International ProStar Operator Manual
NOTICE CALIFORNIA
ProStar+ Models December 2010
PROSTAR
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.
Important
Proposition 65 Warning
Diesel engine exhaust and some of its
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.
Wash hands after handling.
®
+ Series 3878859R2
Printed in the United States of America
© 2010 Navistar, Inc. All Rights Reserved
Operator’s Manual – PROSTAR®+ Series
IMPORTANT
IT IS IMPORTANT THAT THE VEHICLE IDENTIFICATION NUMBER (VIN), AND COMPONENT FEATURE CODE AND SERIAL
NUMBERS BE RECORDED. THESE NUMBERS ARE REQUIRED TO OBTAIN INFORMATION PERTINENT TO THIS VEHICLE.
VIN (VEHICLE IDENTIFICATION
NUMBER) LOCATION
LoneStar®, 9000i, ProStar®+, TranStar®,
®
PayStar
TerraStar™ Series: Located left door
opening, rear post
, WorkStar®, DuraStar®, and
COMPONENT IDENTIFICATION
NUMBERS
Component Feature Codes appear on the
vehicle line set ticket.
Component serial numbers appear on the
components.
Feature Code: Serial Number:
FRONT AXLE
REAR AXLE
TRANSFER CASE
TRANSMISSION
ENGINE
ENGINE SERIAL NUMBER LOCATION
MAXXFORCE®: Stamped on pad – right side
of the crankcase, below cylinder head
WORLD HEADQUARTERS
Navistar, Inc.
4201 Winfield Road
Warrenville, Illinois 60555 USA
INTERNATIONAL INTERNET SITE
internationaltrucks.com
SALES REGIONS
MIDWEST
Navistar, Inc.
4201 Winfield Road
PO Box 1488
Warrenville, Illinois 60555
630-753-5900
NORTHEAST
Navistar, Inc.
Cherry Tree Corporate Center
535 Route 38 East, Suite 300
Cherry Hill, New Jersey 08002
856-486-2300
SOUTHEAST
Navistar, Inc.
2400 Commerce Avenue
Building 1100, Suite 100
Duluth, Georgia 30096
678-584-2700
SOUTHWEST
Navistar, Inc.
2595 Dallas Parkway, Suite 203
Frisco, Texas 75034
972-377-1200
WEST
Navistar, Inc.
3017 Douglas Boulevard, Suite 300
Roseville, California 95661
916-774-7526
CANADA
Navistar Canada, Inc.
5500 North Service Road – 4th Floor
Box 5337
Burlington, Ontario L7L 5H7
905-332-3323
MEXICO
Navistar Mexico SA DE CV
Ejército Nacional 904 – 8° Piso
Col, Palmas Polanco 11510 Mexico D.F.
525-262-6666
BRAZIL
International Caminhões do Brasil
Av. Carlos Gomes, 466 conj 1002
Bairro Auxiliadora – CEP 90480-000Porto Alegre/RS
55 51 4009-5800
CUSTOMER ASSISTANCE CENTER
1-800-448-7825 (1-800-44-TRUCK)
Navistar, International, the International Diamond logo, with and without endorsement, ProStar, 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.
3878859R2
Operator’s Manual – ProStar®+Series
Service P ublications
An Operator’s Manual is shipped with this vehicle for
customer use. Information on the purchase of other available
service publications for this vehicle can be found on the
internationaltrucks.com Web site, or by contacting your local
International dealer.
It is the policy of Navistar, Inc. to improve its products whenever
it is possibleandpractical 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.
Operator’s Manual – ProStar
Operator’s Manual
Form No. 3878859R2
+Series
®
© 2010 Navistar, Inc. All rights reserved.
3878859R2 Printed in the United States of America
Operator’s Manual – ProStar®+Series
Printed in the United States of America 3878859R2
Table of Contents
Section 1 – Foreword
Preface...............................................................1
Cautions and Warnings.............................................1
AssistanceGuide............................................... .....1
Component Code Numbers........................................2
Line SetTicket..................................................2
VehicleStorageInstructions........................................2
Storage Duration - One Month or Less.......................2
Storage Duration - Over One Month ..... ....................3
Storage Facilities ............................................ ...4
Exterior Noise Emissions...........................................4
Tampering with Noise Control System Prohibited................4
Emission ControlSystems..........................................5
MaintenanceRecord –NoiseControl.............................5
Reporting Safety Defects...........................................5
U.S. Registered Vehicles....... ................................5
Canadian Registered Vehicles................................5
Safety Recallsand AuthorizedField Changes...................5
Customer Security Guide for InternationalTrucks.. .............6
Optional Diamond Logic® Electronic Application Solutions.....8
Section 2 – Model Description
Introduction...........................................................9
Available Models..................................... ................9
VehicleIdentification.................................... ...........12
Vehicle Identification Number (VIN)............. ............12
Feature Codes.................................................12
EngineSerial Number........................................13
LineSet Ticket................................... ..............13
Exterior Components..............................................14
Cab Entry andExit..... ............................................18
Hood.................. ...............................................18
Raisingthe Hood............................................ ..18
Lowering the Hood............................................19
Tilt-Away Bumper..................................................19
Lowering the Tilt-Away Bumper..............................20
Raisingthe Tilt-AwayBumper................................20
Luggage Box Access..............................................21
Driver and Passenger Side............ .......................21
Chassis Skirts......................................................21
Removal........................................................21
Installation.....................................................22
Extended Chassis Skirts.......................... ...........22
Section 3 – Inspection Guide
Introduction.........................................................23
GeneralInformation......................................... ..23
Tractor Inspection..................................................24
Preparation................ ....................................24
Exterior Lights Check................................... .....24
LeftSideCab Area............................................25
Left Engine Compartment....................................26
Left Front of Tractor...........................................27
Front of Tractor................................................29
RightFront of Tractor.........................................30
RightEngineCompartment..................................32
RightSide of Cab............... ..............................33
Right Side Under Vehicle................................... ..34
Right Rear of Tractor....... ...................................35
Rearof Tractor.................................................37
LeftRearof Tractor............................................38
Fifth Wheel and Coupling Area..............................40
3878859R2 i
Table of Contents
Cab InteriorInspection.......................................41
Section 4 – Controls/Features
Introduction.........................................................43
GeneralInformation......................................... ..43
Electrical.......................................................43
ElectricalSystem............................................ ..43
Dash Components.................................................44
OverheadConsole.................................................45
Instrument Panel GaugeCluster.................................46
Warning Indicators............................................48
Gauges........................ .................................50
Instrument Panel Gauge Cluster Alarms...................52
Direct DriveWarningIndicators..............................54
Integral Digital Display........................................54
General Text and Warning Messages.......................56
Optional Instrument panel gauge cluster Compass
Calibration Procedure............ .............................57
Compass Declination Zone Set Procedure.................57
Compass DirectionalCalibration Procedure...............60
Integral Digital DisplayDetailedInformation............... .62
Switches........................................................75
Headlights.............. ........................................75
Daytime Running Lights(DRL)..............................75
Lights On With Wipers.................................... ....75
Park Lights.....................................................75
Panel Lighting............ .....................................75
Dome Lighting.................................................76
Courtesy Lights................................................76
Steering Wheel Controls..........................................77
Cruise Control.................................................78
SteeringColumn andSwitches...................................78
Center Dash Panel/Wing Panel...................................81
Gauges......................... ................................82
Switches........................................................82
ClimateControl........................ ........................86
Air Conditioning...............................................88
Dehumidification................... ............................89
ElectronicVehicle Monitoring.....................................89
BaseDisplay................................................. ..89
Premium Display..............................................89
SmartWave® Display..............................................89
Door and Window Controls...... .................................90
Door Lock/Unlock.............................................90
Cab Doors and Locks. ........................................90
Remote Keyless Entry Operation (Optional)...............90
Lock/Unlock From Interior....................................91
Automatic Door Lock Function...............................91
Driver/PassengerWindows..................................91
Manual Operation.............................................91
Power Operation......................................... .....92
Window Lockout Function....................................92
Mirror Controls..... ............................................92
VentWindow.......................... .........................92
Eaton VORAD Collision Warning System (Optio n al)...........93
SystemDescription...........................................93
Driver Reward.................................................93
Section 5 – Sleeper Features
Introduction.........................................................95
GeneralInformation......................................... ..95
Main Features.................................................95
ii 3878859R2
Table of Contents
Lighting..............................................................97
DomeLight.......................... ...........................97
Reading Lights................................................97
FloorLights....................................................97
AccentLights..................................................97
Sleeper Control Panel.............................................98
GeneralInformation........................................ ...98
AccentLightDimmer Switch.................................99
AccentLightSwitch...........................................99
Sleeper Dome/Floor Light Switch...........................99
EngineControl Switch........................................99
Manual Climate Controls................................ ....100
Electronic ClimateController...............................100
Power Receptacle............... ............................101
Radio Remote Control......................................101
Remote Power Inverter Panel..............................101
Windows.......... .................................................102
General Information.........................................102
BunkRestraint System...........................................103
General Information.........................................103
Adjustable Belts..............................................103
Restraint Webbing System.................................103
Lower Bunk........................................................105
General Information.........................................105
UpperBunk.......................................................106
General Information.........................................106
EnteringThe Upper Bunk................... ................107
ExitingThe Upper Bunk......................... ............108
Cabinets/Storage.................................................109
General Information.........................................109
Cabinets...........................................................110
Refrigerator Cabinet...................................... ...110
Horizontal Refrigerator......................................111
DresserCabinet.......... ....................................111
TowerWardrobe Cabinet....................................112
Rear Wardrobe Cabinet.....................................113
Airline Cabinets..............................................114
ConvenienceFeatures...........................................115
General Information.........................................115
Sleeper Curtain..............................................115
Television Mount.............................................115
Power Inverter................................................115
Power Sockets...............................................115
Speakers......................................................115
Floor Covering...............................................115
Sleeper Fan..................................................115
Section 6 – Operation
Operation Safety........................................ ..........117
General Information.........................................117
Cab Controls.................................................118
Seat Belts.........................................................118
General Information.........................................118
General Information.........................................119
Operation.....................................................119
Care of Seat Belts...........................................120
Seats...............................................................121
General Information.........................................121
Starting Procedures..............................................123
General Information.........................................123
EngineStarting..............................................123
After the EngineStarts......................................124
EngineShutdown............................................124
3878859R2 iii
Table of Contents
Emergency Starting....................................... ..124
ColdWeather.................................................125
General Information.........................................125
ColdWeather Starting....... ................................125
Cold WeatherOperation................... .................126
Engine Idling .................................................126
Engine Idle Shutdown Timer (Optional)...................127
Winter Front Usage..........................................127
Hot WeatherOperation......................................127
Operating Instructions..................................... .......128
General Information.........................................128
Steering...................................................... .128
Adjustable Steering Column................................129
General Information.........................................129
Electrical.. ...................................... ..............130
Alternator.....................................................130
Battery........................................................130
BATTERY ON Indicator........... ..........................131
Circuit Breakers, Fuses and Fusible Links................131
ElectricalLoad Control andShedding (ELCS)............132
Engine........................................................132
ChargeAir Cooler................................. ..........132
Electronic Engine Controller................................133
Engine Brake........ ...................................... ...133
MaxxForce® 11, 13 and 15 Engine Brake With
Eaton AutoShift®/UltraShift® Transmissions
Special Driver Instructions..................................133
MaxxForce® Engine Features..............................134
Certified CleanIdle..........................................134
SelfDiagnostics..............................................134
Air Compressor Cycling.....................................135
Cooling System..............................................135
EngineOil....................................................136
EnginePerformance Problems.............................136
Fuel............................................................137
Ultra Low SulfurDiesel Fuel Requirements...............137
Unacceptable Fuel Blends..................................137
Hazards of Diesel Fuel/Gasoline Blends. .................137
Additional Unsafe Practices................................137
Fuel and Lubricant Additives...............................137
FuelingProcedures.................................... ......137
Fueling Precautions.........................................138
Reserve Fuel.................................................138
Exhaust Diesel Particulate Filter Regeneration...........139
Parked RegenerationProcedure...........................141
Regeneration Inhibit Switch................................141
Two-Position RegenerationInhibit Switch.................142
Three-Position Regeneration Inhibit Switch...............142
Transmission.................................................142
Manual Transmissions.......................................142
Engaging the Clutch.........................................143
Hydraulic Clutch ActuationSystem........................144
Double Clutch Procedures..................................145
Clutch Precautions..... .....................................145
Eaton AutoShift® Transmissions(Optional)...............146
Eaton UltraShift® Transmissions (Optional)..............148
Clutch Brake..................................................148
Power Take-off Control......................................148
Rear Axles ...................................................148
Locking orLimited Slip Differentials.......................148
Tandem Axle Power Divider Lock (PDL) Control.........149
Driver ControlledDifferential Lock.........................150
Rear Suspension............................................150
Rear AirRide Suspension..................................150
iv 3878859R2
Table of Contents
RearAir Suspension AirDump.............................150
Air Suspension SystemFaults..............................151
Brakes.............................................................151
General Information.........................................151
DownhillOperation..........................................152
Air Brakes.....................................................152
General Information.........................................152
Air Gauge, Low Air Pressure Beeper and Warning
Indicator.......................................................153
Reservoir MoistureDraining................................153
BrakeApplication............................................154
Parking Brake................................................154
Parking Brake Reset.............................. ...........155
Parking BrakeAlarm................................. .......155
Air Dryer......................................................155
Trailer Brake HandControl. .................................155
Trailer Air Supply and ParkingBrake Modular Controls...156
Parking Brake Indicator ............. ........................157
Bobtail Proportioning System..............................157
Antilock BrakeSystem (ABS)...............................158
General Information.........................................158
ABS Operation...............................................158
ABS Self Check..............................................159
Antilock Driving Tips.........................................159
AutomaticTraction Control(ATC) System .....................159
General Information.........................................159
ATC System Check..........................................160
ATC OFF ROAD or MUD/SNOW Switch..................160
Stability Control Systems – Bendix® RSP/WABCO
RSC/Bendix ESP............................................160
Towing Instructions...............................................162
Tow Hooks....................................................163
Towing Vehicle With Front Wheels Suspended...........164
Towing Vehicles With Driver Controlled Differential
Lock...........................................................164
Removing Axle Shafts Before Towing.............. .......164
Installing Axle Shafts........................................165
TowingVehicle With Rear Wheels Suspended...........165
Tractor-Trailer Connections......................................166
Connecting/Disconnectinga Trailer to a Vehiclewith
Air Suspension................ ...............................166
Fifth Wheel Operation.......................................166
Fifth Wheel SlideSwitch(Optional)........................167
Hook-Up......................................................167
Un-Hook......................................................168
Fifth Wheel JawUnlock Control ...........................168
Fifth Wheel JawMonitoring................................169
Section 7 – Maintenance Instructions
Introduction........................................................171
MaintenanceGuidelines.........................................171
SupportingYour Vehicle for Service............................173
Chassis Lubrication..............................................173
Air Conditioning Service Checks................................174
HVAC Filters..................................................174
SideAccess HVACFilter....................................174
Front Access HVACFilter...................................175
Recirculation Filters.........................................175
Sleeper HVACFilter.........................................176
Axles......................................... ......................176
FrontAxle.. ...................................................176
Inspectionand Lubrication...................... ............176
Normal Maintenance........................................177
3878859R2 v
Table of Contents
Alignment.................... .................................177
Rear Axle ....................................................177
Inspectionand Lubrication...................... ............177
LockingDifferential..........................................178
Brakes.............................................................178
General Information.........................................178
Air Brakes.....................................................179
Inspection and Adjustment.................................179
Air Dryer......................................................180
General Information.........................................180
Desiccant Filter..............................................181
Purge Valve..................................................181
Heater........................................... ..............181
Air Reservoir/Tanks MoistureDraining....................181
ABSConnectionsand Sensors............................182
Cab.................................................................182
Careof Vehicle........... ....................................182
Washingand Waxing........................................182
Bright MetalCare............................................182
Upholstery Care.............................................182
Exposed Rubber and Unpainted Plastic Parts............182
Clutch....................... ...................................... .183
Pedal FreeTravel............................................183
Hydraulic Clutch.............................................183
Electrical...... .....................................................184
Batteries.....................................................184
BatteryCables...............................................185
Electrical Charging and Starting System Test............185
Terminal Inspection-Cleaning-Corrosion Protection......185
Accessory Feed Connections..............................186
Fuses andRelays............................................186
Engine.............................................................186
General Information.........................................186
Engine fluids andcontaminated material..................187
Scheduled Maintenance ....................................187
Air Induction System........................................187
Air Restriction Gauge.......................................188
Air Cleaner Element Service...............................189
Troubleshooting..............................................191
Charge Air Cooler And Radiator Core Inspection
And Cleaning............................. ....................192
Inspection and Cleaning........ ............................192
Cooling System..............................................192
Coolant Level Check........................................192
Filling Instructions...........................................192
Coolant and OptionalCoolant Filter.......................194
Coolant Concentration Freeze Point.......................194
Antifreeze.............. .......................................194
Fan Clutch....................................................194
Fuel System..................................................195
Fuel Tank Draining and Cleaning..........................195
Crankcase VentilationFilter.................................195
Frame... ....................................... ....................195
Noise Emissions –Exterior..................... .................196
Instructions for Proper Maintenance.......................196
Air Intake System............................................196
Body.............. .............................................196
Cooling System..............................................196
Engine Noise Shields/Blankets. ............................196
ExhaustSystem..............................................196
Diesel Particulate Filter (DPF)..................................196
Regeneration............................ .....................196
Cleaning......................................................197
DriveShafts.......................................................197
vi 3878859R2
Table of Contents
Suspension (Airand Steel Springs)............................197
Front Suspension............................................197
Rear Suspension............................................198
Steering............................................................198
General Information.........................................198
Tightening Steering Intermediate Shaft Joint Bolts......198
LubricationPoints............................................199
Power Steering...............................................199
Tires................................................................199
Tire Warnings................................................199
Tire Maintenance............................................201
Checking Inflation............... .............................201
Underinflation................................................201
SmartWave® Tire Pressure Monitoring System
(TPMS)........................................................202
Inspection.............. .......................................202
Loads.........................................................203
Dual TiresMatching.........................................203
Dual TiresMixing......... ...................................203
Rotation...................................................... .203
Rotation Is Advisable........................................203
TireReplacement........ ....................................204
Wheel and TireBalancing..................................204
Wear..........................................................204
Irregular Wear..... ........................................ ...205
Use of TireChains...........................................205
Wheels.............................................................205
Wheel and Wheel Nut Maintenance and Installation. ....205
Wheel NutTorque Maintenance. ...........................206
Hub-PilotedWheelInstallation Procedures...............206
Transmission.................................................208
Section 8 – Maintenance Intervals and
Specifications
Lubrication and Maintenance Intervals........................209
Maintenance Intervals........................ ...............209
Lubrication and FluidsCharts...................................217
Components Requiring Lubrication........................218
Components Requiring Fluid Checkand Fill..............219
Unit Refill Capacities.............................................220
Cooling System Refill Capacities..........................220
Crankcase andOil Filters...................................220
Hydraulic Clutch System....................................220
Power Steering Systems....................................220
Transmission.................................................221
Rear Axle UnitRefillCapacities............................222
Lubricant andSealerSpecifications............................223
TorqueSpecifications............................................227
U-Bolt NutTorque Chart.................... ................227
Disc Wheel Nut Torque Chart..............................228
FuseCharts..... ................................... ...............228
TypicalInterior Fuse Panel Layout.........................229
Typical Luggage Compartment Fuse Panel Layout......230
ProStar
Filter List......................................................232
+ Series Light Information.......... ..............231
®
Section 9 – Customer Assistance
Service Information...............................................233
International Truck Warranty Program..........................233
3878859R2 vii
Table of Contents
Section 10 – Index
Index...............................................................235
viii 3878859R2
SECTION 1 — FOREWORD
Foreword
Preface
Your vehicle has been engineered and manufactured so that it
can provide economical and trouble-free ser vice. However, it is
the owner’s responsib ility to see that the vehicle receives proper
care and maintenance.
Making modifications to various parts, components, and
systems of your vehicle, such as brake, suspension, and
steering systems, can adversely affect the quality and relia bility
of your vehicle. Such modifications must be avoided.
Cautions and Warnings
Throughout this manual, you will find Cautions and Warnings:
WARNING
Warnings advise you of hazards, the
consequences, and what to do to prevent
them, not only to prevent damage to your vehicle
or property, but to help prevent situations and
occurrences, which could result in personal
injury or death.
CAUTION
Cautions will advise you of the proper care to
be taken to prevent damage to your vehicle or
property.
Study this manual carefully. Do not o perateyour vehicle until you
are completely familiar with the contents of this manual. Always
retain this manual in your vehicle for reference. If you sell the
vehicle, make sure the manual goes with it.
Assistance Guide
When parts are required, always provide the unit code number,
vehicle model, and vehicle serial number. Request the
salesperson to assist you in obtaining this information upon
delivery.
For information not given in this manual, or if you require
services of trained service personnel, we urge you to contact a
nearby International dealer or phone 1-800-44-TRUCK (87825)
for assistance.
Every customer is entitled to the best service, both from the
product itself and from the firm that sells and services that
product.
If,forany reason, you do not feel youarereceivingtheseservices
in connection with the operation of your vehicle or the sales
transaction, you should return to your sellingdealer,sothatthese
matters can be corrected to your satisfaction. If the matter is not
resolved at that time, it is suggested that the following steps be
taken:
Contact a Member of Management at the Dealer.
Discuss the details of the difficulty. In most instances, any
problem can be resolved to your satisfaction by the owner or
manager in charge.
3878859R2 1
Foreword
Contact Closest Navistar, Inc. Regional Sales Office.
Addresses of Regional Sales Offices are found in the front
of this manual. Should you desire to contact any of these
offices, it is impor tant to include the following information in your
communication:
• Name under which new vehicle was purchased, address,
and telephone number of purchaser
• Vehicle model, year, vehicle identification number,
component code, and serial number
• Vehicle delivery date and present mileag e
• Location where purchased
• Details of the problem
Component Code Numbers
Code numbers are the basis foridentifyingthe components used
on International trucks. They are used by sales personnel to
order the truck, by manufacturing to build that truck, and by parts
personnel to service the truck. Many items in this manual are
identified by codes.
Code numbers 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.
Line Set Ticket
Each vehicle is provided with a Line Set Ticket (code sheet),
which lists identification code numbers of component units used
to build the vehicle.
One copy of the Line Set Ticket is included in the literature
provided with the vehicle. When replacement par ts are
required, take this copy with you to positively identify vehicle
components to be sure of getting the correct parts.
Be Sure ToReturn Line Set TicketTo VehicleAfterObtaining
Parts.
Vehicle Storage Instructions
When a vehicle is not used for an extended period of time,
precautions must be taken to prevent deterioration of vehicle
components. Vehicles that are out of service for extended
periods of time can experience corrosion and other undesirable
effects. Drive vehicle monthly to exercise the brakes, driveline
and steering. Run the vehicle long enough for the engine to
reach operating temperature.
NOTE:Losses occurring to a unit while it is in storage will not be
considered for warranty reimbursement.
Storage Duration - One Month or Less
1. Wash vehicles as necessary. Always wash vehicles that
have been exposed to road salt.
2 3878859R2
Foreword
NOTE:WashingInstructions - Washthe vehicle with warm water
and mild soap, then wipe wet surfaces with a chamois or soft
cloth. DO NOTuse hot water or strong soaps or detergents. DO
NOT wash the vehicle in direct s un, or when the sheet metal is
hot to the touch. This will streak the f inish. DO NOT wipe dirt off
dry surfaces, as this will scratch the finish.
NOTE: When vehicles are stored outside, particularly in coastal
areas (salt water and high humidity atmosphere) or other
areas of corrosive environment, paint and bright metal may
require frequent washing and waxing to prevent deterioration.
Determining washing frequency is the customers responsibility.
NOTE: For vehicles exposed to ultraviolet rays of the sun, apply
a coating of Bon-Ami® soap, or similar product, to the inside
surfaces of the windshield and windows, to shade the interior
and prevent fading of the interior trim.
2. Inspectpaintedsurfaces;touch up all exposedprimedor raw
metal areas to prevent r ust.
3. a thick coat of wax to prevent discoloration from the
elements; wax all chrome and stainless steel metal parts.
4. Check the radiator coolant for proper level and adequate
freezeprotection [-20°F (-29°C) is standard for medium duty
models and bus chassis, -40°F (-40°C) is standard forheavy
duty models].
5. Cover open ends of vertical exhaust stack(s).
8. Check state of charge eyein batteries and re-charge if open
circuitvoltageisbelow12.6volts. Disconnect battery ground
cables to prevent accidental s tarting, or parasitic electrical
loads from discharging the battery.
Storage Duration - Over One Month
Units in storagelonger than one month should be driven until the
engine reaches operating temperature:
1. Insure all tires are inflated properly, remove vertical exhaust
stack covers and reconnect batteries.
2. Check all vehicle fluid levels and fill as required.
3. Start and r un thevehicleatfastidle,untilitreachesoperating
temperature. To remove surface charge from the battery,
built up from previous start-ups and short idle periods,
operate the heater and/or air conditioner, headlights and
other accessories for several minutes.
4. Turn off heater and/or air conditioner and any other
accessories; shut off the headlights. Park the vehicle and
shut off the engine.
5. Perform the procedure for Storage Duration - One Month
or Less, if returning the vehicle to storage.
NOTE: After every 30 additional days of storage, perform Items
1 through 5.
6. Drain air brake reservoirs and close the drain cocks.
7. Lubricate all exposed transmission, auxiliary transmission
and PTO shift rails.
3878859R2 3
Foreword
Storage Facilities
A. Whenever possible, store vehicles indoors, protected
from sunlight, in a dry, well ventilated area. If indoor
storage is not available, select storage lots to eliminate
conditions that cause deterioration.
B. Park away from transformers and/or electrical motors,
because when the protective wax in tire compound
cracks, ozone in the air attacks the exposed areas.
C. Park away from trees, high weeds and/or grass to
preventdamage from tree or weed sap,and to minimize
bird and insect stains.
D. Park away from railroad tracks, paint shops, smoky
industrial areas, and locations of possible road splash
contact.
E. If a vehicle is parked on an incline, block the wheels.
Exterior Noise Emissions
Many operators and owners of the type of vehicles described
herein are subject to Federal Motor Carr ier Safety Regulations
and Noise Emission Requirements. All owners and operators
are urged to obtain a copy and comply with these regulations.
Copies of these regulations can be purchased from:
Superintendent of Documents
U.S. Government Printing Office
Washington, D.C. 20402
Navistar, Inc. warrants to the first person who purchases this
vehicle for pur poses other than resale and to each subsequent
purchaser that this vehicle, as manufactured by Navistar, Inc.,
was designed, built, and equipped to conform at the time it left
Navistar, Inc. control with all applicable U.S. Environmental
Protection Agency Noise Control Regulations.
This warranty covers this vehicle as designed, built, and
equipped by Navistar, Inc. and is not limited to any particular
part, component, or system of the vehicle manufactured by
Navistar, Inc. Defects in design, assembly, or in any part,
component, or system of the vehicle as manufactured by
Navistar, Inc., which at the time it left Navistar, Inc. control,
that cause noise emissions to exceed Federal standards a re
covered by this warranty for the life of the vehicle.
Tampering with Noise Control System Prohibited
Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any person, other
than for purposes of maintenance, repair, or replacement, of
any device or element of desig n incorporated into any new
vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or (2) The
use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person. Among
those acts presumed to constitute tampering are the acts
listed as follows: A. Air Intake System: Removal of air cleaner,
intake silencer, or piping. B. Acoustical Shielding (Body):
Removal of wheel well splash shields, cab shields, or acoustical
(underhood) insulation. C. Cooling System: 1. Removal or
rendering inoperative the fan clutch. 2. Removalof fan shrouds.
D. Engine and Driveline System: 1. Removal or rendering
engine speed governor inoperative so as to allow engine speed
to exceed manufacturer specifications. 2. Removal of engine
4 3878859R2
Foreword
block shield, oil sump shield, or transmission enclosures. E.
Exhaust System: Removal or rendering inoperative exhaust
system components, including muffler, resonator, or tailpipe.
Use the following Maintenance Record – Noise Control form to
log Noise Emission Maintenance of, at a minimum, the above
systems.
Emission Control Systems
NOTE: Federal and California emission system warranties are
found in your Engine Operation and Maintenance Manual.
Maintenance Record – Noise Control
Chassis Model: Vehicle Identification Number:
Maintenance
Performed
Maintainer
(Name)
Location Date
Reporting Safety Defects
U.S. Registered Vehicles
(NHTSA) in addition to notifying Navistar,Inc. To notify Navistar,
Inc., see regional numbers listed in the front of the manual.
If NHTSA receives similar complaints, it may open an
investigation and, if it finds that a safety defect exists in a
group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involvedinindividualproblems
between you, your dealer, or Navistar, Inc.
To contact NHTSA, you may either ca ll the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 202-366-0123 in
Washington, D.C. area) or write to: NHTSA, U.S. Department
of Transportation, Washington, D.C. 20590. You can also obtain
other information about motor vehicle safety from the hotline.
Canadian Registered Vehicles
If you believe that your vehicle has a defect, which could cause
a crash or could cause injury or death, you should immediately
contact Navistar, Inc. Canada and then Transport Canada.
To contact Navistar, Inc. Canada, you may either call
the Regional Service Manager (Canadian Sales Region)
905-332-2357 or write to: Navistar, Inc. Canada, 5500 North
Service Road, Box 5337, Burlington, Ontario L7L 5H7.
To contact Transport Canada, Defect Investigationsand Recalls,
you may call 1-800-333-0510 or write to: Transport Canada,
ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa,
Ontario K1A 0N5.
If you believe that your vehicle has a defect, which could cause
a crash or could cause injury or death, you should immediately
inform the National Highway Traffic Safety Administration
3878859R2 5
Safety Recalls and Authorized Field Changes
SafetyRecalls and AuthorizedField Changes are two campaigns
that ar e used to notify owners of modifications that may involve
Foreword
their vehicle. If you receivesuch notification, PLEASE FOLLOW
ALL INSTRUCTIONS PROVIDED IN THE CUSTOMER
LETTER. If your vehicle is part of a Safety Recall campaign,
the recall service procedure must be completed to ensure safe
operation of your vehicle. As a vehicle owner, you must provide
International dealers with address corrections and changes to
ensure that you receive all notifications. Please verify that your
local dealer has your correct address. Dealers will also have a
record of any outstanding campaigns that affect your vehicle.
Customer Security Guide for International Trucks
This guide has been prepared to help you protect your vehicle
investment from theft. We realize the financial commitment you
have made is significant, and that you depend on that vehicle
to generate profits and a livelihood. Vehicle theft can be more
than an economic crime. Protecting your vehicle from theft
or hijacking can be crucial to the safety and security of the
country and economy. While no syst em or device is 100 percent
effective, our intention is to provide some tips that you or your
drivers can use to reduce the risk of theft.
If you suspect vehicle theft activity, take a minute to tell the
National Insurance Crime Bureau (NICB) at 1-800-TEL-NICB.
You can make the free call anonymously, and you might be
eligible for a reward. To learn more about vehicle theft and how
youcanprotectyourself,visittheNICB’sWeb site, www.nicb.org.
Add Layers of Protection
Fourlayers of protection are recommended for your vehicle - the
more layers of protection on your vehicle, the more difficult it is
to steal.
Layer 1: Common Sense
• Lock your doors.
• Remove your keys from the ignition.
• Close your windows completely.
• Park in well-lit areas.
• Dropa business card withyour name on it between the glass
and doorframe. This can aid in identifying the truck when it’s
recovered.
• Keepa copy of the lineset ticket in a location other than your
truck for reporting purposes and a copy of the VIN in your
wallet.
• Photograph the interior and exterior of your truck from
various angles and keep these photographs in a safe
nontruck location or send them to your insurance agent.
• Report a theft as soon as it’s discovered to the local police
and to your insurance company.
•Postadr iver has no cash sign on your door to discourage a
robbery.
6 3878859R2
Foreword
• Permanently mount your CB radioor removeitwhen youwill
be away from your truck.
• Do not discuss where your vehicle is located when you are
not on the road.
• Do not share information about your specific destination or
the load you are hauling.
• Be conscious of other vehicles that may be following you
over long distances - call the police.
• Be suspicious of mot orists that are signaling you to stop or
pull over. Call the police, report the incident, and let the
police respond.
Layer 2: Visible or Audible Device
• Audible alarm system
• Steering wheel locks
• Steering column collars
• Theft deterrent decals
• Wheel locks
• Window etching
• Mechanical or electronic steering locks that restrict the
steering shaft U-joint are easy to use and provide a very
high level of affordable theft protection.
Layer 3: Vehicle Immobilizer
A. Fuse cutoffs
B. Kill switches
C. Starter, ignition, and fuel disablers
D. Fuel cutoff switch
Layer 4: Tracking System
The final layer is a tracking system that emits a signal to the
police or a monitoring service when the vehicle is reported
stolen. If your vehicle has a tracking system and is stolen, it can
oftentimes be recovered faster and with less damage.
VIN:
Model/Year:
Engine Serial Number:
License Number:
Insurance Company:
Policy Number:
Phone Number:
Other:
3878859R2 7
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 a 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. Failure to observe this warning may
causepropertydamage, personal injury,ordeath.
NOTE: This vehicle may be equipped with electronic
application-specific options not descr ibed in this Operator’s
Manual. Many of these features are supplied with rocker
switches that have custom labels applied. The presence of
these options as factory-installed can be verified from the
Line Set Ticket included with the vehicle. A truck equipment
manufacturer (TEM), however, may have installed some of
these options after production. In that case, they will not
appear on the Line Set Ticket. If installed by a TEM, you
should receive an operatingguide and/or training for the specific
functions provided. Familiarize yourself with all of the switches
that control chassis, engine, and body equipment and seek
adequate training on the function of all features beforeoperating
this vehicle.
8 3878859R2
SECTION 2 — MODEL DESCRIPTION
Model Description
Introduction
The International® ProStar®+ Ser ies Truck is available in two
models, the International® ProStar
ProStar
This operator’s manual covers all versions. Illustrations in this
manual a re used for reference only, and may differ slightly from
the actual vehicle. However, key components addressed in
the manual are represented as accurately as possible. Models
covered are shown on the following pages.
+ Eagle Series.
®
+ Series, International®
®
Available Models
4x2DayCab
4x2DayCabwithFullAeroPackage
6x4DayCab
3878859R2 9
Model Description
6x4DayCabwithFullAeroPackage
4x2ShortSleeper(56-Inch)
4 x 2 Short Sleeper (56-Inch) with Full Aero Package
6x4ShortSleeper(56-Inch)
10 3878859R2
Model Description
6 x 4 Short Sleeper (56-Inch) with Full Aero Package
4 x 2 Long Sleeper (73-Inch)
4 x 2 Long Sleeper (73-Inch) with Full Aero Package
6x4LongSleepe
r (73-Inch)
3878859R2 11
Model Description
6 x 4 Long Sleeper (73-Inch) with Full Aero Package Vehicle Identification
Vehicle Identification Number (VIN)
The Vehicle Iden
driver-side do
when ordering r
Feature Codes
FeatureCodesare the basisforidentifyingthe components used
on International® Trucks. They are used by sales personnel to
order the truck, by manufacturing to build that truck and by parts
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 Vehicle Line Set Ticket which
is sometimes known as the vehicle specification card or code
sheet.
12 3878859R2
tification Number (VIN) is located on the
or. The VIN and model description are necessary
eplacement parts or service manuals.
Model Description
Engine Serial Number
The engine dataplate provides the engine serial number as
well as other engine information. For the location of this plate
and more information about engine components and engine
identification, refer to the Engine Operation and Maintenance
Manual.
Line Set Ticket
NOTE:Besure to return Line SetTickettovehicleafter obtaining
parts.
Each vehicle is provided with a Line Set Ticket (code sheet)
which lists identification code numbers of component units used
to build the vehicle.
Onecopyofthelineset ticketisincludedinthe literatureprovided
with the vehicle. When replacementparts are required, take this
copywith you t o positively identify vehiclecomponents to be sure
of getting the correct par ts.
3878859R2 13
Model Description
Exterior Components
14 3878859R2
Model Description
1. Luggage Door
2. External Hook-Ups for Telephone and TV
3. External Electrical Hook-Up (Shore Power)
4. Removable Skir t Option (Battery Access)
5. Chassis Skirt (Aero)
6. Fuel Cap
7. External Hook-Up for Block Heater
8. Side Mar ker/Turn Light
9. Fog Light
10. Tilt-Away Bumper
11. Headlight
12. VORAD (optional)
13. Sunshade
3878859R2 15
Model Description
16 3878859R2
Model Description
1. Work Lights
2. Luggage Door
3. Fuel Cap
4. VORAD (optional)
5. In-Transit Heat (optional)
6. Gladhand Storage Bracket
7. Grab Handle
3878859R2 17
Model Description
Cab Entry and Exit
WARNING
Do not step or climb upon any vehicle surface
unless it is slip-resistant and a handhold is
provided. Failure to follow this warning could
cause you to slip or fall and could result in
personal injury or death.
WARNING
A three-point stance should be used (three out
of four extremities should be in contact with
the vehicle climbing system) at all times. Face
inwardtowardsthecabwhenenteringand
exiting. Always keep steps and handholds in
continuous good repair. Make sure all attaching
bolts and hardwareare tight, thus eliminatingany
movement of steps and handholds. Keep steps,
grab handles and shoes free of grease, mud,
dirt, fuel, ice and snow. Use extra care during
inclement we ather. Failure to follow thi s warning
couldcauseyoutosliporfallandcouldresultin
personal injury or death.
Hood
Raising the Hood
1. Hood
2. Hood Latch
3. Cowl
4. Hood Handle
5. Hood Restraining Shock
18 3878859R2
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