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NOTICE
Be advised that this motor vehicle may be equipped with
computer / recording devices. Their function is to allow an
authorized individual to download data or information
relating to the operation or performance of this vehicle.
The stored data or information may be neither downloaded
nor retrieved except by the vehicle's registered owner, or, in
the alternative, by another individual or entity authorized by
the registered owner, such as an International Dealer, who
may need this data or information to properly service or
diagnose this vehicle for repair or following an accident.
Any access to this information without the owner's consent
may be in violation of law and may subject that person or
entity to criminal penalties.
The information, specifications, and illustrations contained in this manual are based on data that
was current at the time of publication. International reserves the right to make changes and/or
improvements at any time without notification or liability, or without applying those changes or
improvements to vehicles previously manufactured.
Make sure your use of this completed vehicle conforms to all federal, state
and local requirements and regulations imposed on owners and operators.
Diesel
constituents are known to the State of California
to cause cancer, birth defects, and other
reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm.
Important
Printed in the United States of America
© 2010 Navistar, Inc.
All Rights Reserved
CALIFORNIA
Proposition 65 Warning
engine
exhaust
and
some
Wash hands after handling.
of
its

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Summary of Contents for Navistar WorkStar Series

  • Page 1 Make sure your use of this completed vehicle conforms to all federal, state and local requirements and regulations imposed on owners and operators. Printed in the United States of America © 2010 Navistar, Inc. All Rights Reserved...
  • Page 2 678-584-2700 Navistar, International, the International Diamond logo, with and without endorsement, WorkStar, and MaxxForce are registered trademarks of Navistar, Inc., or its subsidiaries, in the United States and other countries. All other trademarks are the property of their respective owners.
  • Page 3 International dealer. Form No. 3879634R1 It is the policy of Navistar, Inc. to improve its products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to make such changes on products sold previously.
  • Page 4 Operator’s Manual – WorkStar® Series Printed in the United States of America 3879634R1...
  • Page 5: Table Of Contents

    Table of Contents Section 1 – Foreword Engine Serial Number........12 Line Set Ticket.
  • Page 6 Table of Contents Electrical............37 Mobile Variable Speed Control (12VXV).
  • Page 7 Table of Contents Seats..............93 Circuit Breakers, Fuses, and Fusible Links.
  • Page 8 Table of Contents Exhaust Diesel Particulate Filter Regeneration...117 Main Transmission Controls....... .128 Parked Regeneration Procedure.
  • Page 9 Table of Contents Air Brakes........... .148 Connecting/Disconnecting a Trailer to a Vehicle with Air Gauge, Low Air Pressure Beeper and Warning Air Suspension.
  • Page 10 Table of Contents General Information.........174 Cooling System.
  • Page 11 Table of Contents Tires..............194 Unit Refill Capacities.
  • Page 12 Table of Contents viii 3879634R1...
  • Page 13: Section 1 - Foreword

    Foreword SECTION 1 — FOREWORD Preface Study this manual carefully. Do not operate your vehicle until you are completely familiar with the contents of this manual. Always Your vehicle has been engineered and manufactured so that it retain this manual in your vehicle for reference. If you sell the can provide economical and trouble-free service.
  • Page 14: Component Code Numbers

    Foreword Contact Closest Navistar, Inc. Regional Sales Office. Line Set Ticket Addresses of Regional Sales Offices are found in the front Each vehicle is provided with a Line Set Ticket (code sheet), of this manual. Should you desire to contact any of these which lists identification code numbers of component units used...
  • Page 15: Storage Duration - Over One Month

    Foreword NOTE: Washing Instructions - Wash the vehicle with warm water 8. Check state of charge eye in batteries and re-charge if and mild soap, then wipe wet surfaces with a chamois or soft open circuit voltage is below 12.6 volts. Disconnect battery cloth.
  • Page 16: Storage Facilities

    This warranty covers this vehicle as designed, built, and conditions that cause deterioration. equipped by Navistar, Inc. and is not limited to any particular B. Park away from transformers and/or electrical motors, part, component, or system of the vehicle manufactured by because when the protective wax in tire compound Navistar, Inc.
  • Page 17: Emission Control Systems

    Foreword block shield, oil sump shield, or transmission enclosures. E. (NHTSA) in addition to notifying Navistar, Inc. To notify Navistar, Exhaust System: Removal or rendering inoperative exhaust Inc., see regional numbers listed in the front of the manual. system components, including muffler, resonator, or tailpipe.
  • Page 18: Customer Security Guide For International Trucks

    Foreword that may involve their vehicle. If you receive such notification, Add Layers of Protection PLEASE FOLLOW ALL INSTRUCTIONS PROVIDED IN THE Four layers of protection are recommended for your vehicle - the CUSTOMER LETTER. If your vehicle is part of a Safety Recall more layers of protection on your vehicle, the more difficult it is campaign, the recall service procedure must be completed to to steal.
  • Page 19 Foreword • Do not discuss where your vehicle is located when you are Layer 4: Tracking System not on the road. The final layer is a tracking system that emits a signal to the • Do not share information about your specific destination or police or a monitoring service when the vehicle is reported stolen.
  • Page 20: Optional Diamond Logic® Electronic Application Solutions

    Foreword Optional Diamond Logic® Electronic Application Solutions WARNING This vehicle may be equipped from the factory with electrical switches intended to operate equipment that was installed by truck equipment manufacturer (TEM). Instructions, Cautions, and Warnings for this additional equipment will NOT be found in this manual. Read and understand the appropriate manual for the specific equipment in question before operating.
  • Page 21: Section 2 - Model Description

    Model Description SECTION 2 — MODEL DESCRIPTION Introduction Available Models The WorkStar® Series Truck is available in a variety of models, including the WorkStar® Series Deluxe and the WorkStar® Series Premium. The WorkStar® Series is available in three cab models, including the standard cab, extended cab, and the crew cab.
  • Page 22 Model Description The 6x6 configuration includes these models 7400, 7500. The 4x4 configuration includes these models 7300, 7400, 7500. The 6x4 configuration includes these models 7400, 7500, 7600. 3879634R1...
  • Page 23: Available Cabs

    Model Description Available Cabs Extended Cab The WorkStar® Series Truck is available with a standard cab, extended cab, or crew cab. Each cab has its own unique features and uses. Standard Cab Crew Cab 3879634R1...
  • Page 24: Vehicle Identification

    Model Description Vehicle Identification personnel to service the truck. Many items in this manual are identified by codes. Feature Codes are a combination of numbers and/or letters. These codes are listed on the Line Set Ticket, which is sometimes known as the vehicle specification card or code sheet.
  • Page 25: Exterior Components

    Model Description Exterior Components 1. Headlight 2. Door Latch 3. Fuel Cap 4. Side Marker/Turn Light 5. Bumper 6. Fog Light 1. Glad Hand Storage Bracket 2. Work Light 3. Side Marker/Turn Light 4. Fuel Cap 5. Taillights 3879634R1...
  • Page 26: Cab Entry And Exit

    Model Description Cab Entry and Exit Tilt Hood WARNING WARNING To prevent personal injury or death, never put Do not step or climb upon any vehicle surface any part of your body beneath a raised hood unless it is slip-resistant and a handhold is unless the hood is all the way forward in its provided.
  • Page 27: Section 3 - Inspection Guide

    Inspection Guide SECTION 3 — INSPECTION GUIDE Introduction WARNING General Information If vehicle is equipped with an automatic transmission, have qualified technician regularly check operation of transmission neutral WARNING start switch. If unit starts in gear, the vehicle may inadvertently move, which could result in To prevent property damage, personal injury or property damage, personal injury, or death.
  • Page 28: Vehicle Inspection

    Inspection Guide Vehicle Inspection 2. Press the optional LMP check switch to activate the system. Preparation 3. The exterior light check will now cycle all vehicle lights except the back-up light(s). The test flashes the exterior NOTE: Perform the following procedures prior to conducting the lights ON and OFF in three, 2-second cycles.
  • Page 29: Left Side Cab Area

    Inspection Guide Left Side Cab Area 1. Cab Structure: Check body panels such as doors, air shield, sunshade, and cab for signs of breaks or damage. Check condition of cab mounting brackets and tilt hood latches. 2. Wipers: Check windshield wiper arms for proper spring tension and wiper blades for damage.
  • Page 30: Left Engine Compartment

    Inspection Guide Left Engine Compartment 3. Brake Fluid Level (if equipped): During normal vehicle operation and servicing, the fluid level will vary between the “MIN” and “MAX” lines on the master cylinder mounted “front” reservoir. Do not fill the master cylinder to the top of the reservoir.
  • Page 31: Left Front Of Vehicle

    Inspection Guide • Fuel/Water Separator: Check sight globe (if Davco® Left Front of Vehicle equipped), inform maintenance personnel if fuel level is at top of globe, which is an indication that the filter is due for replacement) and drain into cup periodically. Check for leaks.
  • Page 32 Inspection Guide 1. Steering Gear: Look for missing or loose fasteners, WARNING power steering fluid leaks, and damage to power steering hoses. Do not operate vehicle if any of the following conditions are evident. Loss of steering or 2. Brake Chamber and Hoses: Check to see that the suspension could cause loss of vehicle control brake chambers are not cracked or damaged, and are and result in property damage, personal injury,...
  • Page 33 Inspection Guide 7. Air Suspension (if equipped): Check for air leaks, loose 10. Hub: Check for obvious leaks on outside or inside of components, and damage to air bag. Inspect stabilizer wheel. Verify correct oil level in hub. bar for worn, loose, or damaged components. 11.
  • Page 34: Front Of Vehicle

    Inspection Guide Front of Vehicle 1. Bumper: Inspect for damage and security. 2. Grille: Inspect for damage and security. Check bug screen for damage and cleanliness. 3. Headlights: Lenses should be clean. If equipped, check daytime running lights. 4. Hood and Fenders: Check hood panels and fenders for signs of breaks or damage.
  • Page 35: Right Front Of Vehicle

    Inspection Guide Right Front of Vehicle WARNING To prevent personal injury or death when performing maintenance and repairs to any turbocharged engine with engine air inlet piping disconnected, a turbocharger compressor air inlet protective shield should be installed over the turbocharger air inlet. WARNING Electrical circuits are designed with a particular wire gauge to meet the fuse and circuit breaker...
  • Page 36 Inspection Guide 4. Frame: Check for cracks or bends in frame. Make sure 8. Hub: Check for obvious leaks on outside or inside of there are no loose, cracked, bent, broken, or missing wheel. Verify correct oil level in hub. crossmembers or fasteners.
  • Page 37: Right Engine Compartment

    Inspection Guide Right Engine Compartment 2. Air Cleaner: Check air cleaner element, housing, and hoses for loose connections or damage. Check filter minder gauge for restriction reading. For element replacement, see Air Cleaner Element Service in the Maintenance section. 3. Drive Belts: Inspect all belts for frays, cracks, loose fibers, or visible signs of wear.
  • Page 38: Right Side Of Cab

    Inspection Guide Right Side of Cab CAUTION Do not adjust air suspension height to any setting other than the specified setting. Altering the height setting will change the driveline angle and may result in unwarrantable component damage, such as transmission component damage. 1.
  • Page 39: Right Side Under Vehicle

    Inspection Guide Right Side Under Vehicle WARNING 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. Heat damage to hoses, wires may cause vehicle malfunction that could result in property damage, personal injury, or death.
  • Page 40: Right Rear Of Vehicle

    Inspection Guide Right Rear of Vehicle 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 41 Inspection Guide 5. Tires: Check tread depth and tire inflation and note if 8. Torque Rods and Shock Absorbers: Check to see that tread is evenly worn. Minimum tread depth is 2/32 inch torque rods are not cracked, broken or missing. Check on all drive tires.
  • Page 42: Rear Of Vehicle

    Inspection Guide Rear of Vehicle 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 fasteners.
  • Page 43: Left Rear Of Vehicle

    Inspection Guide Left Rear of Vehicle WARNING Due to tire manufacturers re-marking tires to conform to the SI (metric) system, tires marked with old and new loads or inflation pressures could be placed on the same vehicle. For field maintenance, only inflate and load tires to the maximum of the least-rated tire on the axle.
  • Page 44 Inspection Guide 5. Wheel and Wheel Nuts: Check for damaged or bent 8. Spring Suspension: Check condition of spring for wheel. Check to see that all wheel nuts are present and cracks, breaks, or shifting. Inspect spring hanger not loose (look for rust trails around nuts). Ensure that fasteners, shackles, U-bolts, and nuts for wear, damage, no cracks or damage are present at wheel mount holes.
  • Page 45: Fifth Wheel And Coupling Area

    Inspection Guide Fifth Wheel and Coupling Area 1. Trailer Coupling Cords: Inspect air lines and coupling gaskets, electrical cord for cuts, chafing, damage, and proper security. Check air lines for audible air leaks . 2. Work Light(s): Check operation and clean as needed. 3.
  • Page 46: Cab Interior Inspection

    Inspection Guide Cab Interior Inspection 7. Voltmeter: Check the gauge to see if the alternator is charging between 12.5 and 14.5 volts. 1. Safety/Emergency Equipment: Prior to entering 8. Steering Play: Check for smooth operation. Check cab, verify that vehicle is equipped with the proper for excessive looseness in the steering linkages.
  • Page 47 Inspection Guide 16. Air Brake Check: Check the air brakes in the following manner: a. Chock wheels if necessary. Push in parking brake and start engine. b. Check for air compressor or governor cut- out pressure at 125 to 135 psi (862 to 931 kPa).
  • Page 48 Inspection Guide 3879634R1...
  • Page 49: 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 The controls/features enable the driver to monitor and manage Manual. Many of these features are supplied with rocker the operation of the majority of the vehicle’s functions. This switches that have custom labels applied.
  • Page 50: Dash Components

    Controls/Features Dash Components Overhead Console This vehicle is equipped with an overhead console that provides both dome lighting and storage facilities. The overhead storage capacity consists of two netted storage bins large enough to place many items (one for the driver and one for the passenger). 1.
  • Page 51: Main Instrument/Control Panel

    Controls/Features Main Instrument/Control Panel provide odometer, transmission gear indication, and compass heading and outside temperature displays. This instrument Instrument Panel Gauge Cluster panel gauge cluster displays the crucial operational functions of the vehicle. The following are descriptions and illustrations The instrument panel gauge cluster includes the instrument of the gauges, warning indicators, and integral digital display gauges, warning indicators, and an Integral Digital Display, that options.
  • Page 52 Controls/Features 3879634R1...
  • Page 53: Warning Indicators

    Controls/Features Warning Indicators Illuminates Yellow. Used in conjunction with other Warning Indicators or General The instrument panel gauge cluster contains 25 individual LED Text and Warning Messages to indicate warning indicators. These indicators are used to monitor vehicle an Alert condition to the operator. operation and indicate a WARNING or STOP condition.
  • Page 54 Controls/Features Illuminates Yellow when the traction Illuminates Red when a parking brake control system is turned off. It also system malfunction has been detected. illuminates momentarily when the If the Service Parking Brake indicator traction control system is on and is stays illuminated, have the system limiting wheel spin.
  • Page 55: Gauges

    Controls/Features Flashes Green when the left turn signal Item Item Description or the hazard lights are turned on. Transmission Oil Temperature Gauge: Indicates the transmission lubricant temperature in degrees Fahrenheit or Illuminates Blue when the high beam Celsius. head lamps are turned on. Optional Engine Oil Temperature Gauge: Indicates the engine lubricant temperature in degrees Fahrenheit or...
  • Page 56 Controls/Features Item Item Description Item Item Description Engine Oil Pressure Gauge: Indicates Fuel Level Gauge: Indicates the engine oil pressure. If the needle falls approximate fuel level in the fuel tank. If below the normal range (20–65 psi) at your vehicle is equipped with dual fuel normal operating temperature, stop the tanks, the fuel gauge reads the fuel level vehicle as soon as safely possible, and...
  • Page 57: Instrument Panel Gauge Cluster Alarms

    Controls/Features Item Item Description The Instrument Panel Gauge Cluster will sound an audible alarm that accompanies out of range gauge readings along with the particular gauge warning indicators. The cluster alarms will also Air Pressure Gauge 1: Provides sound when any engine sensor (sender) unit fails; when there is indication of air pressure available for an electronics system fault;...
  • Page 58 Controls/Features Alarm Conditions Audible Alarm Pattern Additional Comments Engine Oil Temperature Gauge out of range reading 5 BEEPS Instrument Panel Gauge Cluster warning indicator illuminates. Engine Coolant Temperature Gauge out of range reading 5 BEEPS Instrument Panel Gauge Cluster warning indicator illuminates.
  • Page 59: Direct Drive Warning Indicators

    Controls/Features Direct Drive Warning Indicators Item Item Color Description The direct drive warning indicators give information to the Yellow Optional Transmission operator of various conditions of the vehicle. Eight spaces are Retarder switch is in the ON available for the direct drive warning indicators. Blank cover position.
  • Page 60 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 1: Informational Messages Informational Display Screens: • Odometer • Trip Odometer •...
  • Page 61: Switches

    Controls/Features Item No. Quadrant Number and Message Function Message Description Quadrant 2: General Text and Warning Displays a variety of messages ranging in priority necessary for vehicle Messages monitoring and operation, and vehicle malfunction warnings. Some messages are used in conjunction with instrument panel gauge cluster warning indicators (see list of messages in the Integral Digital Display section in Vehicle Operations) Quadrant 3: Compass Heading/Outside (Optional) Displays compass heading when vehicle is equipped with a compass...
  • Page 62: Marker Interrupt

    Controls/Features Marker Interrupt Dome Lighting The marker interrupt function is an optional feature that toggles The overhead dome light is used for reading and for illumination the park lights and markers when the operator activates the when entering and exiting the vehicle. The dome light ON/OFF spring-loaded marker interrupt switch.
  • Page 63 Controls/Features Item Item Description Panel Dimmer Adjusts the panel lights brightness. Configured Switch options for this position include: Configured Switch options for this position include: Lift Gate, Work Light, Mirror Heat, Fog Light, Customer MIR, Fog Light Switch, and Plow Light switch. Plow Light, Fan Override, Two Speed Axle, Customer Request...
  • Page 64: 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 65 Controls/Features Declination Zone Map 3879634R1...
  • Page 66 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 67: 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 68: Integral Digital Display Detailed Information

    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 69 Controls/Features Quadrant 1 – Display Messages Description Odometer The odometer displays the total distance traveled. Display Format: 100,000.0 MILES Trip Odometer The trip odometer displays a record of the elapsed distance traveled since the last reset. NOTE: The trip hours and trip miles are independently reset. Display Format: 100,000.0 TRIP MILES...
  • Page 70 Controls/Features Quadrant 1 – Display Messages Description 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. Display Format: 100,000.0 PTO HOURS A PTO HOURS B Machine Trip PTO A or B Hours This display will provide a record of the total accumulated Machine Trip PTO hours, while PTO function A...
  • Page 71 Controls/Features Quadrant 1 – Display Messages Description 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 72 Controls/Features Quadrant 1 – Display Messages Description Machine PTO Trip Fuel Used A and B The display value shall be the calculated Machine PTO Trip Fuel Used. Display Format: 100,000.0 PTO TRP GAL A PTO TRP GAL B PTO TRP L A PTO TRP L B Engine PTO Fuel Used The display value shall be the calculated Engine PTO Fuel Used.
  • Page 73 Controls/Features Quadrant 1 – Display Messages Description Axle Load Indication The instrument panel gauge cluster shall display an approximate value of Axle Load for the front and/or rear axles. NOTE: Axle load readings are most accurate on a level surface with parking brake released. Display Format: approx.
  • Page 74 Controls/Features Quadrant 2 – Display Description Flash (Yes/No) Warning Indicator Messages Association PARKD REGEN ACTIVE Message is displayed during a parked regeneration. Load Shedding Message is displayed when electrical load control and shedding feature is implemented. Washer Fluid Low Indicates low washer fluid level. Electrical Fault When instrument panel gauge cluster’s ability to display diagnostic codes is enabled, this message is displayed...
  • Page 75 Controls/Features Quadrant 2 – Display Description Flash (Yes/No) Warning Indicator Messages Association HVAC Sleeper Blower Speed Bar graph displayed show blower speed setting in Off and low to high increments. Air Pressure Diagnostic Cruise Indicates that the Cruise Control System is turned On. Fuel Filter Indicates that the fuel filter is clogged.
  • Page 76 Controls/Features Quadrant 2 – Display Description Flash (Yes/No) Warning Indicator Messages Association Stop Engine Message is displayed when Red Stop indicator is Red warning indicator illuminated. MaxxForce® engine only. Warn Engine (Priority 1 or 2) (1) Message is displayed when MaxxForce, or MaxxForce® (1) Red warning indicator 11/13 ECM turn on the Red warning indicator.
  • Page 77 Controls/Features Quadrant 2 – Display Description Flash (Yes/No) Warning Indicator Messages Association Electrical Fault (Priority 1 or 2) (1) Message is displayed when EGC requests the Red (1) Red warning indicator warning indicator. (2) Yellow warning (2) Message is displayed when EGC requests the Yellow indicator warning indicator.
  • Page 78 Controls/Features Quadrant 2 – Display Description Flash (Yes/No) Warning Indicator Messages Association ECM, TCM, Shift Selector, ABS, Message is displayed when a module other than the Red warning indicator Retarder – Driveline, EGC, engine requests the red stop warning indicator. Compass Module, ESC, VSM, SD, AGSP, TPMS, Exhaust Module, Telematics, AGSP 2,...
  • Page 79 Controls/Features Quadrant 2 – Display Description Flash (Yes/No) Warning Indicator Messages Association DRV Reward Increasing DRV Reward Decreasing VSL Ovrd Active VSL Ovrd Expiring Blank screen, available only when engine rpm less than or equal to 325 RPM, or vehicle speed less than 2 mph (3 km/h).
  • Page 80 Controls/Features Outside Temperature Reading MaxxForce® Engines The Outside Temperature is displayed on the first line of Warning indicator Warning Message Quadrant 3 above the Compass Heading. The temperature Red Stop Stop Engine sensor is located near the front bumper. Due to its location, Yellow Warning Warn Engine the sensor readings can be affected by road or engine heat...
  • Page 81: Steering Wheel Controls

    Controls/Features Steering Wheel Controls CRUISE/THROTTLE - ON/OFF - Turns the speed control feature ON or OFF. The steering wheel contains the Electric (city) horn, Optional Air Engine speed does not change when horn control, and Cruise/Throttle controls. you press the ON position. This control just activates/deactivates the feature.
  • Page 82: Basic Functions Of Steering Wheel Controls

    Controls/Features Basic Functions of Steering Wheel Controls 2. Bring the vehicle to the desired operating speed (above 35 MPH), and then push the SET/CRUISE position of CRUISE/THROTTLE ON/OFF control turns the steering wheel control. speed control feature ON or OFF. Engine speed does not 3.
  • Page 83: Stationary Variable Speed Control (12Vxt)

    Controls/Features 4. To change from this initial setting, use the appropriate 3. First, press the switch that selects one of the desired control to raise or lower the engine speed as you would speeds. in the cruise control mode. SET/CRUISE reduces 4.
  • Page 84: Steering Column And Switches

    Controls/Features Steering Column and Switches 2. Signaling For A Turn - When signaling your intention to make a turn, move the turn signal lever up or down to the “full turn” position which is past the point of resistance. On some models the switch will automatically cancel if the steering wheel is turned a large enough degree.
  • Page 85 Controls/Features on as long as the lever is held in the pulled position. When the WARNING Lo-Beam headlights are ON, the Hi-Beam lights can be made to flash if the lever is not lifted past the ”click” or dimmer position. Do not use the washers in freezing weather without first warming the windshield with the 5.
  • Page 86: Center Dash Panel/Wing Panel

    Controls/Features Center Dash Panel/Wing Panel 1. Radio 2. Fan Speed Control The Center Control Switch Panel consists of the switches that start the vehicle, control the vehicle’s normal operations, 3. Temperature Control vehicle lights, and special mechanical functions. The panel also 4.
  • Page 87: Switches

    Controls/Features Switches Transmission Retarder – RTARDR ON Up to 25 optional switches can be located in the center and lower Turns ON transmission retarder to slow down drivetrain. right side of the center dash panel. Location of these switches will vary depending on the options installed. Blank cover plates will be used in spaces that do not have switches installed at those Transmission Retarder –...
  • Page 88 Controls/Features MUD/SNOW ENABLE 2 Speed Axle – 2 SPD LO/ 2 SPD HI As part of the automatic traction control system, this A 2 speed switch that allows the operator to select switch, when enabled, allows for greater engine power either high or low rear axle ratio.
  • Page 89 Controls/Features Forward Rear Tandem Axle Differential Lock – DIF FR Engine Shutdown Override – ENG OVRD/ON AXLE LOCK This momentary switch, when pushed to the ON This switch, when set to LOCK, engages the forward position, will allow the vehicle to be restarted in the rear locking differential for improved traction on poor event of an automatic engine shutdown.
  • Page 90: Auxiliary Gauge/Switch Package (Agsp) (Optional)

    Controls/Features Auxiliary Gauge/Switch Package (AGSP) Optional Gauge Function (Optional) Ammeter Gauge Provides reading of battery and alternator current in Amps. The Auxiliary Gauge/Switch Package provides locations for three additional gauges and six switches for optional customer Rear–rear Axle Provides monitoring of temperature of requirements.
  • Page 91 Controls/Features Item Component Description Item Component Description Cigar Type Power Socket Telematics No Data Logged Switch Optional Filter Minder Telematics Driver Alert Switch Three Switch Pack Cigar Lighter Optional Winter/Engine Intake Switch Optional Air Horn Switch Optional Ether Start Switch Optional Engine Start Switch Optional Axle Enable Switch Optional Axle Up/Down Switch...
  • Page 92: Climate Control

    Controls/Features Climate Control WARNING 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, resulting in property damage, personal injury, or death. To improve defroster efficiency, remove ice and/or snow by hand from the windshield and windows with a non-metallic scraper.
  • Page 93 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 start up in very hot or humid weather.
  • Page 94: Air Conditioning

    Controls/Features Mix Mode In this mode 50 percent of the airflow is directed to the defrost and side demist air outlets and 50 percent of the airflow is directed to the floor air outlets, and fresh (outside) air is circulated inside the vehicle.
  • Page 95: Dehumidification

    Controls/Features NOTE: If your air conditioning performance seems lower Dehumidification than expected, check the front of the A/C condenser for an The heater/defroster systems can be operated simultaneously accumulation of dirt or insects. Clean with a gentle water spray with the air conditioner during mild weather and high humidity from behind the radiator and through the condenser as required.
  • Page 96: Remote Keyless Entry Operation (Optional)

    Controls/Features 1. Door Handle Remote Keyless Entry Operation (Optional) 2. Key Lock 3. Interior Lock 4. Interior Door Handle To open any door from inside, pull out on interior door handle. To open any door from outside, grab door handle and pull downward.
  • Page 97: Door Opening/Unlock

    Controls/Features NOTE: This device complies with Part 15 of the FCC Rules and with RSS-210 of Industry Canada. Operation is subject to the following two conditions: 1. This device may not cause harmful interference. 2. This device must accept any interference received, including interference that may cause undesirable operation.
  • Page 98: Automatic Door Lock Function

    Controls/Features Unlocking the Door For one-touch windows down operation, press and release the window control in the “Down” direction. The window will then go To unlock, push the lock/unlock button on the unlock symbol in to the full down position automatically. the door control panel located by the vent window.
  • Page 99: Vent Window

    Controls/Features These controls provide the driver with the ability to operate both The following driver reward visual indications appear in the form driver- and passenger-side flat mirrors. Use the mirror select of text messages in the gauge cluster digital display: switch to select which mirror is to be adjusted and adjust the •...
  • Page 100 Controls/Features 3879634R1...
  • Page 101: Section 5 - Operation

    Operation SECTION 5 — OPERATION Operation Safety WARNING Do not exceed the truck’s gross axle weight, WARNING gross vehicle weight, and gross combination weight ratings. Exceeding these ratings by Operation of a diesel engine near flammable overloading cause component failure vapors in the air may cause the engine speed resulting in property damage, personal injury, or to increase uncontrollably and overspeed.
  • Page 102: Cab Controls

    Operation WARNING WARNING When parking your vehicle, do not leave All vehicles have blind spots. Make sure your transmission in gear. Always use parking brake. way is clear in all directions before moving your When parking on a grade, chock wheels and vehicle.
  • Page 103: Seat Belts

    Operation Seat Belts NOTE: Periodically inspect the seat belts for wear and function. Replace any parts whose performance is in doubt. WARNING General To prevent personal injury or death, do not ride Safety belts must be worn by the driver and all passengers at in the vehicle cargo area or on the outside of all times.
  • Page 104: 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 105: Care Of Seat Belts

    Operation Shorten the belt after it is connected by pulling on the loose end WARNING until the belt is snug and comfortable. Reckless operation of this vehicle over rough To release: Push in the button release latch to release the seat roads or surfaces can cause loss of vehicle belt.
  • Page 106: Starting Procedures

    Operation Starting Procedures Engine Starting The ignition switch has four key WARNING positions as follows: Never start the engine unless you’re sure the 1. ACC (Accessory) transmission selector is in neutral and the brake 2. OFF is applied, otherwise accidental movement of the vehicle can occur, which could result in property 3.
  • Page 107: After The Engine Starts

    Operation 8. To place the ignition switch in ACC (Accessory) position, follow the size of the engine in order to avoid seals or like rotate key counterclockwise to the ACC position. features of an engine being damaged by rising heat. Accessory features can now be used without engine 1.
  • Page 108: Engine Idle Shutdown Timer (Optional)

    Operation engine to be restarted so that the vehicle can be moved. The System Operation engine should be run no longer than absolutely necessary. A The Vehicle Shutdown system operates in the following manner: decal located in front of the operator provides instructions on how the override should be operated.
  • Page 109: Theft Deterrent Code Entry Procedures

    Operation Theft Deterrent Code. The theft deterrent code is any Theft Deterrent Code Entry Procedures combination of one to eight digits between 0 and 99999999, Engine Start/Theft Deterrent Code Entry Sequence. The obtained from the dealer, and kept in a secured location. correct engine start and theft deterrent code entry sequence is Six switches, located in the instrument panel gauge cluster, as follows:...
  • Page 110 Operation The following table provides a summary of all the possible system responses to various driver attempts to start and drive the vehicle. Driver Action System Alerts Engine Operating Status Engine started with parking brake set No system alerts Engine runs without interruption Correct theft deterrent code entered (vehicle An alarm will sound one short beep and, at the same time, the...
  • Page 111 Operation Driver Action System Alerts Engine Operating Status Correct theft deterrent code is entered after The continuous alarm beeps and ENGINE STOP indicator Engine runs without the warning sequence has begun (within the flashes and stops after the alarm sounds once and the interruption programmable delay time) ENGINE STOP indicator flashes once...
  • Page 112: Emergency Starting Using Jumper Cables

    Operation Emergency Starting Using Jumper Cables 6. Connect one end of the first jumper cable to positive (+) terminal of the dead battery or (+) terminal of jump start stud and then the other end to the positive (+) terminal of WARNING the booster battery.
  • Page 113: Cold Weather Starting

    Operation Cold Weather Starting Winter/Engine Intake Operation For vehicles frequently operating in cold climates an optional When the WINTER position is selected, the optional engine block heater is available. The block heater utilizes an yellow Snow Valve warning indicator in the instrument external power source to keep the engine coolant warm and a panel gauge cluster turns on.
  • Page 114: Winter Front Usage

    Operation • Maintain a minimum of 1250 RPM idle by use of the hand 2. Fill fuel tank at end of daily operation to prevent throttle. Always make sure that parking brake is applied and condensation in tank. transmission is in (N) Neutral before applying hand throttle. 3.
  • Page 115: Operating Instructions

    Operation Operating Instructions WARNING Do not adjust the steering column while WARNING the vehicle is moving. It could suddenly or All vehicles have blind spots. Make sure your unexpectedly move, causing the driver to lose control of vehicle which could result in property way is clear in all directions before moving your vehicle.
  • Page 116: Adjustable Tilt/Telescoping Steering Column

    Operation Adjustable Tilt/Telescoping Steering Column • Using both hands, grab the sides of the steering wheel and adjust the telescoping feature to the desired position and then the steering wheel tilt to the desired position. • 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.
  • Page 117: Electrical

    Operation Electrical NOTE: Familiarize yourself with all of the switches that control chassis, engine, and body equipment and seek adequate training on the function of all features before WARNING operating this vehicle. Additional detailed information on these optional features may be found in the CT-471 Body This vehicle may be equipped from the factory Builder Manual, Electrical System Component Section, and with electrical switches intended to operate...
  • Page 118: Alternator

    Operation Alternator Battery CAUTION WARNING Before connecting a fast charger or booster Keep lighted tobacco, flames, sparks or other battery, or installing a new battery, make sure ignition sources away from the batteries. Gas that the ground polarities of the fast charger, from the battery cells is flammable and can booster battery, or alternator (when installing a ignite and/or explode.
  • Page 119: Battery Disconnect Switch

    Operation Circuit Breakers, Fuses, and Fusible Links WARNING Do not check battery condition by shorting WARNING (flashing) across terminals. Failure to observe Electrical circuits are designed with a particular this warning could result in personal injury wire gauge to meet the fuse and circuit breaker and/or damage to the vehicle.
  • Page 120: Engine

    Operation distribution center is located behind a hand-removable cover on Engine Brake, Retarder (Optional) the instrument panel on the passenger side of the vehicle. WARNING Engine Do not use the vehicle retarder, engine brake The engine for this vehicle is an electronically controlled diesel on slippery road surfaces.
  • Page 121: Engine Brake System Operation

    Operation SELECTOR 1/2/3 switches that are located in the center NOTE: The engine brake feature will automatically control switch panel. The following paragraphs provide a brief deactivate if either the accelerator or the clutch is description of these optional braking features. pushed, or when the engine speed falls to 1000 RPM.
  • Page 122: Automatic Transmission Operation

    Operation • The gear display on the shift selector will stop blinking The engine brakes will deactivate when the transmission shifts when the downshift is completed, and the driver will notice from converter lock-up to normal torque converter operation. resumption of engine braking as an indication that the shift is completed.
  • Page 123: Certified Clean Idle

    Operation Some Optional Features: while operating the vehicle, it is an indication that the vehicle needs service. When the warning indicator is illuminated, a • Engine Warning System - this system illuminates the Red Diagnostic Trouble Code (DTC) will be generated. Take the “Engine”...
  • Page 124: Optional Coolant Warning Level System - 3 Way

    Operation NOTE: If the Oil/Water Warning Indicator comes ON, bring the and will operate in a de-rated mode for an additional 30 seconds vehicle to a safe stop and shut the engine OFF before shutdown if the conditions causing the shutdown are still present (See occurs.
  • Page 125: Cooling System

    Operation • Clutched Air Compressor: This high-capacity, two Cooling System cylinder, air compressor is periodically engaged by using an on-off clutch. It works in conjunction with air governor WARNING and air dryer to pump air to the air dryer and air tanks. When additional compressed air is not needed, the clutch To prevent personal injury or death from hot is disengaged, compressor speed goes to zero, and all...
  • Page 126: Antifreeze

    Operation Consult the Engine Operation and Maintenance Manual for WARNING coolant service life details. Do not exceed the pressure rating on the For vehicles with MaxxForce® 11 and 13 engines, the cooling deaeration tank cap. Ensure that the pressure system of your new vehicle will be filled at the factory with rating of the deaeration tank cap matches that nitrite-free Shell Rotella®...
  • Page 127: Engine Performance Problems

    Operation The lubricating oil in a diesel engine becomes dark in color Unacceptable Fuel Blends after short periods of engine operation. This discoloration is not Biodiesel blends having more than 5 percent pure biodiesel are harmful to engine parts as long as the oil and oil filter element not within ASTM D975 diesel specifications.
  • Page 128: Fuel And Lubricant Additives

    Operation CAUTION Therefore, when refueling, be sure that both tanks are filled completely, as it is sometimes difficult to determine which tank To prevent engine damage, do not mix engine is the draw tank and which is the reserve tank. oil with diesel fuel.
  • Page 129: Exhaust Diesel Particulate Filter Regeneration

    Operation Exhaust Diesel Particulate Filter Regeneration WARNING This vehicle is equipped with a Diesel Particulate Filter Failure to perform a Parked Regeneration when (DPF) to meet 2010 emissions requirements. The DPF traps exhaust filter indicator is ON will cause the engine exhaust particulate matter generated by normal engine usage.
  • Page 130 Operation 2010 Federal Emissions Label Vehicle Level Indication Audible Alarm LCD Text Message Action Required Conditions/Operation Drive on highway at highway speeds or start Parked Scrolls between Regeneration to prevent loss of power. See Visor for info Exhaust filter None and Parked Regen regeneration required.
  • Page 131: 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 132: Two-Position Regeneration Inhibit Switch

    Operation Two-Position Regeneration Inhibit Switch fully engaged, there is no heat generated and little or no wear. However, during the brief period when the clutch is picking up With the optional two-position switch, pressing the ON position the load, considerable heat is generated. By riding or slipping of the ON/INHIBT REGEN switch will inhibit both normal and the clutch, the period of partial engagement is lengthened, parked regeneration.
  • Page 133: Clutch Brake (Vehicles With Nonsynchronized Transmission) - Vehicle Not Moving

    Operation are driving the disc through the multiplication of the rear axle and when the vehicle is at a standstill and the engine running at idle transmission ratios. This can result in over 10,000 RPM, which speed. Clutch brake application occurs in the last 1 inch (25mm) is beyond the burst strength of the facing material.
  • Page 134: Clutch Precautions

    Operation • Depress the clutch pedal immediately and shift into the Steady pressure on shift lever will help the synchronizer perform desired gear. its job quicker. If the shift lever is forced into gear it is possible to override a blocker and defeat the purpose of the synchronizer, •...
  • Page 135: Eaton Ultrashift® Transmissions (Optional)

    Operation To shift the Eaton® transmission into Reverse (R) or Drive (D), first place foot on the brake and optional clutch pedal. When in Drive (D), the transmission selects the starting gear and automatically selects the proper gears for operating loads. To select a higher or lower gear, first press the Hold button and use either the up arrow or down arrow shift buttons.
  • Page 136: Parking The Vehicle

    Operation the shift selector places the transmission in “N” (Neutral) and Parking The Vehicle engages the park pawl (always use with the Parking brake). The following WARNINGS provide the methods of parking the vehicle using the various transmission shift selectors. NOTE: If you attempt to engage “P”...
  • Page 137: Preparing To Drive The Vehicle

    Operation Manual Parking Brake WARNING After starting the engine, place foot firmly on brake pedal. • For the Auto Apply Parking Brake (“PB” transmissions), With foot still on brake pedal, select the desired transmission make sure that the “PB” selection has applied the operating position.
  • Page 138: Allison Generation Iv T-Bar Gearshift Control

    Operation Both the T-Bar gearshift control and the Push-button gearshift When the vehicle is started, the transmissions are designed control are available with the Allison automatic transmissions. to operate in the standard performance mode. Pressing the They provide the same gear shift functions and control the Mode button on the shift tower will switch the transmission transmission in the same manner.
  • Page 139: Operation Of The Allison Generation Iv Push-Button

    Operation Operation of the Allison Generation IV Push-button Shift Selector 1. Digital Display 2. Mode Id 3. Mode Button 4. Range Selector Buttons To shift the Allison transmission into Reverse (R) or Drive (D), first place foot on brake pedal. With foot on brake pedal, press either R or D, release the Parking Brake, and then release the brake pedal.
  • Page 140: Operation Of The Column-Mounted Shifter

    Operation Operation of the Column-Mounted Shifter • For reverse, pull on shift control lever and move lever to “R” position (as indicated on LCD display), and then release column shift lever. • Release the Parking Brake. • Lift foot from service brake pedal to allow the vehicle to move backward.
  • Page 141: Backup Alarm

    Operation Selection of the OD (overdrive) gear in the auxiliary transmission Auto Neutral permits increased road speeds in the various transmission ratios. WARNING A loaded vehicle should not be operated with the auxiliary When using the AUTO NEUTRAL feature, always transmission in OD (overdrive) with the main transmission in hold the brake pedal down when releasing either of the two lowest speed gears.
  • Page 142 Operation 3. The transmission shifter’s digital display shows a blinking “N”, indicating the transmission is in Neutral, and the instrument panel gauge cluster LCD display will indicate Neutral gear. When the parking brake is released, the transmission will go back to the gear originally selected, the shifter’s digital display will show that gear, the LCD display will also indicate that gear, and the AUTO NEUTRAL indicator will go off.
  • Page 143: Power Take Off Control

    Operation 3. The transmission shifter’s digital display will show Power Take Off Control a non-blinking “N”, indicating the transmission is in If your vehicle is equipped with a power take off (PTO), refer to Neutral. the PTO equipment manufacturer’s instructions. T-Bar shifter: when the parking brake is released, the shift If vehicle is equipped with an Allison Automatic Transmission, lever has to be moved to Neutral and then back to the...
  • Page 144: Rear Drive Axles

    Operation Rear Drive Axles Tandem Axle Power Divider Lock (PDL) Control Locking Differentials CAUTION Do not operate the vehicle with the PDL engaged on dry pavement (good traction) continuously. WARNING This will result in excessive tire wear and To prevent vehicle damage, personal injury, or premature axle wear.
  • Page 145: Driver-Controlled Differential Lock

    Operation When highway conditions improve (good traction), the PDL mounted on the instrument panel gauge cluster, the driver can should be disengaged, again at a low, even speed. Letting lock or unlock the rear axle differential(s) when the vehicle is up on the accelerator momentarily will unlock the interaxle moving or stopped.
  • Page 146: Controlled Traction Differential

    Operation The vehicle may need to be decelerated or turned once or twice Locking Differential (Optional) for the differential lock to fully disengage. WARNING Controlled Traction Differential Axles equipped with locking differentials can Some Eaton drive axles are equipped with a controlled traction deliver power to both wheels even when only one differential.
  • Page 147: Two Speed Rear Axle

    Operation NOTE: These differentials require a certain amount of resistance Two Speed Rear Axle in order to start the power transfer. If the spinning wheel is off the ground, transfer may not begin. If spinning occurs, often a WARNING light application of the brakes, while carefully applying power, will slow the spinning wheel enough to allow the differential to Never attempt to shift a two-speed axle when transfer power to the other wheel.
  • Page 148: Split Shifting

    Operation Split Shifting Axle Operating Temperature Combined Axle and Transmission Shift Normally, axle operating temperature will not exceed more than 100ºF (38ºC) above ambient temperature. However, intermittent To Downshift the axle to a slower ratio and upshift or downshift operation (5 percent of time) at higher temperatures under the transmission, shift the transmission and just before the extreme loads (long pulls) will not harm the axle.
  • Page 149: Transfer Case

    Operation CAUTION In-Switch Indicator Do not keep the front axle engaged when The ON/FRONT AXLE switch contains an indicator that operating on dry, hard surfaced roads. Operating will be lit steadily when switch is in the ON position and on hard, dry surfaces with both the front and the front axle has been safely engaged.
  • Page 150 Operation NOTE: Ensure that the wheels are not slipping while performing The transfer case gear ratio can be selected and the front axle these steps, and that there are no error conditions or indicators can be engaged at the same time by performing the following displayed.
  • Page 151: International® Ride Optimized Suspension (Iros)

    Operation 3. If no leaks are found, resume driving at 15 mph slower NOTE: To lower the suspension (dump operation), the vehicle than when the indicator came on. speed must be less than 5 mph (8 km/h). 4. Resume safe speed if indicator stays off. When the SUSP/DUMP switch is in the DUMP position and the vehicle speed is below 5 mph (8 km/h), air International®...
  • Page 152: Air Suspension System Faults

    Operation NOTE: The system will automatically switch from DUMP to Axle and Suspension Conversions SUSP if, while the system is commanding a DUMP operation, the vehicle speed exceeds 5 mph (8 km/h). Once this occurs, WARNING the only means to deflate the suspension will be to slow the vehicle to 5 mph (8 km/h) and recycle the SUSP/DUMP switch When operating a loaded vehicle, always keep all to the DUMP position.
  • Page 153: Lift Axle Locations

    Operation NOTE: The “Down” indicator on the UP/DOWN switch signals The two lift axle designs are (1) “Fixed” (Rigid) and (2) that the axle, controlled by that switch, is in the lowered position, “Self-Steering” lift axles. and is operational. Fixed lift axle. The fixed lift axle design provides 20,000 pounds maximum load carrying capacity.
  • Page 154: Lift Axle Controls

    Operation Lift Axle Controls Instrument Panel Controls The lift axle system controls consist of all the controls, regulators, and gauges needed to raise and lower the lift axle(s) and to monitor the load air bag pressures for each axle. These controls are available in three possible configurations and are the same for all configurations.
  • Page 155 Operation In-Cab Controls seat. This system’s controls consist of one AXLE ENABLE system switch, an UP/DOWN switch, an air Pressure Regulator control, and an air Pressure Gauge for each lift axle. Mixed Controls 1. Axle Enable System Switch 2. UP/DOWN Switch 3.
  • Page 156 Operation 1. Air Pressure Gauge 2. Air Pressure Regulator In this configuration, the lift axle controls are located on the floor-mounted pedestal and on a panel that is mounted externally 1. UP/DOWN Switch – Axle 1 on the rear of the cab. The controls on the floor-mounted pedestal are the AXLE ENABLE system switch, an UP/DOWN 2.
  • Page 157: Lift Axle System Operation

    Operation Lift Axle System Operation WARNING To prevent the unintentional lowering of a lift axle(s), set all UP/DOWN switches to the UP position before turning system on. Be aware, lift axle(s) will automatically rise to the UP position when the key is turned off. Ensure lift axle(s) are clear of people, animals and objects before turning system on, or turning ignition off.
  • Page 158 Operation Lowering the Lift Axles venting air from the axle load air bag and supplying air to the lift bag. This lifts the axle (s) regardless of the position of the With the lift axle system enabled, when the DOWN position of UP/DOWN switch.
  • Page 159: Brakes

    Operation Brakes Mounting Height Ground Axle 10 in. 11 in. 12 in. WARNING Load 8,000 lbs 52 psi 56 psi 60 psi Always check and maintain brakes in proper condition and adjustment. Out of adjustment 9,000 lbs 60 psi 64 psi 69 psi brakes could cause reduced braking ability and 10,000 lbs...
  • Page 160: Air Brakes

    Operation • Downhill speed is controlled by removing one’s foot from the Air Brakes accelerator pedal (engine running with closed throttle) and putting the transmission/rear axle in reduced gear. If the WARNING transmission/rear axle is in a gear that results in more than the appropriate speed, a proper downshift should be made Stopping distance may increase under the failed to avoid overuse of the brakes.
  • Page 161: Indicator

    Operation Air Gauge, Low Air Pressure Beeper and Warning Indicator If the red indicator, beeper, and gauge indicate a loss of pressure while driving, the vehicle still has a portion of the braking capability, because one-half of the split system braking WARNING capability is retained.
  • Page 162: Parking Brake Reset

    Operation It should be noted that upon loss of air pressure, partial spring WARNING brake application will occur prior to automatic application of the control valve. Always chock the wheels when manually releasing the spring brakes, or the vehicle could To release, recharge system to 70 psi (483 kPa) and push in the roll causing property damage, personal injury, or parking brake control.
  • Page 163: Reservoir Moisture Draining

    Operation reinstall the access plug in the chamber opening. Reinstall the a replaceable desiccant cartridge and oil blocking filter that is release stud and nut in the carrying pocket on the brake chamber periodically serviced. It also may include a heater to prevent the housing.
  • Page 164: Trailer Air Supply And Parking Brake Modular Controls

    Operation Trailer Air Supply and Parking Brake Modular Controls the tractor spring brakes will apply, and the trailer emergency system will be activated. On vehicles equipped with the standard two-valve system, the operation of one valve together with the other permits the operator to select the desired functions described below: Red Valve Yellow Valve...
  • Page 165: Parking Brake Indicator

    Operation NOTE: When attempting to readjust/slide the position of the To turn off the alarm, press the service brake pedal. Then, after tractor fifth wheel or the trailer’s tandem axles with the tractor turning the ignition switch to the RUN or ACC position, make and trailer fully connected, leave the tractor’s PARKING BRAKE sure that the parking brake is set.
  • Page 166: Abs Operation

    Operation is imminent. The standard air brake system controls normal similarly limited. Vehicle speed must be reduced to compensate braking when the ABS is not engaged. for the extended time and distance required to stop or slow the vehicle on slippery roads. ABS Operation The wheel hubs carry exciter rings used by axle-mounted sensors to transmit wheel speed information to the ABS...
  • Page 167: Antilock Driving Tips

    Operation If overbraking causes wheel lockup on the rear drive axles while Air Brake Bendix® ABS-6 retarding devices are in operation, the ABS will interrupt and disable the retarder until the lockup situation has stopped. WARNING If the ABS warning indicator is lit, consult your nearest Vehicles equipped with Stability Control cannot International truck service center for further assistance in be used to pull double or triple trailers.
  • Page 168: Traction Control (If Equipped)

    Operation monitoring individual wheel turning motion during braking. For The Traction Control switch for Air Brake-equipped a complete description of the core ABS system, see the ABS vehicles. If the system is enabled (traction control section above. switch in the TRAC ENAB position), the traction control indicator on the instrument panel gauge cluster will Traction Control (If Equipped) flash during a Traction Control event, and the engine...
  • Page 169: Stability Control Systems - Bendix® Esp

    Brake Demand Sensors: The stability control system was Modification to vehicles equipped with ESP designed to supplement the driver’s actions. By directly require prior approval thru Navistar’s Tech measuring driver brake demand, the system can transition Services # 1-(800)-336-4500. Unapproved seamlessly between driver-intended and system-intended modifications may result in diminished stability...
  • Page 170: Bobtail Proportioning System

    Operation Towing Instructions brake pedal quickly to apply a higher [above 40 psi (276 kPa)] braking level, the driver’s braking input overrides the temporary change made by the system. WARNING ABS/Stability System Interaction: With the ABS–based This vehicle may be equipped with (optional) stability control system, the ABS system is given priority at the dual tow hooks for recovery purposes only.
  • Page 171: Towing Vehicle With Front Wheels Suspended

    Operation NOTE: Important factors to keep in mind when using tow hooks: Towing Vehicle with Front Wheels Suspended • use both tow hooks when retrieving vehicle CAUTION • use a slow steady pull, do not jerk on hooks To prevent vehicle, engine, or transmission •...
  • Page 172: Lock

    Operation Towing Vehicles with Driver Controlled Differential Lock 2. Remove cap screws and washers or stud nuts and washers from flanges of both axle shafts. Removing Axle Shafts Before Towing 3. Loosen tapered dowels in flanges of both axle shafts by holding a 1-1/2 inch-diameter brass drift or hammer CAUTION against axle shaft center and hitting it with a five to six...
  • Page 173: Towing Vehicle With Rear Wheels Suspended

    Operation 3. Install right-hand and left-hand axle shafts as follows: Whenever possible, it is preferable to tow a disabled vehicle from the rear by raising the rear of the chassis by the rear axles. a. Place gaskets on wheel hub studs. When towing a vehicle with rear of the chassis suspended, the b.
  • Page 174: Connecting/Disconnecting A Trailer To A Vehicle With

    Operation Connecting/Disconnecting a Trailer to a Vehicle with Air Fifth Wheel Operation Suspension WARNING The Air Suspension has a dump valve system option (Code 14899) that permits exhausting air from the suspension system, Always follow the fifth wheel manufacturer’s thus lowering the frame when connecting, disconnecting, or instructions for hooking and unhooking as well loading the trailer.
  • Page 175: Hook-Up

    Operation allow it to be moved forward or backward and re-lock it once 5. Back tractor squarely under trailer, engaging fifth wheel the desired position is attained. jaws on trailer kingpin. Always back slowly, making sure trailer is neither too high nor too low. Avoid backing To unlock the fifth wheel, press the top portion of the under trailer from an angle.
  • Page 176 Operation 3. Lower trailer landing gear, making sure it is on solid, 6. Pull coupler release lever to disengage fifth wheel jaws. level ground. The weight of trailer must be on landing 7. Release tractor parking brakes. gear. 8. Pull out from trailer slowly, allowing landing gear to take 4.
  • Page 177: Section 6 - Maintenance Instructions

    Maintenance Instructions SECTION 6 — MAINTENANCE INSTRUCTIONS Introduction about performing some service, consult your International dealer or have the service done by a skilled technician. WARNING Maintenance Guidelines If the owner/operator of the vehicle is a skilled technician and intends to perform the vehicle WARNING maintenance and servicing, he/she is strongly urged to purchase and follow the appropriate...
  • Page 178 Maintenance Instructions CAUTION WARNING To prevent damage to electrical components To prevent property damage, personal injury, during electric welding operations, follow these 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 179: Supporting Your Vehicle For Service

    Maintenance Instructions Chassis Lubrication 10. Correct any problems that were revealed during inspection prior to operating the vehicle. New vehicles are lubricated at the factory and again during the predelivery inspection. After the vehicle is placed in operation, Supporting Your Vehicle for Service regular lubrication and maintenance intervals, based on the type of service and road conditions, should be established.
  • Page 180: Air Conditioning Service Checks

    Maintenance Instructions Air Conditioning Service Checks Side Access HVAC Filter Have your air conditioning system serviced each spring. The refrigerant charge, cleanliness of condenser-evaporator cores, cab filter, and belt condition are essential to air conditioning performance. Remove the fresh air filter(s) once each season and check for dirt, lint, etc.
  • Page 181: 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 dash. 1. Air Intake Housing 2. Screws 3. Filter Access Door 1.
  • Page 182: Axles

    Maintenance Instructions Axles • Inspect, lubricate and adjust the wheel bearings at regular intervals. Refer to SECTION 7 — MAINTENANCE Front Axle INTERVALS AND SPECIFICATIONS for the correct intervals, lubricants, and torques. Inspection and Lubrication Normal Maintenance Check to make sure that the front axle mounting U-bolts, attaching or mounting bolts and nuts are securely tightened.
  • Page 183: Alignment

    Maintenance Instructions Alignment Re-torque the U-bolt nuts after the first 1,000 miles (1,600 km) and every 36,000 miles (58,000 km) thereafter. Refer to the Maintaining front axle alignment is very important to achieving LUBRICATION AND MAINTENANCE INTERVAL CHART for maximum tire life and vehicle control. Inspecting steer axle tires recommended service intervals.
  • Page 184: Brakes

    Maintenance Instructions The mechanical items of the lift axle system require periodic Follow these precautions: maintenance to maintain reliable operation. Drain cocks, in the • Always wear a respirator approved by National Institute of bottom of each air tank, are installed to provide a convenient Occupational Studies of Health (NIOSH) or Mine Safety and means of periodically draining condensation from the tank.
  • Page 185: Air Brakes

    Maintenance Instructions Air Brakes WARNING Inspection and Adjustment Brake Automatic Slack Adjusters (ASA’s) should not need to be manually adjusted in service. ASA’s should not routinely have to be adjusted WARNING to correct excessive push rod stroke. Excessive Always chock the wheels when manually stroke indicates that a problem exists with the releasing the spring brakes, or the vehicle could...
  • Page 186: Air Dryer

    Maintenance Instructions Brake chamber push rods on original equipment chambers now 2. Condition of drums, brake chambers, and slack incorporate an overstroke indicator (an orange paint marker adjusters for wear, corrosion, maladjustment, cracks, near the base of the push rod) to aid adjustment checks. If the missing components, etc.
  • Page 187: Desiccant Filter

    Maintenance Instructions control, and desiccant quantity. Regularly check the desiccant, engine is started, turn on the ignition and touch the air dryer purge valve and air dryer heater performance. housing. It should be warmer than other metallic items on the vehicle.
  • Page 188: Abs Connections And Sensors

    Maintenance Instructions ABS Connections and Sensors for cleaning. Damage to these parts can occur if cleaning solutions having excessive acidity or alkalinity (pH) are used. Periodically, push together the ABS wiring connections to ensure Also, the higher the solution temperature ranges, the more they are fully-seated.
  • Page 189: Clutch

    Maintenance Instructions Clutch Electrical Pedal Free-Travel Batteries Each time the vehicle chassis is lubricated, check clutch pedal Battery life and performance varies greatly depending on free-travel. If clutch pedal free-travel is outside the 1 to 1 1/2 duty cycle. Conditions such as short runs between starts, inch (25 to 38 mm) range, the clutch must be adjusted to ensure low ambient operating temperatures, using battery current that the clutch is fully engaging and the clutch brake will activate.
  • Page 190: Battery Cables

    Maintenance Instructions CAUTION corrosion and for cleaning the top of the battery. Brighten the contact surfaces with steel wool, apply a light coat of lubricant Allowing batteries to become heavily discharged sealing grease, such as Fleetrite® 472141-C1 or equivalent or and exposed to subfreezing weather will cause a spray protectant, and reassemble.
  • Page 191: Accessory Feed Connections

    Maintenance Instructions Connectors that are more subject to corrosion may be Fuses and Relays disassembled and sprayed internally with a light coating of Fuses and relays are located inside the cab within the fuse dielectric grease. Use grease sparingly, as too much grease will panel cover.
  • Page 192: Engine Fluids And Contaminated Material

    Maintenance Instructions Service intervals are based upon average operating conditions. and inspection and adjustment of items such as valve lash, etc., In certain environments and vocations, more frequent servicing refer to the Engine Operation and Maintenance Manual supplied will be required. with the vehicle.
  • Page 193: Air Restriction Gauge

    Maintenance Instructions • Check for ruptured, bulging, or collapsed pipes. on air cleaner mounted gauge is on the end of the gauge. See illustrations below. • Check air cleaner housing and air restriction gauge for cracks. It is recommended that the operator NOT reset the gauge until after it has been determined if the air filter element must be Air Restriction Gauge replaced.
  • Page 194: Air Cleaner Element Service

    Maintenance Instructions Air Cleaner Element Service This vehicle comes with a selection of two air cleaner options. The first option is a single element. The second option is a dual element air cleaner that is available for applications in excessively dusty environments that may require more frequent service intervals.
  • Page 195 Maintenance Instructions 3. Visually inspect the air cleaner housing for damage or distortion, which could allow unfiltered air to enter the engine. Inspect to be sure that the rubber dust unloader valve at bottom of housing is in place, free of debris, and not cracked.
  • Page 196: Troubleshooting

    Maintenance Instructions Troubleshooting Problem: No Restriction Reading POSSIBLE CAUSES HOW TO CHECK Plugged fitting or vacuum line Apply vacuum to gauge until locked up at red zone. Re-connect line and hold in reset button. Indicator will fully return unless line or fitting is plugged. A slow return is normal due to safety filter in fitting.
  • Page 197: Charge Air Cooler And Radiator Core Inspection

    Maintenance Instructions Charge Air Cooler And Radiator Core Inspection And ELC - Extended Life Coolant (P/N 94042). Refer to the label Cleaning on the deaeration tank to determine the coolant type. If no label is present, use Type II Fully-Formulated Coolant (Purple) Inspection and Cleaning and maintain the Supplemental Coolant Additives (SCA’s) accordingly.
  • Page 198: Filling Instructions

    Maintenance Instructions CAUTION • If coolant level is above MAX mark, remove coolant until coolant level is between ADD and MAX marks on tank. If the coolant should get extremely low and the engine very hot, let the engine cool for For vehicles equipped with a translucent deaeration tank with engine HOT: approximately 15 minutes before adding coolant;...
  • Page 199: Filling Instructions (Maxxforce® 11 And 13 Engines)

    Maintenance Instructions To function properly, the system must be completely filled with 4. After adding coolant over a period of two minutes and coolant and all air must be expelled. To accomplish this, the keeping the coolant deaeration tank full, replace the coolant following procedures should be carefully completed: deaeration tank cap tightly.
  • Page 200: Coolant And Optional Coolant Filter

    Maintenance Instructions 1. Turn on ignition without starting the vehicle. This opens the electrically actuated LTR coolant flow valve. 2. Fully open cab heater coolant shut-off valves and coolant system vent valve. 3. Remove fill cap and pour a 50/50 mixture (75/25 if it has been flushed with water) of the proper (Nitrite-Free Shell®...
  • Page 201: Antifreeze

    Maintenance Instructions Ultra ELC (Yellow) coolant. International Truck recommends Fuel System using only the approved coolant with the 2010 cooling packages, and will not warrant these cooling systems that have not utilized the recommended coolant. GOVERNMENT REGULATION: Diesel fuel sold for The label on the deaeration tank provides additional use in 2007 and later highway vehicles must be limited coolant/antifreeze information.
  • Page 202: Frame

    Maintenance Instructions Noise Emissions – Exterior all microbes, fuel tank draining alone will not eliminate the problem. For vehicle operators experiencing microbe growth in their fuel, the following is recommended: Instructions for Proper Maintenance 1. Drain and clean the fuel tank(s) every 12 months or In order to comply with federal exterior noise regulations, your more often.
  • Page 203: Engine Noise Shields/Blankets

    Maintenance Instructions Engine Noise Shields/Blankets Cleaning • Engine valve covers, oil pans, and block covers are made to If on-vehicle regeneration is unsuccessful at removing soot from damp out engine mechanical noise and, if needed, should the DPF, the DPF may need to be removed from the vehicle and be replaced with original equipment parts.
  • Page 204: Automatic Transmissions

    Maintenance Instructions Automatic Transmissions Periodically: • Check condition of spring leaves for evidence of fatigue, Check operation of the transmission neutral safety switch. Try to bending, or breakage. start the vehicle in all shift selector positions. The starter should ONLY operate when the shift selector is in Neutral or Park (if •...
  • Page 205: Tightening Steering Intermediate Shaft Joint Bolts

    Maintenance Instructions Ask your service technician to examine the steering mechanism. PM interval or annually, whichever occurs first. Tighten bolts to Minor adjustments could head off further problems. torque specified in the Torque Specification chart at the end of this section. DO NOT OVERTIGHTEN. Check tie rod ends, drag link ends, and kingpins.
  • Page 206: 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 207: Tire Maintenance

    Maintenance Instructions WARNING WARNING To prevent personal injury or death, always • Do not mix stud-piloted wheels or fasteners with follow these instructions when mounting tires on hub-piloted wheels or fasteners. Premature wheel wheels: failure can result in property damage, personal injury, or death.
  • Page 208: Checking Inflation

    Maintenance Instructions pressures should be checked daily and always before tire components (i.e., ply and tread separation and reduced long-distance trips. retreadability). Follow the tire manufacturer’s recommended cold inflation Underinflation is also the primary cause of blowouts. In addition, low inflation causes an increase in rolling resistance. This results pressure for the tire size, type, load range (ply rating), and axle loading typical for your operation.
  • Page 209: Loads

    Maintenance Instructions Loads Dual Tires Mixing NOTE: Never mix bias and radial tires on this vehicle. WARNING It is recommended for best overall performance that only radial Loading tires beyond their rated capacity tires be used on this vehicle. decreases tire life requiring more frequent Never mix different tire sizes or constructions on the same axle.
  • Page 210: Tire Replacement

    Maintenance Instructions 2. In a dual assembly, reverse the position of the tires if Wheel and Tire Balancing one tire wears much faster than its mate. Out-of-round or out-of-balance wheels or tires can cause vehicle 3. On the drive axle, if heel and toe wear or alternate wheel vibration and bounce, and shimmy.
  • Page 211: Irregular Wear

    Maintenance Instructions Wheels Irregular Wear If irregular wear is present, check the axle alignment, tire Wheel and Wheel Nut Maintenance and Installation pressure, wheel balance, shock and suspension component condition, and wheel bearing end play. WARNING This condition not only shortens tire life, but will adversely affect To prevent personal injury or death, always the handling of your vehicle.
  • Page 212: Wheel Nut Torque Maintenance

    Maintenance Instructions Wheel Nut Torque Maintenance WARNING Tighten and maintain wheel and rim mounting nuts to the proper • Do not mix stud piloted wheels or fasteners with hub torque. Loose nuts or overtightened nuts can lead to premature piloted wheels or fasteners. Premature wheel failure wear and possible failure of the wheel, rim, and/or mounting can result in property damage, personal injury, or death.
  • Page 213 Maintenance Instructions surfaces or the wheel clamping effectiveness will be reduced! 4. To prevent aluminum wheels from getting stuck on the hub due to corrosion, apply a thin coat of antiseize compound or disc brake corrosion control grease to the hub pilot pads only.
  • Page 214 Maintenance Instructions 3879634R1...
  • Page 215: Section 7 - Maintenance Intervals And Specifications

    Maintenance Intervals And Specifications SECTION 7 — MAINTENANCE INTERVALS AND SPECIFICATIONS Lubrication and Maintenance Intervals These intervals may be expressed in miles (kilometers), hours of operation, and/or months of operation. It is important to note All new vehicles are factory-lubricated. Once the vehicle is that in high duty cycle types of operation and/or where operating in operation, regular lubrication and maintenance intervals conditions are extremely severe (such as in deep water, mud or...
  • Page 216 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. Severe Service City < 59,000 Highway <...
  • Page 217 Maintenance Intervals And Specifications 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 – Check All Inspection Front Axle Wheel Bearing-Oil Type – Check Level A, B Suspension Fasteners / Components –...
  • Page 218 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 Axle Flange Nuts – Retorque Ride Height – Check Axle U-bolts –...
  • Page 219 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 220 Maintenance Intervals And Specifications Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3) : miles (km) / hours / months Air Brakes Air Wet Tank – Drain Water A, B Service Brakes Operation – Check A, B Parking Brakes Operation –...
  • Page 221 Maintenance Intervals And Specifications Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3) : miles (km) / hours / months Engine Engine Oil Level – Inspect A, B Fan Belt – Inspect A, B Air Filter –...
  • Page 222 Maintenance Intervals And Specifications Lubrication and Maintenance Interval — Recommended Synchronized Intervals (cont.) System Item Intervals Special Interval (3) : miles (km) / hours / months Transmission Trans Fluid, Automated/Manual – Check Level A, B Shift Selector/Linkage – Check Function A, B Neutral Start Switch –...
  • Page 223: Lubrication And Fluids Charts

    Maintenance Intervals And Specifications Lubrication and Fluids Charts Fluid Check and Fill Notes NOTE: The components requiring lubrication and fluid check CAUTION shown in this manual are typical representations. Use only recommended viscosity engine oil. Lubrication Notes Refer to the Engine Operation and Maintenance Manual for engine oil specifications.
  • Page 224: Components Requiring Lubrication

    Maintenance Intervals And Specifications Components Requiring Lubrication 1. Steering Gear 6. Steering Drag Link Ends 2. Steering Intermediate Shaft 7. Clutch Cross Shafts and Release Bearing 3. Front S-Cams and Slack Adjusters 8. Drive Shaft U-joints and Slip Joint 4. King Pin Bushings and Thrust Bearings 9.
  • Page 225: Components Requiring Fluid Check And Fill

    Maintenance Intervals And Specifications Components Requiring Fluid Check and Fill 1. Coolant Make-up Tank 6. Drive Axle Oil Fill/Level Check Plug 2. Coolant Deaeration Tank 7. Manual Transmission Oil Fill/Level Check Plug 3. Engine Oil Dipstick 8. Automatic Transmission Dipstick/Fluid Fill 4.
  • Page 226: Unit Refill Capacities

    Maintenance Intervals And Specifications Unit Refill Capacities Forward Rear Axle Model No. Liters Pints Liters Pints Front Drive Axles Meritor RS-21-160, 18.5 Model Liters Quarts RS-21-230, RS-23-160 Meritor RS-21-162 18.7 39.5 Meritor MX-10–120, MX-12–120, Dana Spicer® S23-170, 17.5 MX-14–120 S23-170D, S23-190, Meritor MX-16–120 S23-190D, S26-190, S26-190D...
  • Page 227 Maintenance Intervals And Specifications Forward Rear Forward Rear Axle Model No. Liters Pints Liters Pints Axle Model No. Liters Pints Liters Pints Dana Spicer® 14.7 Dana Spicer® 18.5 17.5 DS405P/RS405 D46-170DHP/R46-170DH Dana Spicer® 14.7 Dana Spicer® 18.5 17.5 DS405/RD405 D46-170P/R46-170 Dana Spicer®...
  • Page 228: Cooling System Refill Capacities

    Maintenance Intervals And Specifications Cooling System Refill Capacities Power Steering Systems Cooling system refill capacities vary considerably due to Steering Gear Power Steering Fluid Volume differences in engine models, variations in chassis, and body (in³/pints/liters) options, in addition to the amount of coolant remaining in the TAS-85 240/8.4/3.9* system after draining.
  • Page 229: Transmission

    Maintenance Intervals And Specifications Transmission Model Liters Pints Manual Fuller® 5 Speed: 6305A 8.8* 18.5* Fuller® 6 Speed: FS-5406N; FS-6406N; FSO-8406 19.5* International® 7 Speed: ES 56–7B; ESO 66 Spicer® 7 Speed: PS110-7B Fuller® FR—11210B —10 Speed — wet clutch 23.5* Fuller®...
  • Page 230: Tire And Rim Combinations

    Maintenance Intervals And Specifications Model Liters Pints Automatic Allison Automatic: 2500_HS, RDS P 5 Speed ** Allison Automatic: 3000_HS, EVS P, RDS P 5 & 6 Speed; ** Allison Automatic: 3500_ EVS P, RDS P 5 & 6 Speed; ** Allison Automatic: 4000_HS, EVS P, RDS P 5 &...
  • Page 231: Lift Axle System

    Maintenance Intervals And Specifications Lift Axle System Maintenance Chart Procedure Interval Check for proper brake operation Daily/Per operation Inspect for signs of structural damage, cracks or wear in all components of Daily suspension parts (arms, hangers, axle seats, etc.) Check for air leaks Daily/Per operation Check bushings for excessive wear or movement Every 30 days...
  • Page 232 Maintenance Intervals And Specifications DISC WHEELS 22 mm Flange: International®/Budd - 33 mm Across 450-500 610-678 Flats NOTE: Do not use lubrication on dry threads. Where excessive corrosion exists, a light coat of lubricant on first three threads of stud on bolt is permitted.
  • Page 233: U-Bolt Nut Torque Chart

    Maintenance Intervals And Specifications U-BOLT NUT TORQUE CHART Torque Feature Code Rear Suspension Capacity and Type lbf - ft N • m 14SAB 23,000-lb Capacity, RR, Spring, Single, with 3 Torque Rods 400-425 542-576 14SAH 18,500-lb Capacity, RR, Spring, Single Vari-Rate 370-400 502-542 14SAL...
  • Page 234 Maintenance Intervals And Specifications Torque Feature Code Front Suspension Capacity and Type lbf - ft N • m 3ACP 12,000-lb Capacity, Multileaf , Shackle Type 260-300 353-407 3ACR 18,000-lb Capacity, Multileaf , Shackle Type 260-300 353-407 3ACS 20,000-lb Capacity, Multileaf , Shackle Type 260-300 353-407 20,000-lb Capacity, Multileaf , Shackle Type, (with SBA and CAT Engine)
  • Page 235: Spring U-Bolt Checks

    Maintenance Intervals And Specifications SPRING U-BOLT CHECKS Lift Axle U-Bolt Nut Torque Chart Check U-Bolt Nuts and re-torque every 36,000 miles (57, 936 U-Bolt Size 1 1/8 km) after initial 1,000 mile re-torque. (UNF – Grade 8) Size in inches LIFT AXLE TORQUE CHARTS Min.
  • Page 236: Fuse Charts

    Maintenance Intervals And Specifications Fuse Charts The following fuse illustrations represent the fuse panel layouts. The actual vehicle fuse panels will vary depending on the vehicle options. 3879634R1...
  • Page 237: Workstar® Series Light Information

    Maintenance Intervals And Specifications WorkStar® Series Light Information Lamp Description Candlepower or Watt Bulb P/N Cab Dome Light 12 Watts 211-2 Cab Mount Clearance/Marker Light 3 CP GE193 Headlight 65 Watts GE9007 Fog Light 56 Watts VH550 Front Park/Marker/Turn Light 2356 Side Marker Light 2548...
  • Page 238 Maintenance Intervals And Specifications 3879634R1...
  • Page 239: Section 8 - Customer Assistance

    Customer Assistance SECTION 8 — CUSTOMER ASSISTANCE Service Information availability, and fee structure can be obtained by contacting your local International Truck dealer or, in the case of a National The continued premium performance of this International® Account, an International Fleet Service Manager. chassis can best be assured through proper servicing.
  • Page 240 Customer Assistance Custom Service Contracts, the most flexible aspect of the • International®, North America’s leader truck International Truck Warranty Program, can provide extended manufacturing, is also North America’s leader in warranty protection that is specifically tailored to meet each customer’s value specific requirements.
  • Page 241: Index

    Index SECTION 9 — INDEX (CONT.) Air Conditioning........... .82 ABS Connections and Sensors.
  • Page 242 Index (CONT.) (CONT.) Antilock Driving Tips..........155 Available Cabs.
  • Page 243 Index (CONT.) (CONT.) Batteries............177 Brakes (cont.) Battery.
  • Page 244 Index (CONT.) (CONT.) Center Dash Panel/Wing Panel........74 Components Requiring Fluid Check and Fill.
  • Page 245 Index (CONT.) (CONT.) Daytime Running Lights (DRL)........49 Double Clutch Procedures, Nonsynchronized.
  • Page 246 Index (CONT.) (CONT.) Engine Idle Shutdown Timer (Optional)......96 Engine (cont.) Air Induction System......... . .180 System Operation.
  • Page 247 Index (CONT.) (CONT.) Fueling Precautions..........116 Fifth Wheel Operation (cont.) Hook-Up.
  • Page 248 Index (CONT.) Integral Digital Display Detailed Information (cont.) Left Engine Compartment.........18 Outside Temperature and Compass Displays (Optional).
  • Page 249 Index (CONT.) (CONT.) Line Set Ticket...........2, 12 Main Instrument/Control Panel (cont.) Load Capacity Chart for 13,200 Pound Steerable Lift Axle.
  • Page 250 Index (CONT.) MaxxForce® 11 and 13 Engine Brake With Eaton Operating Instructions..........103 AutoShift®/UltraShift®...
  • Page 251 Index (CONT.) (CONT.) Operating Instructions (cont.) Operating Instructions (cont.) Transfer Case..........137 Fuel and Lubricant Additives.
  • Page 252 Index (CONT.) (CONT.) Outside Temperature Reading........68 Operating Instructions (cont.) Manual Transmissions.
  • Page 253 Index Raising the Hood...........14 Safety Recalls and Authorized Field Changes.
  • Page 254 Index (CONT.) (CONT.) Switches............49, 75 Starting Procedures (cont.) Engine ShutDown.
  • Page 255 Index (CONT.) (CONT.) Tire Warnings........... . .194 Towing Instructions (cont.) Tires.
  • Page 256 Index (CONT.) (CONT.) Transmission (cont.) Vehicle Identification (cont.) Shifting with Synchronized Transmission....122 Engine Serial Number......... .12 Troubleshooting.
  • Page 257 Index (CONT.) (CONT.) Washing and Waxing..........176 Window Lockout Function.
  • Page 258 Index 3879634R1...

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