNING To prevent property damage, personal injury, and / or death, never start the engine unless you're sure the transmission selector is in Neutral and the brake is applied;...

  • Page 152: After The Engine Starts

    Operation 4. Turn the key to the START position. After the Engine Starts 5. When the engine starts, release the key. NOTE: For additional information, see Engine Operation 6. The key will return to the ON position and the engine will and Maintenance Manual.

  • Page 153: Engine Shutdown

    Operation Engine Shutdown Emergency Starting NOTE: For additional information, see Engine Operation WARNING and Maintenance Manual. To prevent property damage, personal injury, Idle the engine for 3 - 5 minutes before shutting down. This and / or death, the following procedure must be few minutes of idling allows the lubricating oil and water to carry performed exactly as outlined;...

  • Page 154: Cold Weather

    Operation 1. To prevent shorting of the electrical system, remove Cold Weather metal rings or watches and do not allow metal tools to contact the positive terminal of battery or jumper cables. General Information 2. Place transmission in Neutral and set parking brake in WARNING both the discharged and booster vehicle.

  • Page 155: Cold Weather Operation

    Operation Cold Weather Operation Engine Idling In order to operate the engine in temperatures of 32°F (0°C) or CAUTION lower, observe the following instructions: To prevent property damage, adhere to this • Make certain that batteries are of sufficient size and in Caution.

  • Page 156: Engine Idle Shutdown Timer (Optional)

    Operation Engine Idle Shutdown Timer (Optional) Cooling air flow restriction affects emissions and can cause high exhaust temperatures, power loss, excessive fan usage, and a This vehicle may be equipped with an optional Idle Shutdown reduction in fuel economy. If you insist on using a winter front, Timer that will limit engine idle time to comply with certain state the device should have a permanent opening above or directly and local regulations and / or owner / operator preferences.

  • Page 157: Operating Instructions

    Operation Operating Instructions Steering Be alert to any change (feel) in steering when driving. This General Information change or feel includes increased steering effort, unusual sounds when turning, excessive wheel play, or pulling to WARNING either side. If any of the above are detected, have the vehicle inspected and repaired at once by a qualified mechanic.

  • Page 158: Adjustable Steering Column

    Operation Adjustable Steering Column • Hold the steering wheel in the newly acquired position with your right hand and pull the release handle backward towards you, to the locked position, with your left hand. • Make certain the steering wheel is in the proper position and the column is locked.

  • Page 159: Electrical

    Operation Electrical Battery Alternator WARNING CAUTION To prevent property damage, personal injury, and / or death, keep lighted tobacco, flames, sparks, To prevent property damage, avoid improper or other ignition sources away from the batteries. usage of fast charger, hook-up of booster battery, Gas from the battery cells is flammable and can or battery installation, which can cause damage ignite and / or explode, including when jumper...

  • Page 160: Battery On Indicator

    Operation BATTERY ON Indicator WARNING To prevent property damage, personal injury, and / or death, whenever disconnecting battery terminals, always disconnect ground terminal first. When reconnecting, always connect ground terminal last. Failure to follow this procedure could also result in a short to ground. WARNING To prevent property damage, personal injury, and / or death, always wear eye protection...

  • Page 161: Circuit Breakers, Fuses And Fusible Links

    Operation Circuit Breakers, Fuses and Fusible Links • The various electrical units in the cab and engine compartments are protected by either fuses or circuit breakers. The power distribution center is located within WARNING the instrument panel (glove box area) on the passenger side of the vehicle.

  • Page 162: Charge Air Cooler

    Operation controls all engine functions. This ECM also communicates with Electronic Engine Controller the body electrical system which will generate or activate the Each vehicle contains an Engine Operation and Maintenance necessary warning indicators to alert the driver of out-of-range Manual in the driver’s door pocket.

  • Page 163: Engine Brake With Allison Transmissions

    Operation To activate the engine brake, press the push button preselected shift schedule in order to enhance the engine brake ENG BRAKE ON / OFF switch on the steering wheel performance. (pressing this switch again will deactivate the system). The ENGINE BRAKE SELECTOR 1/2/3 switch is then Engine Brake With Eaton ®...

  • Page 164: Engine Features

    Operation When the transmission is in manual mode, engine protection engine function indicators and warning indicators. Since many upshifts are disabled. This could result in an undesirable engine of the engine performance features are owner selectable and overspeed condition. It is the operator’s responsibility to prevent electronically programmable, some of the operating parameters mechanical damage to the truck.

  • Page 165: Hd-Obd Overview

    Operation Some Optional Features: The operator will be alerted to emissions or other system problems when the Malfunction Indicator Lamp (MIL) illuminates. • Engine Warning System – This system illuminates the When the MIL illuminates, bring the vehicle in for service at Red Stop Lamp and actuates a beeper when warning the next available opportunity.

  • Page 166: Air Compressor Cycling

    Operation Air Compressor Cycling engine operation, this cycle will be evident by the fluctuation of the primary air tank pressure gauge. The engines can be equipped with one of two different types of air compressor and may have one or two cylinders. Cooling System •...

  • Page 167: Engine Oil

    Shell Rotella ® ELC (Red) coolant. Engine Performance Problems Navistar, Inc. recommends using only the approved coolant with the 2010 cooling packages, and will not warrant these cooling • Low engine power can be the result of a plugged fuel filter.

  • Page 168: Fuel

    Operation Fuel space, which will pose an extreme fire / explosion hazard during refueling or engine operation. Ultra Low Sulfur Diesel Fuel Requirements Additional Unsafe Practices Ultra Low Sulfur Diesel (ULSD) fuel is required for all on-highway diesel engines used with advanced aftertreatment systems CAUTION (Diesel Particulate Filters –...

  • Page 169: Fueling Precautions

    Operation Dual tank systems are equipped with dual draw and dual return 4. Do not permit any other person to engage in such fuel line systems to equalize the fuel temperature and level activities as would be likely to result in fire or explosion. between the dual tanks.

  • Page 170: Transmission Fluid Temperature

    Operation Transmission Fluid Temperature the transmission fluid level is correct and that the engine temperatures are within normal limits. If the high transmission CAUTION or engine temperatures persist, stop the engine and contact your nearest International Dealer for further assistance. To prevent property damage, observe the following: Transmission malfunction or damage...
  • Page 171 Operation obtained in LO range, the operator preselects the range shift lever for HI range. The range shift occurs automatically as the shift lever is moved from 5th gear position to the 6th gear position. 1. When operating off-highway, or under adverse conditions, always use the lowest gear when starting to move the vehicle.

  • Page 172: Engaging The Clutch

    Operation 7. Double-clutch between all upshifts and downshifts. • Never hold a vehicle on a hill with the clutch. To hold on a hill with the clutch requires that the clutch be 8. After your shifting ability improves, you may want to purposely slipped.

  • Page 173: Hydraulic Clutch Actuation System

    Operation clutch pedal since the vehicle will experience erratic If non-self adjusting clutches are used in this application, it is engagement. important that clutch adjustments be maintained. Adjustment intervals should be every 20,000 miles (32,000 km). When Erratic engagement can cause engine stalling and potential utilizing an Eaton ®...

  • Page 174: Double Clutch Procedures

    Operation Double Clutch Procedures When using the clutch brake, fully depress the clutch pedal and shift the transmission into either first or reverse gear. If the In order to properly upshift or downshift, be sure to do the transmission does not go into first gear or reverse, tooth butting following: may be occurring.

  • Page 175: Eaton Cummins Alliance Transmissions

    For operating If your vehicle is equipped with a power take-off (PTO), refer to instructions, refer to the Transmission Driver Instruction Manual. the PTO equipment manufacturer’s instructions. Eaton ® Navistar ® Alliance Transmissions Rear Axles The optional Eaton ®...

  • Page 176: Tandem Axle Power Divider Lock (Pdl) Control

    Operation CAUTION WARNING To prevent vehicle and / or component damage, To prevent property damage, personal injury, and engage the PDL only when stopped or moving at / or death, pay strict attention to the following: low speed. Never try to engage the PDL while the wheels are spinning as this may result in shock Care should be taken to prevent sudden damage to the power divider components.

  • Page 177: Driver Controlled Differential Lock

    Operation Under normal highway conditions (good traction), the PDL When the differential is fully locked, the vehicle will have a slight should be disengaged, which allows differential action between “under-steer” condition. This will increase the turning radius of the forward rear axle and the back rear axle preventing inter-axle the vehicle.

  • Page 178: Rear Suspension

    Operation Rear Suspension air tanks have sufficient pressure to fill the suspension. When the ignition switch is turned off, power to the solenoid will be Rear Air Ride Suspension removed; therefore, the suspension will remain in the state last set by the SUSP / DUMP switch. CAUTION NOTE: The suspension will dump when the ignition switch To prevent ride degradation and suspension...

  • Page 179: Exhaust Aftertreatment

    The SUSP / DUMP switch indicator will blink slowly in CAUTION the event of an ESC command fault, regardless of the To prevent property damage, Navistar, Inc. position of the SUSP / DUMP switch. requires the use of Diesel Exhaust Fluid (DEF) that meets or exceeds ISO-22241-1.

  • Page 180: Low Def Level

    Operation After the key is turned OFF on a vehicle with SCR system, a Low DEF Level pumping sound may be heard from underneath the vehicle. The sound is made by the Aftertreatment DEF dosing unit while it WARNING purges any unused DEF from the system and returns it to the DEF tank.
  • Page 181 Operation ® Indicators about Low DEF level (For Vehicles Equipped with Cummins ISX15 Engines) Vehicle Conditions Level Indication Audible Alarm LCD Text Message / Operation Scrolls between SEE Initial Warning – normal VISOR FOR INFO and 1 Beep engine operation. DEF DEF LOW REFILL level is 10% or lower.
  • Page 182 Operation Indicators about Low DEF level (For Vehicles Equipped with Cummins ® ISX15 Engines) (cont.) Vehicle Conditions Level Indication Audible Alarm LCD Text Message / Operation Scrolls between SEE VISOR FOR INFO, DEF Engine performance is (Flashing) 1 Beep LOW ENG DERATED LIMITED.
  • Page 183 Operation ® Indicators aboutLow DEF level (For Vehicles Equipped with Navistar N13 engines) Vehicle Conditions / Level EIndication Audible Alarm LCD Text Message Operation Initial Warning – normal DEF LOW REFILL 1 Beep engine operation. DEF SOON. level is 5.6% or lower.

  • Page 184: Def Contamination Or Scr System Fault

    Operation DEF Contamination or SCR System Fault If incorrect liquid is in the DEF tank or if some other fault is detected within the SCR system, the Amber Warning Lamp or Malfunction Indicator Lamp will illuminate. If no action is taken WARNING in the initial warning stages, engine performance will be derated by at least 25%, and eventually vehicle speed may be limited to...
  • Page 185 Operation ® Indicators about DEF Quality Problem (For Vehicles Equipped with Cummins ISX15 Engines) Vehicle Conditions / Level Indication Audible Alarm LCD Text Message Operation Scrolls between DEF QUALITY SERVICE Initial Warning – fault code 1 Beep SOON and WARN has been set.
  • Page 186 Operation ® Indicators about DEF Quality Problem (For Vehicles Equipped with Navistar N13 Engines) Vehicle Conditions / Level Indication Audible Alarm LCD Text Message Operation DEF QUALITY SERVICE Initial Warning – fault code None SOON. has been set. Engine performance is...
  • Page 187 Operation ® Warnings of SCR System Fault (For Vehicles Equipped with Cummins ISX15 Engines) Level Indication Audible Alarm Vehicle Conditions / Operation Initial Warning – fault code has 1 Beep been set. Engine performance is derated by 1 Beep at least 25%. Engine performance is 1 Beep progressively derated by up...
  • Page 188 Operation Warnings of SCR System Fault (For Vehicles Equipped with Cummins ® ISX15 Engines) (cont.) Level Indication Audible Alarm Vehicle Conditions / Operation Engine performance is derated by 1 Beep 40%. Vehicle speed is limited to 5 mph (8 km/h).
  • Page 189 Operation ® Warnings of SCR System Fault (For Vehicles Equipped with Navistar N13 Engines) Level Indication Audible Alarm Vehicle Conditions / Operation Initial Warning – fault code has 1 Beep been set. Engine performance is derated by 1 Beep at least 25%.

  • Page 190: Exhaust Diesel Particulate Filter Regeneration

    Operation Exhaust Diesel Particulate Filter Regeneration WARNING This vehicle is equipped with a Diesel Particulate Filter To prevent property damage, personal injury, and (DPF) to meet 2010 emissions requirements. The DPF traps / or death, do not perform a Parked Regeneration exhaust particulate matter generated by normal engine usage.
  • Page 191 Operation NOTE: The following table is a typical representation of 2010 DPF emissions procedures. Diesel Particulate Filter (DPF) Regeneration Table Vehicle Audible LCD Text Level Engine Option Indication Conditions Action Required Alarm Message / Operation Scrolls Drive on highway at highway speeds or between start Parked Regeneration to prevent loss of power.
  • Page 192 Operation Diesel Particulate Filter (DPF) Regeneration Table (cont.) ® MaxxForce Navistar ® engines Scrolls WARNING only between (Flashing) An alarm Failure observe will beep Exhaust filter VISOR following warning may cause continuously is full. Engine property damage, personal while performance INFO and injury, or death.

  • Page 193: Parked Regeneration Procedure

    Operation Parked Regeneration Procedure information display, and the switch indicator will illuminate when the cycle is started. If the indicator is blinking, check Perform the following steps to initiate Parked Regeneration to be sure that all conditions in Step 2 have been met. Once (cleaning) of the exhaust filter: started, the regeneration cycle will last approximately 30 minutes.

  • Page 194: Two-Position Regeneration Inhibit Switch

    Operation Two-Position Regeneration Inhibit Switch Downhill Operation With the optional two-position switch, pressing the ON position WARNING of the ON / INHIBT REGEN switch will inhibit both normal and parked regeneration. Regeneration will be inhibited (latched) To prevent property damage, personal injury, and when in this position and the switch indicator is turned on.

  • Page 195: Air Brakes

    Operation • The common rule to follow in using the engine and or secondary brake system. In the event air pressure loss transmission / rear axle to control vehicle speed is to occurs in one system, the remaining system continues to select a lower gear going down the hill than would be provide braking action.

  • Page 196: Reservoir Moisture Draining

    Operation Should the RED indicator and beeper not shut off soon after Brake Application startup, the air pressure gauge / gauges should also indicate Rapid successive brake applications and release, sometimes at least one section of the split system has low air pressure. referred to as fanning or pumping the pedal, should be avoided.

  • Page 197: Parking Brake Reset

    Operation To release the parking brake after a low-pressure occurrence, Remove release stud assembly from carrying pocket. recharge system to at least 70 psi (483 kPa) and push in the Apply a light coat of antiseize to the threads of the release stud to parking brake control.

  • Page 198: Air Dryer

    Operation Air Dryer To apply the trailer service brakes utilizing the hand control, move the lever clockwise (down). The further the handle is The function of the air dryer is to collect and remove moisture moved clockwise, the greater the air pressure applied to the and contaminants before the compressed air reaches the air trailer brakes.
  • Page 199 Operation The PARKING BRAKE valve knob (YELLOW) should be pushed The PARKING BRAKE valve (YELLOW knob) controls the spring in first, after sufficient air pressure is built up (apply foot brake to brakes on the tractor and when pulled out simultaneously causes prevent vehicle from rolling).

  • Page 200: Parking Brake Indicator

    Operation Parking Brake Indicator Antilock Brake System (ABS) General Information WARNING To prevent property damage, personal injury, and WARNING / or death, avoid driving with the parking brakes To prevent property damage, personal injury, applied, which can lead to excessive heat buildup and / or death, Antilock Brake System(s) (ABS) and possible fire.

  • Page 201: Abs Operation

    Operation ABS Operation any wheel(s) are about to lock. If wheel lockup is about to occur, the control unit commands the appropriate modulator valve to adjust air pressure delivery to prevent wheel lockup. WARNING ABS Self Check To prevent property damage, personal injury, and / or death, if the ABS warning indicator Bendix ®...

  • Page 202: Antilock Driving Tips

    Operation Antilock Driving Tips integrated addition to the ABS. This system utilizes input from the individual wheel sensors to determine if drive axle wheel Brake just the way you always have. Apply brakes as slip is occurring during vehicle acceleration. If drive axle wheel normal to stop in time.

  • Page 203: Atc Off Road Or Mud / Snow Switch

    SNOW switch in the ENABLE position. The switch to vehicles equipped with stability control indicator will flash slowly to indicate that this function systems require prior approval through Navistar has been selected, and will flash rapidly whenever or the stability control system manufacturer.
  • Page 204 Operation RSP is an all-axle ABS solution that helps reduce vehicle speed acceleration that might cause a potential roll event. A steering by applying all vehicle brakes as needed, reducing the tendency angle sensor provides a greater stability margin than a vehicle to roll over.

  • Page 205: Towing Instructions

    Operation Towing Instructions CAUTION To prevent property damage, observe the WARNING following: Due to many variables that exist in towing, positioning and lifting, towing is the sole To prevent property damage, personal injury, and responsibility of the towing operator. / or death, always use both tow hooks to prevent Refer to the differential and transmission possible overloading and breaking of individual equipment manufacturer for specific instructions...

  • Page 206: Tow Hooks

    Operation Before moving the towed vehicle, check for adequate road clearance of vehicle components. Navistar, Inc. recommends unloading the towed vehicle prior to towing to reduce any abnormal loads to the vehicle components resulting from the towing procedures. Before towing, be sure to fully release the parking brake.

  • Page 207: Towing Vehicle With Front Wheels Suspended

    Operation Towing Vehicle With Front Wheels Suspended Towing Vehicles With Driver Controlled Differential Lock CAUTION Removing Axle Shafts Before Towing To prevent transmission damage, vehicles CAUTION should not be towed even short distances without suspending rear wheels or removing the axle To prevent differential and / or transmission shafts or propeller shaft.

  • Page 208: Installing Axle Shafts

    Operation Applicable RR DIFF or FR DIFF ENGAGE indicator must a. Place gaskets on wheel hub studs. be illuminated in instrument panel gauge cluster to validate b. Push right-side axle shaft into wheel end and DIFF LOCK is FULLY engaged and axle shaft can be housing until shaft stops against differential shift removed.

  • Page 209: Tractor-Trailer Connections

    Operation Tractor-Trailer Connections WARNING WARNING To prevent personal injury and / or death, do not climb on the back of a tractor unless it has been To prevent property damage, personal injury, provided with a deck plate and handholds. Use and / or death, whenever possible, make trailer a three-point stance when climbing up and down connections while standing on the ground.

  • Page 210: Fifth Wheel Operation

    Operation Fifth Wheel Operation To unlock the fifth wheel, press in the top portion of the switch. The switch indicator will illuminate steadily when the fifth wheel is unlocked. WARNING To prevent property damage, personal injury, and / or death, always follow the fifth wheel manufacturer’s instructions for hooking and NOTE: The fifth wheel cannot be unlocked above a preset unhooking as well as sliding the fifth wheel.

  • Page 211: Un-Hook

    Operation 5. Back tractor squarely under trailer, engaging fifth wheel 3. Lower trailer landing gear, making sure it is on solid, jaws on trailer kingpin. Always back slowly, making sure level ground. The weight of trailer must be on landing trailer is neither too high nor too low.

  • Page 212: Fifth Wheel Jaw Monitoring

    Operation To unlock the fifth wheel jaw, perform the following:. NOTE: If the continuous tone alarm shuts off before the repetitive beep is heard, jaw unlocking was incomplete. • Depress and hold the UNLOCK FIFTH JAW switch. • If the switch is only pressed momentarily, jaw Fifth Wheel Jaw Monitoring unlock will not occur.

  • Page 213: Section 7 - Maintenance Instructions

    Maintenance Instructions SECTION 7 — MAINTENANCE INSTRUCTIONS Introduction about performing some service, consult your International Truck dealer or have the service done by a skilled technician. WARNING Maintenance Guidelines To prevent property damage, personal injury, and / or death, if the owner / operator of the WARNING vehicle is a skilled technician and intends to perform the vehicle maintenance and servicing,...
  • Page 214 Maintenance Instructions CAUTION WARNING To prevent damage to electrical components To prevent property damage, personal injury, during electric welding operations, follow these and / or death, take care when performing any cautions: Prior to electric welding, disconnect maintenance or making any check or repair. any negative and positive battery cables that Some of the materials in this vehicle may also connect the batteries to the vehicle.

  • Page 215: Supporting Your Vehicle For Service

    The use of inferior products will reduce the When performing service repairs on a vehicle, first: service life of the vehicle or result in failure of its components. Navistar, Inc. recommends the use of Fleetrite ® lubricants and 1.

  • Page 216: Hvac Filters

    Maintenance Instructions To reduce costs, the filter(s) may be carefully power-washed with Side Access HVAC Filter a soap solution and reused. Be sure to wash and rinse both sides and be sure to keep the spray head at least 6 inches away from the filter to prevent damage.

  • Page 217: Front Access Hvac Filter

    Maintenance Instructions Front Access HVAC Filter Recirculation Filters The recirculation filters are mounted on the left and right sides of the HVAC unit, which is located in-cab under the left side instrument panel. Air Intake Housing Screws Filter Access Door Recirculation Filter Cab HVAC Filter Replacement –...

  • Page 218: Sleeper Hvac Filter

    Maintenance Instructions Axles Sleeper HVAC Filter Front Axle Inspection and Lubrication Check to make sure that the front axle mounting U-bolts, attaching or mounting bolts, and nuts are securely tightened. Loose or misaligned front axles will affect vehicle alignment, front tire wear, and handling. Re-torque the U-bolt nuts after the first 1,000 miles (1,600 km) and every 36,000 miles (58,000 km) thereafter.

  • Page 219: Normal Maintenance

    Maintenance Instructions Normal Maintenance • Excessive wear on the inside or outside of one steer tire but not the other can indicate a toe-in or toe-out condition During operation, the air and oil inside the hub / wheel cavity coupled with a misaligned front or rear axle. expands.

  • Page 220: Brakes

    Maintenance Instructions Brakes • Clean brake parts and assemblies in the open air. During disassembly, carefully place all parts on the floor to General Information avoid getting dust into the air. Use an industrial vacuum cleaner with a HEPA filter system to clean dust from the brake drums, backing plates, and other brake parts.
  • Page 221 Maintenance Instructions used in a wide variety of applications and conditions. If you WARNING are uncertain of the proper schedule and procedures for your vehicle, contact your International dealer. To prevent property damage, personal injury, and / or death, under no circumstances should Periodic checking of push rod travel or brake adjustment is the spring brake section of the spring and brake essential for good braking.

  • Page 222: Air Dryer

    Maintenance Instructions At least once a year, the entire brake system must be inspected The air dryer is installed between the air compressor discharge by a trained mechanic. Deteriorated components or components line and the air tanks. The air dryer has a desiccant cartridge worn outside of specifications must be replaced.

  • Page 223: Heater

    Maintenance Instructions be rebuilt. Purge valves may also stick if the air dryer heater has On vehicles equipped with automatic drain valve(s), moisture failed and ice is clogging the valve. and contaminants are automatically removed from the reservoir to which it is connected. It operates automatically during each Heater compression cycle and requires no manual assistance or control lines from other sources.

  • Page 224: Bright Metal Care

    Maintenance Instructions Always make sure that steps and grab handles are clean and Remove soap residue and wipe dry. If commercial cleaners are free of road grime, grease, ice, and other debris. used, follow instructions supplied with cleaner. Prior to using any wax or polish, the vehicle must be thoroughly Exposed Rubber and Unpainted Plastic Parts washed to avoid scratching the finish.
  • Page 225 Maintenance Instructions NOTE: Proper clutch and linkage adjustment will provide fiberglass, mineral wool, aramid, ceramic or carbon) is a adequate clearance between the release yoke fingers and potentially serious health hazard. the release bearing as well as between the release bearing and the clutch brake for proper operation.

  • Page 226: Hydraulic Clutch

    Maintenance Instructions Hydraulic Clutch Your vehicle is equipped with a hydraulic clutch actuation system. The reservoir is located just below the cowl, left of center on the firewall. CAUTION To prevent vehicle and / or engine component damage, use only approved hydraulic clutch fluid (DOT 3 or DOT 4 brake fluid) in the clutch hydraulic system.

  • Page 227: Electrical

    Maintenance Instructions Electrical Cold batteries resist charging. Battery performance can be improved by regularly or even periodically storing vehicles and Batteries charging batteries with an automatic float charger for 8 - 24 hours in a warm garage during the cold winter months. Battery life and performance varies greatly depending on duty cycle.

  • Page 228: Auto Start / Stop System Battery Cables

    Maintenance Instructions Battery Cables CAUTION To prevent property damage, when working around the terminals and battery, use extra care to prevent shorting. A good practice is to insulate pliers and screwdrivers. Do not check battery condition by shorting (flashing) across terminals. Battery cable terminals must be clean and tight.

  • Page 229: High Current Relay

    Maintenance Instructions High Current Relay qualified technician perform an electrical system test using an International ® Electronic System Tester (Midtronics in TELLECT CAUTION EXP HD Expandable Electrical Diagnostics Platform available through your local International dealer) to catch electrical system To prevent property damage, when servicing problems before they cause further damage to the batteries and the isolation battery, be sure that all cables prevent a stranded vehicle.

  • Page 230: Accessory Feed Connections

    Maintenance Instructions Engine Accessory Feed Connections General Information WARNING NOTE: complete operation maintenance To prevent property damage, personal injury, and information pertaining to your engine, refer to the Engine / or death, do not increase size of fuse or circuit Operation and Maintenance Manual provided with the breaker or change type of breaker supplied vehicle.

  • Page 231: Engine Fluids And Contaminated Material

    Maintenance Instructions Engine Fluids and Contaminated Material Once each year perform a complete inspection of the air induction system. In areas where road salt is used, the inspection consists of disassembling the joints of each metal component and inspecting for salt buildup that can cause GOVERNMENT REGULATION: Engine fluids particles to flake off and enter the engine combustion chambers.

  • Page 232: Air Cleaner Element Service

    Maintenance Instructions It is recommended that the operator not reset the gauge until it will drop to near or below the window so the air restriction gauge has been determined if air cleaner service is required. can be reused. NOTE: After starting engine, indicator may be seen in lower part of window.
  • Page 233 Maintenance Instructions NOTE: Be careful not to bump the air filter element while it is in the housing; this can raise a cloud of dust that can enter the clean side of the piping to the turbocharger. 1. Lift and hold the locking tab (located at the 2 o’clock position).
  • Page 234 Maintenance Instructions 2. Wipe the inside of the air cleaner housing with a clean, 7. When servicing is completed, reset air restriction gauge damp cloth. Be sure to clean the gasket sealing surface. by pushing and holding the reset button and releasing it. Be sure to wipe out any dust that has fallen into the port The YELLOW indicator will drop below the window.

  • Page 235: Troubleshooting

    Maintenance Instructions Troubleshooting No Restriction Reading POSSIBLE CAUSES HOW TO CHECK Plugged fitting or vacuum line Remove the gauge and apply a vacuum until it is locked up at the red zone. Reinsert the gauge and hold in the reset button. Indicator will fully return unless line or fitting is plugged. A slow return is normal due to safety filter in fitting.

  • Page 236: Charge Air Cooler And Radiator Core Inspection And Cleaning

    ® ® For vehicles with MaxxForce and Navistar N13 engines, the cap. After the pressure has been released, see the following instructions on filling the cooling system. the pressure cap may be removed.
  • Page 237 Maintenance Instructions To function properly, the coolant system must be completely filled with coolant and all air must be expelled. To accomplish this, the following procedures should be carefully completed: 1. Turn on ignition without starting the vehicle. This opens the electrically actuated coolant flow valve.
  • Page 238 Maintenance Instructions off as needed to achieve a coolant level at the COLD To function properly, the coolant system must be completely filled MAX line when cold. with coolant and all air must be expelled. To accomplish this, the following procedures should be carefully completed: For vehicles with Cummins ®...

  • Page 239: Coolant And Optional Coolant Filter

    Shell Rotella ® ELC (Red) coolant. To prevent property damage, always use Shell Navistar, Inc. recommends using only the approved coolant with Rotella ® Ultra ELC or equivalent to top-off Ultra the 2010 cooling packages, and will not warrant these cooling ELC-equipped cooling systems.

  • Page 240: Fuel System

    Maintenance Instructions Start cold engine and view fan to see that it is rotating more Since Ultra-Low Sulfur Diesel (ULSD) fuel tends to absorb slowly than the fan pulley (fan clutch is disengaged). Achieve more water and engines are operating at higher temperatures, operating temperature and observe that the fan is engaged.

  • Page 241: Noise Emissions - Exterior

    Maintenance Instructions Noise Emissions – Exterior • Fan speed ratio should not be changed and fan spacer dimensions and position should not be altered. Instructions for Proper Maintenance • Inspect for proper operation of fan clutch, making sure that the fan is disengaged when cooling of engine is not In order to comply with federal exterior noise regulations, your required.

  • Page 242: Maintenance Record - Noise Control

    Maintenance Instructions Maintenance Record – Noise Control Chassis Model: Vehicle Identification Number: Maintenance Performed Maintainer (Name) Location Date...
  • Page 243 Maintenance Instructions...

  • Page 244: Def Tank Filling

    Maintenance Instructions DEF Tank Filling Diesel Particulate Filter (DPF) CAUTION Regeneration To prevent property damage, proper care Collected soot particles in the Diesel Particulate Filter (DPF) should be taken when handling, dispensing, are automatically burned off through normal regeneration or transporting DEF, as it is corrosive to some (initiated by normal exhaust heat during the normal operation metals and materials.

  • Page 245: Suspension (Air And Steel Springs)

    Maintenance Instructions Suspension (Air and Steel Springs) • Check U-bolts as follows: 1. After the chassis has been operating under CAUTION load for 1,000 miles (1,600 km) or six months, To prevent property damage, do not adjust air whichever comes first, the U-bolt nuts must be suspension height to any setting other than the re-torqued.

  • Page 246: Steering

    Maintenance Instructions Steering Tightening Steering Intermediate Shaft Joint Bolts As a good maintenance practice, it is recommended that General Information steering intermediate shaft joint bolts be checked for tightness every 120,000 miles (193,000 km) or annually, whichever occurs WARNING first. To prevent property damage, personal injury, Lubrication Points and / or death, always follow recommended...

  • Page 247: Power Steering

    Maintenance Instructions Tires Power Steering Whenever the power steering system has been drained and Tire Warnings refilled for any reason, air must be bled from the system before returning the vehicle to service. Failure to properly bleed the WARNING hydraulic system can result in degradation of power system performance.
  • Page 248 Maintenance Instructions WARNING WARNING To prevent property damage, personal injury, and To prevent property damage, personal injury, and / or death, always follow these instructions when / or death: mounting tires on wheels: • Do not mix stud-piloted wheels or fasteners with •...

  • Page 249: Tire Maintenance

    Maintenance Instructions Tire Maintenance shop air dryers is strongly recommended to avoid moisture in the high-pressure air used for tire inflation. Preserving proper inflation pressure is a very important maintenance practice to ensure safe vehicle operation and long Underinflation life for the tires. Tires should not be allowed to become underinflated.

  • Page 250: Inspection

    Maintenance Instructions ® The optional SmartWave Tire Pressure Monitoring System Proper tire inflation, toe-in adjustment, loads, and road (TPMS) warns the driver that tire pressure is below set pressure. speeds are important factors governing tire life, steering ease, Air pressure sensors are installed on the inner rim of each maneuverability, fuel economy, and ride quality.

  • Page 251: Dual Tires Matching

    Maintenance Instructions Dual Tires Matching • Another rotation possibility for fleets with rib tires in all wheel positions is to break in the new steer tires in the Dual tires should be matched using tires of equivalent size. Tires drive axle positions, then move them to steer axles. This which differ more than 1/4 inch (6 mm) in diameter or 3/4 inch will wear away tread rubber relatively quick in the early (19 mm) in circumference should not be mounted on the same...

  • Page 252: Tire Replacement

    Maintenance Instructions Tire Replacement Wear Radial tires can exhibit three types of normal wear patterns, NOTE: Retread tires are not recommended for use on even, erosion, or chamfer. steering axles of trucks. Even Wear is a sign that the tire is being properly used and •...

  • Page 253: Use Of Tire Chains

    Maintenance Instructions Wheels altogether. See Tires – Rotation for more information. Some of the more effective tire rotation programs are: Wheel and Wheel Nut Maintenance and Installation Irregular wear can be minimized by: • Using the right inflation pressure for the load being WARNING carried.

  • Page 254: Wheel Nut Torque Maintenance

    Maintenance Instructions WARNING WARNING To prevent property damage, personal injury, and To prevent property damage, personal injury, / or death: and / or death, when installing the tire and rim assembly on disc brake-equipped axles, make • Do not mix stud piloted wheels or fasteners with sure the tire valve stem clears the brake caliper.
  • Page 255 Maintenance Instructions Out-of-round tires and wheel assemblies can sometimes be against the wheel. The purpose of this step is to snug the corrected by reclocking the tire relative to the wheel. wheel(s) in the correct position, not to apply the final torque. The tightening of each nut should be stopped immediately Tightening procedure for disc wheels with flange nuts when the wheel is contacted, resulting in a wheel nut torque...

  • Page 256: Transmission

    Maintenance Instructions to specification using the appropriate pattern shown in the Transmission wheel nuts torque sequence diagram. NOTE: Refer to the Original Equipment Transmission 10. As part of a daily pretrip inspection, look for loose or missing Manufacturer specific service instructions wheel nuts.

  • Page 257: Section 8 - Maintenance Intervals And Specifications

    In addition to the “A” and “B” service service life of the vehicle or result in failure of its components. intervals, the “Special” Service Interval column is provided Navistar, Inc. recommends the use of Fleetrite ® lubricants for for items that need infrequent servicing.
  • Page 258 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Chart Symbols Key Lubrication and Maintenance Interval Chart Notes Symbol Interval Definition NOTE 1: A hand-pumped grease gun should be used for optimal grease distribution within the component joint. Every 25,000 miles (40,000 km) / 600 hours / 3 Months NOTE 2: Kingpin thrust bearings must be lubricated through the lower kingpin grease zerk with the vehicle weight on the...
  • Page 259 Maintenance Intervals and Specifications NOTE: Refer to the Original Equipment Component Manufacturer for the most up to date specific service instructions, required capacities and lubricating oils. Lubrication and Maintenance Interval – Recommended Synchronized Intervals System Item Intervals Special Interval (3): miles (km) / hours / months Pre-Trip Pre-trip Inspection Items listed in SECTION 3 –...
  • Page 260 Maintenance Intervals and Specifications Lubrication and Maintenance Interval – Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3): miles (km) / hours / months Rear Axle Suspension Fasteners / Components – Check A, B Rear Axle Lubricant – Level Checks A, B Axle Flange Nuts –...
  • Page 261 Maintenance Intervals and Specifications Lubrication and Maintenance Interval – Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3): miles (km) / hours / months Electrical Engine Start and Gauge / Warning Indicators – Check A, B Instrument Readings Proper – Check A, B ABS Wiring Connections &...
  • Page 262 Maintenance Intervals and Specifications Lubrication and Maintenance Interval – Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3): miles (km) / hours / months Air Brakes Service Brakes Operation – Check A, B Parking Brakes Operation – Check A, B Governor Cut-in / Cut-out Pressure –...
  • Page 263 A, B A, B Davco ® Fuel / Water Separator Filter – Replace For Maxxforce ® and Navistar ® Engines: A, B For Cummins ® ISX15 engine: 30,000 miles (48,000 km) / 1000 hours / 6 Months Fuel Tank(s) – Drain and flush (NOTE 3) 100,000 miles (160,000 km) / –...
  • Page 264 Maintenance Intervals and Specifications Lubrication and Maintenance Interval – Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3): miles (km) / hours / months Transmission NOTE: Refer to the Original Equipment Transmission Manufacturer for specific service instructions and recommendations, required capacities, and transmission fluids.
  • Page 265 Maintenance Intervals and Specifications Lubrication and Maintenance Interval – Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3): miles (km) / hours / months Tires Tire Pressure Check / Tire Wear Check Daily, A, B Low Air Pressure Warning Alarm – Check A, B...

  • Page 266: Lubrication And Fluids Charts

    Maintenance Intervals and Specifications Lubrication and Fluids Charts Fluid Check and Fill Notes NOTE: Components requiring lubrication and fluid check CAUTION and fill diagrams are typical representations. prevent property damage, only Lubrication Notes recommended viscosity engine oil. Refer to the Engine Operation and Maintenance Manual for CAUTION engine oil specifications.

  • Page 267: Components Requiring Lubrication

    Maintenance Intervals and Specifications Components Requiring Lubrication Steering Gear Tie Rod Ends Rear S-Cams and Slack Adjusters Steering Intermediate Shaft Steering Drag Link Ends 10. Fifth Wheel Pivot Points and Top Plate Front S-Cams and Slack Adjusters Clutch Cross Shafts and Release Bearing Kingpin Bushings and Thrust Bearings Drive Shaft U-joints and Slip Joint...

  • Page 268: Components Requiring Fluid Check And Fill

    Maintenance Intervals and Specifications Components Requiring Fluid Check and Fill Coolant Surge Tank Drive Axle Oil Fill / Level Check Plug Transmission Oil Fill / Level Check Plug Windshield Washer Fluid Bottle Diesel Exhaust Fluid (DEF) Tank (on Engine Oil Dipstick Front Axle Oil-Filled Hubs vehicles equipped with Selective Catalytic Engine Oil Fill Tube...

  • Page 269: Unit Refill Capacities

    Engine Operation and Maintenance Manual provided with If system has been drained: vehicle. • For vehicles equipped with MaxxForce ® or Navistar ® Hydraulic Clutch System engines, fill with a 50/50 mixture of Nitrite-free Shell Rotella ® Ultra Extended Life Coolant (ELC) concentrate...

  • Page 270: Transmission

    Maintenance Intervals and Specifications Transmission NOTE: A variety of transmissions are available for your vehicle. Refer to the Original Equipment Transmission Manufacturer for the most up to date specific service instructions, required capacities and transmission oils. Description Transmission Type Feature Code Eaton ®...
  • Page 271 Maintenance Intervals and Specifications Description Transmission Type Feature Code Eaton ® Navistar ® Alliance 10-Speed Automated 13GXW Eaton ® Navistar ® Alliance 10-Speed Manual 13GXM, 13GXN, 13GXR, 13GXU, 13GXV Eaton ® Cummins ® Alliance 10-Speed Automated 13GXJ, 13GXK Eaton ®...

  • Page 272: Rear Axle Unit Refill Capacities

    Maintenance Intervals and Specifications Rear Axle Unit Refill Capacities 6X4 TANDEM AXLE Forward Rear Description Code Liters Pints Liters Pints 4X2 SINGLE AXLE Dana Spicer 0014GYB, 12.21 25.8 8.71 18.40 Description Feature Code Liters Pints AdvanTEK D40-156 / 0014GYG, RS-23-160 14051, 14ARB 18.7 39.5...

  • Page 273: Lubricant And Sealer Specifications

    Maintenance Intervals and Specifications Lubricant and Sealer Specifications NOTE: Refer to the Original Equipment Manufacturer for up-to-date specific service instructions, required capacities, and lubricating oils. Component Component Vendor / Lubrication Type Viscosity Applicable Temperatures Non-driving Front Axle Front axle Mineral Oil 75W: -40°F to -15°F (-40°C to -26°C) wheel bearing...
  • Page 274 Maintenance Intervals and Specifications Component Component Vendor / Lubrication Type Viscosity Applicable Temperatures ® ® ® Front Axle Tie Eaton -Dana axle, Hendrickson Steertek Rod Ends, Drag International ® Multi-Link axle, and Meritor axle: Link, Kingpins Fleetrite ® NLGI #2 Lithium Complex Based Moly and Bushings grease P/N 991044C2 or equivalent GC/LB NLGI #2 Multi-purpose Lithium Complex grease...
  • Page 275 Bearing / P/N 991044C2 or equivalent GC/LB NLGI #2 Shafts / Fork Multi-purpose Lithium Complex grease – Lubricant Cooling System Extended Life For MaxxForce ® and Navistar ® engines: Shell ® See Engine Operation Coolant Rotella ® Ultra Extended Life Coolant...
  • Page 276 Maintenance Intervals and Specifications Component Component Vendor / Lubrication Type Viscosity Applicable Temperatures Transmission Mineral Gear Oil API-GL-1 (Rust and Oxidation SAE 90 – Meritor only Above 10°F (-12°C) Inhibited) Fleetrite ® P/N 991061C1 SAE 80 – Meritor only Above 10°F (-12°C) Heavy Duty Engine Oil API –...
  • Page 277 Maintenance Intervals and Specifications Component Component Vendor / Lubrication Type Viscosity Applicable Temperatures Rear Axle Rear Drive Synthetic – Emgard ® FE and Emgard ® 75W-90 All Temperatures Axle(s) Synthetic Lubricant. Electrical Terminals Fleetrite ® 472141-C1 – Lubricant Sealing Grease Connectors NYOGEL ®...

  • Page 278: Torque Specifications

    Maintenance Intervals and Specifications Torque Specifications U-BOLT NUT TORQUE CHART Torque Feature Code Rear Suspension Capacity and Type lb-ft N•m 14SAN 23,500-lb (10,660 kg) Capacity, RR, Springs, Single, Vari-Rate 260-300 353-407 14SAU 20,000-lb (9,070 kg) Capacity, RR, Springs Multileaf with Single Torque Rod 258-295 350-400 14SAW...

  • Page 279: Disc Wheel Nut Torque Chart

    Maintenance Intervals and Specifications Torque Feature Code Front Suspension Capacity and Type lb-ft N•m 3AHN 12,350 lb (5600 kg) Capacity, Parabolic Taper Leaf 260-300 353-407 NOTE: For all other vendor supplied suspensions, refer to vendor's web site for proper torque specifications. Fuse Charts DISC WHEEL NUT TORQUE CHART The following fuse illustrations represent typical fuse panel...

  • Page 280: Typical Interior Fuse Panel Layout

    Maintenance Intervals and Specifications Typical Interior Fuse Panel Layout NOTE: F11-D, Wabco & Bendix both will use 10 amp fuse instead of 5 amp fuse.

  • Page 281: Typical Luggage Compartment Fuse Panel Layout

    Maintenance Intervals and Specifications Typical Luggage Compartment Fuse Panel Layout Typical Under-Hood Power Distribution Module (PDM) on the air cleaner bracket and is immediately underneath the Fuse Panel Layout cowl panel. See the following illustration about the location of the under-hood PDM. On certain ProStar ®...
  • Page 282 Maintenance Intervals and Specifications If you cannot find the PDM in this location, it means that your vehicle has in-line fuses instead of a PDM fuse panel. The following illustration shows the typical layout of the fuse panel in the under-hood PDM. CAUTION To prevent electrical component damage, when replacing a fuse, always use one with the same...
  • Page 283 Maintenance Intervals and Specifications 1A: cold start aid, 80A 2D: not in use 11. 3C: not in use 1B: cab PDC-1, 100A 2E: ECM (25A for Navistar ® ’s engines, 12. 3D: TCM, (30A for Eaton transmissions, 1C: cab PDC-2, 100A 30A for Cummins ®...

  • Page 284: Prostar + Series Light Information

    Maintenance Intervals and Specifications ProStar + Series Light Information ® Lamp Description Bulb P/N Sleeper Dome Lamp GE921 Cab Dome Lamp GE211-2 Accent Lamps GE211-2 Under Bunk Lamp GE211-2 Cab Floor Lamp GEW5W Sleeper Floor Lamp GEW5W Sleeper Reading Lamp GE912 LED Cab Map Lamp See Dealer...

  • Page 285: Filter List

    Maintenance Intervals and Specifications Lamp Description Bulb P/N Headlight Low Beam: GE9006 High Beam: GE9005 Side Marker: GE194 Parking / Turn: GE3357 Side Turn and Marker Lamp assembly 3599250C92 Side Turn Lamp (Incandescent) GE3156 Filter List Filter part numbers and / or specifications may change during the lifecycle of this vehicle.
  • Page 286 Maintenance Intervals and Specifications...

  • Page 287: Section 9 - Customer Assistance

    This can an International Fleet Service Manager. be accomplished in several ways. The OnCommand™ Service Information DVD contains Navistar International Truck Dealers … Your local International branded truck, engine, and bus information including service Truck dealer provides an excellent resource –...
  • Page 288 • Customized warranty programs are offered to suit your International Truck Warranty Program, please contact needs - your specification - your vocation. your International dealer today! • Navistar, Inc., North America's leader truck manufacturing, is also North America's leader in warranty...

  • Page 289: Index

    Index SECTION 10 — INDEX (CONT.) Air Dryer (cont.) ABS Connections and Sensors....... . .211 Purge Valve.
  • Page 290 Index (CONT.) (CONT.) Automatic Traction Control (ATC) System (cont.) Brakes (cont.) ATC System Check..........190 Air Gauge, Low Air Pressure Beeper and Warning Stability Control Systems –...
  • Page 291 Index (CONT.) (CONT.) Charge Air Cooler and Radiator Core Inspection and Cab (cont.) Bright Metal Care..........212 Cleaning.
  • Page 292 Index (CONT.) Component Code Numbers (cont.) Dash Components..........48 Line Set Ticket.
  • Page 293 Air Induction System......... . .219 Eaton ® Navistar ® Alliance Transmissions..... .163 Air Restriction Gauge.
  • Page 294 Index (CONT.) (CONT.) Engine Idle Shutdown Timer (Optional)......144 Engine (cont.) Inspection and Cleaning........224 Engine Idling.
  • Page 295 Index (CONT.) (CONT.) Exterior Components..........18 Front of Tractor.
  • Page 296 Left Rear of Tractor..........43 ® with Navistar N13 Engines) Table......174...
  • Page 297 Index (CONT.) Left Side Cab Area (for Vehicles Not Equipped with Selective Main Features........... . .107 Catalytic Reduction (SCR) System).
  • Page 298 Transmissions Special Driver Instructions....151 Eaton ® Navistar ® Alliance Transmissions....163 Engine Features..........152 Eaton ®...
  • Page 299 Index (CONT.) (CONT.) Outside Temperature and Compass Displays (Optional)..79 Parking Brake Indicator......... .188 Outside Temperature Reading.
  • Page 300 Indicators about DEF Quality Problem (For Vehicles Remote Keyless Entry Operation (Optional)....97 Equipped with Navistar ® N13 Engines) Table....174 Remote Power Inverter Panel.
  • Page 301 Index (CONT.) (CONT.) Sleeper Control Panel (cont.) Steering (cont.) Engine Control Switch.........111 Power Steering.
  • Page 302 Index (CONT.) (CONT.) Television Mount..........130 Towing Instructions (cont.) Terminal Inspection-Cleaning-Corrosion Protection.
  • Page 303 Underinflation........... . .237 Eaton ® Navistar ® Alliance Transmissions....163 Unit Refill Capacities.
  • Page 304 Vehicle Identification..........16 Navistar ®...

Table of Contents

Save PDF