International ProStar Operator Manual

0 (0)

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.

CALIFORNIA

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.

Important

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.

Printed in the United States of America

<![if ! IE]> <![endif]>ProStar+	<![if ! IE]> <![endif]>TARSROP
<![if ! IE]> <![endif]>Models	<![if ! IE]> <![endif]>Series+
	<![if ! IE]> <![endif]>®

<![if ! IE]>

<![endif]>23878859R 2010 December

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® , WorkStar® , DuraStar® , and TerraStar™ Series: Located left door opening, rear post

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 90480-000- Porto 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 Publications	Operator’s Manual – ProStar® + Series
	Operator’s Manual – ProStar® + Series
An Operator’s Manual is shipped with this vehicle for
customer use. Information on the purchase of other available	Operator’s Manual
service publications for this vehicle can be found on the
internationaltrucks.com Web site, or by contacting your local	Form No. 3878859R2
International dealer.
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.

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 Assistance Guide. ... ... ... ... ... .. ... ... ... ... ... .. ... ... ... ... ... ..1 Component Code Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Line Set Ticket. . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .2 Vehicle Storage Instructions... .... ..... ..... ..... .... ..... ..... ....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 Control Systems..........................................5 Maintenance Record – Noise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Reporting Safety Defects. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .5 U.S. Registered Vehicles....... ........... ........... ..........5 Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . . . . . . .5 Customer Security Guide for International Trucks. . . . . . . . . . . . . . .6 Optional Diamond Logic® Electronic Application Solutions. . .. .8

Section 2 – Model Description

Introduction.......... ................. ................ ................9

Available Models.... ........ ........ ......... ........ ........ ........9

Vehicle Identification.. .. .. .. ... .. .. .. .. .. .. .. ... .. .. .. .. .. .. ... .. ..12

Vehicle Identification Number (VIN). . . . . . . . . . . . . . . . . . . . . . . . .12

Feature Codes... ... .... .... .... .... ... .... .... .... .... ... .... .12

Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Line Set Ticket. ... ... .... ... .... ... .... ... ... .... ... .... ... ... .13

Exterior Components.. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. .14

Cab Entry and Exit.. ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... ...18

Hood...... ............ ............ ............ ............ ...........18

Raising the Hood.. ... .. .. .. .. ... .. .. .. .. ... .. .. .. .. ... .. .. .. ..18

Lowering the Hood. .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .19

Tilt-Away Bumper. . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .19

Lowering the Tilt-Away Bumper..... .... .... ..... .... .... ....20

Raising the Tilt-Away Bumper................................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

General Information.. .. ... .. ... .. ... .. ... .. .. ... .. ... .. ... .. ..23

Tractor Inspection. .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .24

Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Exterior Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Left Side Cab Area. .. ... ... .. ... .. ... .. ... ... .. ... .. ... .. ... ..25

Left Engine Compartment. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .26

Left Front of Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Front of Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Right Front of Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Right Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Right Side of Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Right Side Under Vehicle.. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ..34

Right Rear of Tractor.. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... ..35

Rear of Tractor. .... ..... .... ..... .... .... ..... .... ..... .... ....37

Left Rear of Tractor...................... ......................38

Fifth Wheel and Coupling Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

3878859R2

Table of Contents

Cab Interior Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Section 4 – Controls/Features

Introduction. . .. .. . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. .43 General Information.. .. .. ... .. ... .. ... .. ... .. .. ... .. ... .. ... ..43 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .43 Electrical System.. .. ... .. ... .. ... .. ... .. .. ... .. ... .. ... .. ... ..43 Dash Components.. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. .44 Overhead Console.. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. ..45 Instrument Panel Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Warning Indicators. . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . .48 Gauges.. .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... ... .. ... ..50 Instrument Panel Gauge Cluster Alarms. . . . . . . . . . . . . . . . . . .52 Direct Drive Warning Indicators. ...... ...... ..... ...... ......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 Directional Calibration Procedure. . . . . . . . . . . . . . .60 Integral Digital Display Detailed Information... ...... ...... .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

Steering Column and Switches.. ... ... .. ... ... ... ... ... .. ... ... ..78

Center Dash Panel/Wing Panel...................................81

Gauges.. ... ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ..82

Switches.................... .................... ................82

Climate Control.. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .86

Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Dehumidification.......... ......... .......... .......... ........89

Electronic Vehicle Monitoring. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .89

Base Display... ... ... ... ... ... ... .... ... ... ... ... ... ... ... ... ..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/Passenger Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Manual Operation. . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . ..91

Power Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Window Lockout Function. . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .92

Mirror Controls..... ...... ...... ..... ...... ...... ..... ...... ....92

Vent Window. ... ... .. ... ... ... ... ... .. ... ... ... ... ... .. ... ... ..92

Eaton VORAD Collision Warning System (Optional). . . . . . . . . . .93

System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Driver Reward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Section 5 – Sleeper Features

Introduction. .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .95

General Information.. ... .. ... .. ... .. .. ... .. ... .. ... .. ... .. .. ..95

Main Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

3878859R2

Table of Contents

Lighting..... ....... ....... ....... ....... ....... ...... ....... ....... ..97

Dome Light. ........ ......... ........ ........ ........ ......... ..97

Reading Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Floor Lights. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .97

Accent Lights. .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . .97

Sleeper Control Panel. .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . .98

General Information. ... .. .. ... .. ... .. ... .. ... .. .. ... .. ... .. ...98

Accent Light Dimmer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Accent Light Switch. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . .99

Sleeper Dome/Floor Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .99

Engine Control Switch. .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . .99

Manual Climate Controls... ... .. ... ... .. ... ... .. ... .. ... ... .100

Electronic Climate Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Power Receptacle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Radio Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Remote Power Inverter Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Windows... .... ... .... .... .... .... .... .... .... ... .... .... .... .... ..102

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Bunk Restraint System............ ............ ............ .......103

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Adjustable Belts. ... ... ... ... .... ... ... ... ... ... ... ... ... ... ..103

Restraint Webbing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Lower Bunk......... ............................. ..................105

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Upper Bunk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Entering The Upper Bunk.. .. ... .. .. .. .. .. .. .. ... .. .. .. .. .. .107

Exiting The Upper Bunk... ... ... .. ... ... .. ... ... ... .. ... ... .108

Cabinets/Storage.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .109

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Cabinets. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .110

Refrigerator Cabinet. .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .110

Horizontal Refrigerator. . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . .111

Dresser Cabinet.......... ................ ............... .....111

Tower Wardrobe Cabinet. ...... ....... ....... ....... ...... ..112

Rear Wardrobe Cabinet.. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. ..113

Airline Cabinets. . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . .114

Convenience Features. . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. .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

Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

After the Engine Starts. .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. .124

Engine Shutdown. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . ..124

3878859R2

iii

Table of Contents

Emergency Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Cold Weather...... ............ ............. ............ ......125

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Cold Weather Starting. ...... ...... ...... ...... ...... ...... ..125

Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Engine Idling .... ...... ...... ...... ...... ...... ...... ...... ...126

Engine Idle Shutdown Timer (Optional). . . . . . . . . . . . . . . . . . .127

Winter Front Usage.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..127

Hot Weather Operation. ........... ........... .......... .....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

Electrical Load Control and Shedding (ELCS)..... ..... ..132

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

Charge Air 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 Clean Idle.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. .134

Self Diagnostics.. .... .... .... .... ... .... .... .... .... .... .... .134

Air Compressor Cycling.. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . ..135

Cooling System. . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . .135

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Engine Performance Problems.. . .. . .. . . .. . .. . .. . .. . . .. . .. .136 Fuel................................................. ...........137 Ultra Low Sulfur Diesel Fuel Requirements. . . .. . . . . . . . . . .137 Unacceptable Fuel Blends. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. .137 Hazards of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . .137 Additional Unsafe Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Fueling Procedures.. ... ... ... ... ... .... ... ... ... ... ... ... ...137 Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Reserve Fuel. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. ..138 Exhaust Diesel Particulate Filter Regeneration. .. ... ... ..139 Parked Regeneration Procedure. .. . . . .. . . . . .. . . . .. . . . .. . . .141 Regeneration Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 Two-Position Regeneration Inhibit Switch. . . . . . . . . . . . . . . . .142 Three-Position Regeneration Inhibit Switch. . .. . .. . . .. . .. .142 Transmission. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Manual Transmissions....... .......... .......... ........... .142 Engaging the Clutch.. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..143 Hydraulic Clutch Actuation System. . . . . . . . . . . . . . . . . . . . . . . .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 or Limited Slip Differentials. . . . . . . . . . . . . . . . . . . . . . .148 Tandem Axle Power Divider Lock (PDL) Control. . . . . . . . .149 Driver Controlled Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . .150 Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 Rear Air Ride Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

3878859R2

Table of Contents

Rear Air Suspension Air Dump... .... ... .... ... ... .... ... ..150 Air Suspension System Faults..............................151 Brakes. .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . ..151 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151 Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 Air Brakes......... ........................... .................152 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

Air Gauge, Low Air Pressure Beeper and Warning Indicator........... ............................................153 Reservoir Moisture Draining.. . . .. . .. . . .. . . .. . . .. . . .. . .. . . ..153 Brake Application. . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . .154 Parking Brake. . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. .154 Parking Brake Reset............ .................. ...........155 Parking Brake Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 Air Dryer. . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . ..155 Trailer Brake Hand Control. ..... ..... ..... ..... ..... ..... ...155 Trailer Air Supply and Parking Brake Modular Controls...156 Parking Brake Indicator .... ......... ......... ......... ......157 Bobtail Proportioning System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 Antilock Brake System (ABS)... ................. ...........158 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158 ABS Operation. .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . ..158 ABS Self Check. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .159 Antilock Driving Tips. ... ... .... ... ... ... ... .... ... ... ... ... ..159

Automatic Traction 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

Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . .165

Tractor-Trailer Connections. .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. .166

Connecting/Disconnecting a Trailer to a Vehicle with

Air Suspension. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. ..166

Fifth Wheel Operation. .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. .166

Fifth Wheel Slide Switch (Optional). . . .. . .. . . .. . . .. . .. . . .. .167

Hook-Up. . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . .167

Un-Hook. . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . .168

Fifth Wheel Jaw Unlock Control . . . . . . . . . . . . . . . . . . . . . . . . . . .168

Fifth Wheel Jaw Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

Section 7 – Maintenance Instructions

Introduction....... ........ ........ ........ ....... ........ ........ ..171 Maintenance Guidelines. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . .171 Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . .173 Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 Air Conditioning Service Checks.. .... ..... .... .... .... .... .... .174

HVAC Filters... ..... ..... ..... ..... ..... ...... ..... ..... ..... .174 Side Access HVAC Filter.. ... ... ... ... ... ... ... ... ... ... ....174 Front Access HVAC Filter.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .175 Recirculation Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 Sleeper HVAC Filter. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . .176

Axles.. ... .. .. .. .. .. .. ... .. .. .. .. .. ... .. .. .. .. .. ... .. .. .. .. .. .. ... ..176 Front Axle.. ... .... .... .... .... .... .... .... .... .... ... .... .... .176 Inspection and Lubrication. .. ... .. .. ... .. .. ... .. .. ... .. .. ...176 Normal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

3878859R2

Table of Contents

Alignment. .. .. .. .. .. ... .. .. .. .. .. ... .. .. .. .. .. .. ... .. .. .. .. .. .177

Rear Axle . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .177

Inspection and Lubrication. .. .. ... .. .. ... .. .. ... .. .. ... .. .. .177

Locking Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Moisture Draining. . . . . . . . . . . . . . . . . . . .181

ABS Connections and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . .182

Cab............ ............ ............ ............ ............ .....182

Care of Vehicle... ... .. ... ... ... .. ... ... .. ... ... .. ... ... .. ... .182

Washing and Waxing. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. ..182

Bright Metal Care. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .182

Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

Exposed Rubber and Unpainted Plastic Parts. .. .. .. .. .. .182

Clutch... .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. ... .. .. ... .. .. .. ... .. .. .. .183

Pedal Free Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183

Hydraulic Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183

Electrical...... ...... ..... ...... ...... ..... ...... ..... ...... ...... ..184

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

Battery Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185

Electrical Charging and Starting System Test. . . . . . . . . . . .185

Terminal Inspection-Cleaning-Corrosion Protection.. ....185

Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186

Fuses and Relays..... ........... ............ ........... .....186

Engine. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . ..186

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 Engine fluids and contaminated 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 Optional Coolant Filter. . . . . . . . . . . . . . . . . . . . . . .194 Coolant Concentration Freeze Point. . . . . . . . . . . . . . . . . . . . . . .194 Antifreeze.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...194 Fan Clutch. .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. .194 Fuel System. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . ..195 Fuel Tank Draining and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . .195 Crankcase Ventilation Filter......... ........... ............ .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 Exhaust System........... ................ ................. ..196

Diesel Particulate Filter (DPF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 Regeneration.. .. ... ... .. ... ... .. ... .. ... ... .. ... ... .. ... .. ...196 Cleaning. . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . .197 Drive Shafts. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. .197

3878859R2

Table of Contents

Suspension (Air and Steel Springs). . . . . . . . . . . . . . . . . . . . . . . . . . . .197 Front Suspension. .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . ..197 Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 Steering...... ..................... .................... .............198 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 Tightening Steering Intermediate Shaft Joint Bolts. . . . . .198 Lubrication Points. ... ... ... ... .... ... ... ... .... ... ... ... ... ..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 Tires Matching. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . .203 Dual Tires Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203 Rotation. ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... .203 Rotation Is Advisable. .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .203 Tire Replacement.. ... ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .204 Wheel and Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .204 Irregular Wear.. ... .. .. ... .. .. ... .. .. ... .. .. ... .. ... .. .. ... .. .205 Use of Tire Chains... ... ... .. ... ... ... .. ... ... ... .. ... ... ... .205

Wheels...... ......... ........ ........ ........ ......... ........ .....205 Wheel and Wheel Nut Maintenance and Installation.. ...205 Wheel Nut Torque Maintenance. ... .... .... ... .... ... .... ..206 Hub-Piloted Wheel Installation Procedures. . . . . . . . . . . . . . .206 Transmission. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .208

Section 8 – Maintenance Intervals and

Specifications

Lubrication and Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . .209

Maintenance Intervals... .. ... .. .. ... .. ... .. .. ... .. ... .. .. ...209

Lubrication and Fluids Charts. .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. .217

Components Requiring Lubrication.. . . . . . . . .. . . . . . . . .. . . . .218

Components Requiring Fluid Check and Fill.. . .. . .. . .. . ..219

Unit Refill Capacities.. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. .220

Cooling System Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . .220

Crankcase and Oil Filters. . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . .220

Hydraulic Clutch System. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . ..220

Power Steering Systems.. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . ..220

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .221

Rear Axle Unit Refill Capacities. . . . .. . . . . . . . .. . . . . . . . .. . . . .222

Lubricant and Sealer Specifications. . . . . . . . . . . . . . . . .. . . . . . . . . . .223

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

Disc Wheel Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228

Fuse Charts. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. ... .. .. ..228

Typical Interior Fuse Panel Layout. . . . . . . . . . . . . . . . . . . . . . . . .229

Typical Luggage Compartment Fuse Panel Layout. . . . . .230

ProStar® + Series Light Information. . . . . . . . . . . . . . . . . . . . . . . .231

Filter List. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ..232

Section 9 – Customer Assistance

Service Information....... .......... ......... ......... ......... ...233

International Truck Warranty Program. ... .... ... .... ... .... ... .233

3878859R2

vii

Table of Contents

Section 10 – Index

Index. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. ..235

viii

3878859R2

Foreword

SECTION 1 — FOREWORD

Preface

Your vehicle has been engineered and manufactured so that it can provide economical and trouble-free service. However, it is the owner’s responsibility 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 reliability 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 operate your 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, for any reason, you do not feel you are receiving these services in connection with the operation of your vehicle or the sales transaction, you should return to your selling dealer, so that these 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

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 important 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 mileage

•Location where purchased

•Details of the problem

Component Code Numbers

Code numbers are the basis for identifying the 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 parts are required, take this copy with you to positively identify vehicle components to be sure of getting the correct parts.

Be Sure To Return Line Set Ticket To Vehicle After Obtaining 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.

3878859R2

Foreword

NOTE: Washing Instructions - Wash the vehicle with warm water and mild soap, then wipe wet surfaces with a chamois or soft cloth. DO NOT use hot water or strong soaps or detergents. DO NOT wash the vehicle in direct sun, or when the sheet metal is hot to the touch. This will streak the finish. 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.Inspect painted surfaces; touch up all exposed primed or raw metal areas to prevent rust.

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 freeze protection [-20°F (-29°C) is standard for medium duty models and bus chassis, -40°F (-40°C) is standard for heavy duty models].

5.Cover open ends of vertical exhaust stack(s).

6.Drain air brake reservoirs and close the drain cocks.

7.Lubricate all exposed transmission, auxiliary transmission and PTO shift rails.

8.Check state of charge eye in batteries and re-charge if open circuit voltage is below 12.6 volts. Disconnect battery ground cables to prevent accidental starting, or parasitic electrical loads from discharging the battery.

Storage Duration - Over One Month

Units in storage longer 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 run the vehicle at fast idle, until it reaches operating 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.

3878859R2

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 prevent damage 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 Carrier 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 purposes 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 are 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 design 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. Removal of 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

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	Maintainer	Location	Date
Performed	(Name)

Reporting Safety Defects

U.S. 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 inform the National Highway Traffic Safety Administration

(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 involved in individual problems between you, your dealer, or Navistar, Inc.

To contact NHTSA, you may either call 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 Investigations and 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.

Safety Recalls and Authorized Field Changes

Safety Recalls and Authorized Field Changes are two campaigns that are used to notify owners of modifications that may involve

3878859R2

Foreword

their vehicle. If you receive such 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 system 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 you can protect yourself, visit the NICB’s Web site, www.nicb.org.

Add Layers of Protection

Four layers 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.

•Drop a business card with your name on it between the glass and doorframe. This can aid in identifying the truck when it’s recovered.

•Keep a 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.

•Post a driver has no cash sign on your door to discourage a robbery.

3878859R2

Foreword

•Permanently mount your CB radio or remove it when you will 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 motorists 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

Foreword

Optional Diamond Logic® El ectronic 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 cause property damage, personal injury, or death.

NOTE: This vehicle may be equipped with electronic application-specific options not described 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 operating guide 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 before operating this vehicle.

3878859R2

Model Description

SECTION 2 — MODEL DESCRIPTION

Introduction

4 x 2 Day Cab with Full Aero Package

The International® ProStar ® + Series Truck is available in two models, the International® ProStar ® + Series, International® ProStar® + Eagle Series.

This operator’s manual covers all versions. Illustrations in this manual are used for reference only, and may differ slightly from the actual vehicle. However, key components addressed in the manual are represented as accurately as possible. Models covered are shown on the following pages.

Available Models

4 x 2 Day Cab

6 x 4 Day Cab



3878859R2	9

Model Description

6 x 4 Day Cab with Full Aero Package		4 x 2 Short Sleeper (56-Inch) with Full Aero Package

4 x 2 Short Sleeper (56-Inch)

6 x 4 Short Sleeper (56-Inch)

3878859R2

Model Description

6 x 4 Short Sleeper (56-Inch) with Full Aero Package		4 x 2 Long Sleeper (73-Inch) with Full Aero Package

4 x 2 Long Sleeper (73-Inch)

6 x 4 Long Sleeper (73-Inch)



3878859R2	11

Model Description

6 x 4 Long Sleeper (73-Inch) with Full Aero Package		Vehicle Identification
		Vehicle Identification Number (VIN)
		Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) is located on the driver-side door. The VIN and model description are necessary when ordering replacement parts or service manuals.

Feature Codes

Feature Codes are the basis for identifying the components used on International® 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.

3878859R2

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: Be sure to return Line Set Ticket to vehicle after 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.

One copy of the line set ticket is included in the literature provided with the vehicle. When replacement parts are required, take this copy with you to positively identify vehicle components to be sure of getting the correct parts.

3878859R2

Model Description

Exterior Components



14	3878859R2

Model Description

1.	Luggage Door	8.	Side Marker/Turn Light
2.	External Hook-Ups for Telephone and TV	9.	Fog Light
3.	External Electrical Hook-Up (Shore Power)	10.	Tilt-Away Bumper
4.	Removable Skirt Option (Battery Access)	11.	Headlight
5.	Chassis Skirt (Aero)	12.	VORAD (optional)
6.	Fuel Cap	13.	Sunshade
7.	External Hook-Up for Block Heater

3878859R2

Model Description



16	3878859R2

Model Description

1.	Work Lights	5.	In-Transit Heat (optional)
2.	Luggage Door	6.	Gladhand Storage Bracket
3.	Fuel Cap	7.	Grab Handle
4.	VORAD (optional)

3878859R2

Model Description

Cab Entry and Exit

Hood

Raising the Hood

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 inward towards the cab when entering and exiting. Always keep steps and handholds in continuous good repair. Make sure all attaching bolts and hardware are tight, thus eliminating any 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 weather. Failure to follow this warning could cause you to slip or fall and could result in personal injury or death.

1.Hood

2.Hood Latch

3.Cowl

4.Hood Handle

5.Hood Restraining Shock

3878859R2

+ 233 hidden pages