Navistar WorkStar 7500 Manuals

Manuals and User Guides for Navistar WorkStar 7500. We have 1 Navistar WorkStar 7500 manual available for free PDF download: Operator's Manual

Navistar WorkStar 7500 Operator's Manual

Navistar WorkStar 7500 Operator's Manual (258 pages)

Brand: Navistar | Category: Trucks | Size: 2 MB

Table of Contents

Table of Contents
5
Section 1 - Foreword

13
Section 2 - Model Description

21
- Introduction
  21
  - Available Models
    21
  - Available Cabs
    23
  - Standard Cab
    23
  - Extended Cab
    23
  - Crew Cab
    23
  - Vehicle Identification
    24
  - Vehicle Identification Number (VIN)
    24
  - Feature Codes
    24
  - Engine Serial Number
    24
  - Line Set Ticket
    24
  - Exterior Components
    25
  - Cab Entry and Exit
    26
  - Tilt Hood
    26
  - Raising the Hood
    26
  - Lowering the Hood
    26
Section 3 - Inspection Guide

27
- Introduction
  27
  - General Information
    27
- Vehicle Inspection
  28
  - Preparation
    28
  - Exterior Lights Check
    28
  - Left Side Cab Area
    29
  - Left Engine Compartment
    30
  - Left Front of Vehicle
    31
  - Front of Vehicle
    34
  - Right Front of Vehicle
    35
  - Right Engine Compartment
    37
  - Right Side of Cab
    38
  - Right Side under Vehicle
    39
  - Right Rear of Vehicle
    40
  - Rear of Vehicle
    42
  - Left Rear of Vehicle
    43
  - Fifth Wheel and Coupling Area
    45
  - Cab Interior Inspection
    46
Section 4 - Controls/Features

49
- Introduction
  49
  - Electrical
    49
  - Electrical System
    49
- Dash Components
  50
- Overhead Console
  50
- Main Instrument/Control Panel
  51
  - Instrument Panel Gauge Cluster
    51
  - Warning Indicators
    53
  - Gauges
    55
  - Instrument Panel Gauge Cluster Alarms
    57
  - Direct Drive Warning Indicators
    59
  - Integral Digital Display
    59
  - Switches
    61
  - Headlights
    61
  - Daytime Running Lights (DRL)
    61
  - Lights on with Wipers
    61
  - Park Lights
    61
  - Marker Interrupt
    62
  - Panel Lighting
    62
  - Dome Lighting
    62
  - Courtesy Lights
    62
  - Optional Instrument Panel Gauge Cluster Compass
    64
  - Calibration Procedure
    64
  - Compass Declination Zone Set Procedure
    64
  - Compass Directional Calibration Procedure
    67
  - Integral Digital Display Detailed Information
    68
- Steering Wheel Controls
  81
- Center Dash Panel/Wing Panel
  86
  - Switches
    87
- Auxiliary Gauge/Switch Package (AGSP) (Optional)
  90
  - Panel Component Arrangements (Optional)
    90
- Climate Control
  92
  - Air Conditioning
    94
  - Dehumidification
    95
- Door and Window Controls
  95
  - Door Lock/Unlock
    95
  - Cab Doors and Locks
    95
  - Remote Keyless Entry Operation (Optional)
    96
  - Door Opening/Unlock
    97
  - Lock/Unlock from Interior
    97
  - Automatic Door Lock Function
    98
  - Windows
    98
  - Manual Operation
    98
  - Power Operation
    98
  - Window Lockout Function
    98
  - Mirror Controls
    98
  - Vent Window
    99
- Driver Reward
  99
Section 5 - Operation

101
- Operation Safety
  101
  - Cab Controls
    102
- Seat Belts
  103
  - General
    103
  - Operation
    104
  - Care of Seat Belts
    105
- Seats
  105
  - Extended Cab Bunk (Optional)
    105
- Starting Procedures
  106
  - Engine Starting
    106
  - After the Engine Starts
    107
  - Engine Shutdown
    107
  - Shut-Down Warning Indicator or Beeper
    107
  - Engine Idle Shutdown Timer (Optional)
    108
  - System Operation
    108
  - Theft Deterrent System (Optional)
    108
  - Theft Deterrent Code Entry Procedures
    109
  - Emergency Starting Using Jumper Cables
    112
  - Cold Weather
    112
  - Cold Weather Starting
    113
  - Cold Weather Operation
    113
  - Winter/Engine Intake Operation
    113
  - Engine Idling
    113
  - Winter Front Usage
    114
  - Hot Weather Operation
    114
  - Starting a Turbocharged Vehicle on a Grade
    114
  - Proper Starting Procedure
    114
- Operating Instructions
  115
  - Steering
    115
  - Tilt Steering Column
    115
  - Adjustable Tilt/Telescoping Steering Column
    116
  - General
    116
  - Electrical
    117
  - Electrical System
    117
  - Alternator
    118
  - Ammeter
    118
  - Battery
    118
  - Battery Disconnect Switch
    119
  - Circuit Breakers, Fuses, and Fusible Links
    119
- Charge Air Cooler
  120
- Engine
  120
- Engine Brake, Retarder (Optional)
  120
- Autoshift®/Ultrashift® Transmissions Special
  121
- Driver Instructions
  121
- Engine Brake System Operation
  121
- Maxxforce® 11 and 13 Engine Brake with Eaton
  121
- Operational Modes
  121
- ABS Operation
  122
- Automatic Transmission Operation
  122
- Maxxforce® Engine Features
  122
- Certified Clean Idle
  123
- Engine Warning/Protection System (EWPS)
  123
- Self Diagnostics
  123
- (08Wwj)
  124
- Air Compressor Cycling
  124
- Optional Coolant Warning Level System - 3 Way
  124
- Optional Engine Protection System - 3 Way (08WPP)
  124
- Cooling System
  125
- Antifreeze
  126
- Engine Oil
  126
- Additional Unsafe Practices
  127
- Engine Performance Problems
  127
- Fuel
  127
- Hazards of Diesel Fuel/Gasoline Blends
  127
- Ultra Low Sulfur Diesel Fuel Requirements
  127
- Unacceptable Fuel Blends
  127
- Fuel and Lubricant Additives
  128
- Fueling Precautions
  128
- Fueling Procedures
  128
- Reserve Fuel
  128
- Exhaust Diesel Particulate Filter Regeneration
  129
- Parked Regeneration Procedure
  131
- Regeneration Inhibit Switch
  131
- Engaging the Clutch
  132
- Manual Transmissions
  132
- Three-Position Regeneration Inhibit Switch
  132
- Transmission
  132
- Two-Position Regeneration Inhibit Switch
  132
- Clutch Brake (Vehicles with Nonsynchronized Transmission) - Vehicle Not Moving
  133
- Double Clutch Procedures, Nonsynchronized
  133
- And Shifter
  134
- Clutch Precautions
  134
- Operation of the Eaton Autoshift® Transmission
  134
- Shifting with Nonsynchronized Transmission
  134
- Shifting with Synchronized Transmission
  134
- Allison Transmission with "P" - (Park) Park Pawl Mechanism or "PB" - Parking Brake Position
  135
- Allison Transmissions
  135
- Automatic Transmissions
  135
- Eaton Ultrashift® Transmissions (Optional)
  135
- Parking the Vehicle
  136
- Air Parking Brake or Power Parking Brake
  137
- Controls
  137
- Manual Parking Brake
  137
- Preparing to Drive the Vehicle
  137
- Allison Generation IV T-Bar Gearshift Control
  138
- Torque Lock
  138
- Operation of the Allison Generation IV Push-Button
  139
- Shift Selector
  139
- Operation of the Column-Mounted Shifter
  140
  - Main Transmission Controls
    140
  - Backup Alarm
    141
  - Auto Neutral
    141
  - Power Take off Control
    143
  - Automatic Transmission Operating Temperature
    143
  - Rear Drive Axles
    144
  - Locking Differentials
    144
  - Tandem Axle Power Divider Lock (PDL) Control
    144
  - Driver-Controlled Differential Lock
    145
  - Controlled Traction Differential
    146
  - Locking Differential (Optional)
    146
  - Two Speed Rear Axle
    147
  - Axle Shift Only
    147
  - Split Shifting
    148
  - Axles and Suspensions
    148
  - Gross Weight (Axle - Vehicle)
    148
  - Axle Operating Temperature
    148
  - Front Axle (4X4, 6X6)
    148
  - Transfer Case
    149
  - Operation
    149
  - International® Ride Optimized Suspension (IROS)
    151
  - (Optional)
    151
  - Air Suspension Dump (ASD) Switch (Optional)
    151
  - Air Suspension System Faults
    152
  - Axle and Suspension Conversions
    152
- Lift Axle Options
  152
  - Lift Axle Locations
    153
  - Lift Axle Types
    153
  - Lift Axle Controls
    154
  - Lift Axle System Operation
    157
- Brakes
  159
  - Downhill Operation
    159
  - Air Brakes
    160
  - Indicator
    161
  - Brake Application
    161
  - Parking Brake
    161
  - Parking Brake Reset
    162
  - Reservoir Moisture Draining
    163
  - Air Dryer
    163
  - Trailer Brake Hand Control
    163
  - Trailer Air Supply and Parking Brake Modular Controls
    164
  - Parking Brake Indicator
    165
  - Parking Brake Alarm
    165
  - Antilock Brake System (ABS)
    165
  - ABS Operation
    166
  - ABS Self-Check
    166
  - Antilock Driving Tips
    167
  - Air Brake Bendix® ABS-6
    167
  - Core ABS Functions
    167
  - Traction Control (if Equipped)
    168
  - ATC System Check
    168
  - ATC off ROAD or MUD/SNOW Switch
    168
  - Stability Control Systems - Bendix® ESP
    169
- Bobtail Proportioning System
  170
- Towing Instructions
  170
  - Towing Vehicle with Front Wheels Suspended
    171
  - Lock
    172
  - Removing Axle Shafts before Towing
    172
  - Installing Axle Shafts
    172
  - Towing Vehicle with Rear Wheels Suspended
    173
- Tractor-Trailer Connections
  173
  - Connecting/Disconnecting a Trailer to a Vehicle with
    174
  - Air Suspension
    174
  - Fifth Wheel Operation
    174
  - Fifth Wheel Slide Switch (Optional)
    174
  - Hook-Up
    175
  - Un-Hook
    175
Section 6 - Maintenance Instructions

177
- Introduction
  177
- Maintenance Guidelines
  177
- Chassis Lubrication
  179
- Supporting Your Vehicle for Service
  179
- Air Conditioning Service Checks
  180
  - HVAC Filters
    180
  - Side Access HVAC Filter
    180
  - Front Access HVAC Filter
    181
  - Recirculation Filters
    181
- Axles
  182
  - Front Axle
    182
  - Inspection and Lubrication
    182
  - Normal Maintenance
    182
  - Alignment
    183
  - Front Drive Axle and Transfer Case (Optional)
    183
  - Inspection and Lubrication
    183
  - Rear Axle - Inspection and Lubrication
    183
- Lift Axle System
  183
- Brakes
  184
  - General Information
    184
  - Air Brakes
    185
  - Inspection and Adjustment
    185
  - Air Dryer
    186
  - General Information
    186
  - Desiccant Filter
    187
  - Purge Valve
    187
  - Heater
    187
  - Air Reservoir/Tanks Moisture Draining
    187
  - ABS Connections and Sensors
    188
- Cab
  188
  - Care of Vehicle
    188
  - Washing and Waxing
    188
  - Bright Metal Care
    188
  - Upholstery Care
    188
  - Exposed Rubber and Unpainted Plastic Parts
    188
- Clutch
  189
  - Pedal Free-Travel
    189
- Electrical
  189
  - Batteries
    189
  - Battery Cables
    190
  - Electrical Charging and Starting System Test
    190
  - Terminal Inspection-Cleaning-Corrosion Protection
    190
  - Accessory Feed Connections
    191
  - Fuses and Relays
    191
- Engine
  191
  - General
    191
  - Engine Fluids and Contaminated Material
    192
  - Scheduled Maintenance
    192
  - Air Induction System
    192
  - Air Restriction Gauge
    193
  - Air Cleaner Element Service
    194
  - Troubleshooting
    196
  - Charge Air Cooler and Radiator Core Inspection
    197
  - And Cleaning
    197
  - Inspection and Cleaning
    197
  - Cooling System
    197
  - Coolant Level
    197
  - Filling Instructions
    198
  - Filling Instructions (Maxxforce® 11 and 13 Engines)
    199
  - Coolant and Optional Coolant Filter
    200
  - Antifreeze
    201
  - Fan Clutch
    201
  - Fuel System
    201
  - Fuel Tank Draining and Cleaning
    201
  - Frame
    202
  - Tow Hooks, Tow Pins, and Pintle Hooks
    202
- Noise Emissions - Exterior
  202
  - Instructions for Proper Maintenance
    202
  - Air Intake System
    202
  - Body
    202
  - Cooling System
    202
  - Engine Noise Shields/Blankets
    203
  - Exhaust System
    203
- Diesel Particulate Filter (DPF)
  203
  - Regeneration
    203
  - Cleaning
    203
- Transmission
  203
  - Neutral Start Switch
    203
  - Manual/Automated Manual Transmissions
    203
  - Automatic Transmissions
    204
- Drive Shafts
  204
- Steering
  204
  - General Information
    204
  - Tightening Steering Intermediate Shaft Joint Bolts
    205
  - Lubrication Points
    205
  - Power Steering
    206
- Suspension (Air and Steel Springs)
  204
- Tires
  206
  - Tire Warnings
    206
  - Tire Maintenance
    207
  - Checking Inflation
    208
  - Underinflation
    208
  - Inspection
    208
  - Loads
    209
  - Dual Tires Matching
    209
  - Dual Tires Mixing
    209
  - Rotation
    209
  - Rotation Is Advisable
    209
  - Tire Replacement
    210
  - Wheel and Tire Balancing
    210
  - Wear
    210
  - Irregular Wear
    211
  - Use of Tire Chains
    211
- Wheels
  211
Section 7 - Maintenance Intervals and Specifications

215
- Lubrication and Maintenance Intervals
  215
  - Maintenance Intervals
    215
- Lubrication and Fluids Charts
  223
  - Components Requiring Lubrication
    224
  - Components Requiring Fluid Check and Fill
    225
- Unit Refill Capacities
  226
  - Front Drive Axles
    226
  - Rear Axle Unit Refill Capacities
    226
  - Cooling System Refill Capacities
    228
  - Crankcase and Oil Filters
    228
  - Power Steering Systems
    228
  - Transfer Case
    228
  - Transmission
    229
- Tire and Rim Combinations
  230
  - Approved Tire and Rim Combinations
    230
- Lift Axle System
  231
- Torque Specifications
  231
  - Disc Wheel Torque Chart
    231
  - U-Bolt Nut Torque Chart
    233
  - Spring U-Bolt Checks
    235
  - Lift Axle Torque Charts
    235
- Fuse Charts
  236
- Filter List
  237
Section 8 - Customer Assistance

239
- Workstar® Series Light Information
  237
- International Truck Warranty Program
  239
- Service Information
  239
- Index
  241

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