Terrastar WorkStar Operator Manual
NOTICE CALIFORNIA
7300 • 7400 • 7500 • 7600 Models August 2010
WORKSTAR
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 3879634R1
Printed in the United States of America
© 2010 Navistar, Inc. All Rights Reserved
Operator’s Manual – WORKSTAR® 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, WorkStar, and MaxxForce
are registered trademarks of Navistar, Inc., or its subsidiaries, in the United States and other countries.
All other trademarks are the property of their respective owners.
3879634R1
Operator’s Manual – WorkStar® Series
Service Publications
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 ispossibleandpractical 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.
WorkStar® Series
Operator’s Manual – WorkStar® Series
Operator’s Manual
Form No. 3879634R1
© 2010 Navistar, Inc. All rights reserved.
3879634R1 Printed in the United States of America
Operator’s Manual – WorkStar® Series
Printed in the United States of America 3879634R1
Table of Contents
Section 1 – Foreword
Preface...............................................................1
Cautions and Warnings.............................................1
Assistance Guide.................. ..................................1
Component Code Numbers.................... ....................2
Line SetTicket..................................................2
Vehicle StorageInstructions........................................2
Storage Duration -One Monthor Less.......................2
Storage Duration -OverOne Month.........................3
Storage Facilities ...............................................4
Exterior NoiseEmissions...........................................4
Tampering with Noise Control System Prohibited................4
EmissionControl 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 Guidefor International Trucks...............6
Optional Diamond Logic® Electronic Application Solutions.....8
Section 2 – Model Description
Introduction.......... .................................................9
Available Models................................................9
Available Cabs......... ........................................11
Standard Cab..................................................11
ExtendedCab..................................................11
CrewCab.......................................................11
Vehicle Identification..........................................12
Vehicle Identification Number (VIN).........................12
Feature Codes.................................................12
Engine Serial Number........................................12
LineSet Ticket........ .........................................12
Exterior Components.........................................13
Cab Entry and Exit............................................14
Tilt Hood........... .............................................14
Raising theHood........................... ...................14
Lowering the Hood............................................14
Section 3 – Inspection Guide
Introduction.........................................................15
General Information...........................................15
Vehicle Inspection..................................................16
Preparation....................................................16
Exterior Lights Check ........................................16
LeftSide CabArea................................ ............17
Left EngineCompartment....................................18
LeftFrontof Vehicle...........................................19
Frontof Vehicle.............................. ..................22
Right Front of Vehicle.........................................23
Right Engine Compartment..................................25
Right Side ofCab......................................... ....26
RightSideUnderVehicle.....................................27
Right Rear ofVehicle.........................................28
Rear of Vehicle................................................30
Left Rear of Vehicle...........................................31
Fifth Wheel and Coupling Area..............................33
Cab Interior Inspection........................................34
Section 4 – Controls/Features
Introduction.........................................................37
3879634R1 i
Table of Contents
Electrical.......................................................37
Electrical System...................... ........................37
Dash Components.................................................38
OverheadConsole.......................................... .......38
Main Instrument/Control Panel...................................39
Instrument Panel Gauge Cluster............................39
Warning Indicators............................................41
Gauges............................................ .............43
Instrument PanelGauge Cluster Alarms...................45
Direct Drive Warning Indicators.. ............................47
IntegralDigital Display.................................. ......47
Switches........................................................49
Headlights......................................................49
DaytimeRunning Lights(DRL)..............................49
Lights on with Wipers.........................................49
ParkLights...... .................................... ...........49
Marker Interrupt...............................................50
Panel Lighting.................................................50
DomeLighting.................................................50
CourtesyLights................................................50
Optional Instrument panel gauge cluster Compass
CalibrationProcedure.........................................52
CompassDeclination Zone Set Procedure.................52
Compass Directional Calibration Procedure...............55
Integral Digital Display Detailed Information...............56
Steering Wheel Controls..........................................69
Cruise Control.................................................69
BasicFunctions of Steering Wheel Controls...............70
Operational Procedures......................................70
Throttle.........................................................70
Stationary Variable Speed Control (12VXT)................71
Stationary Pre-SetSpeed Control (12VXU)................71
Mobile Variable Speed Control (12VXV)....................71
SteeringColumnand Switches................. ..................72
Center DashPanel/WingPanel..................................74
Switches........................................................75
Auxiliary Gauge/Switch Package (AGSP ) (Optional)..........78
Panel Component Arrangements (Optional)...............78
Climate Control................. ....................................80
Air Conditioning........................................ .......82
Dehumidification................... ............................83
Doorand Window Controls...... .................................83
Door Lock/Unlock.............................................83
Cab Doors andLocks........... ..............................83
RemoteKeylessEntry Operation (Optional)...............84
Door Opening/Unlock.........................................85
Lock/Unlock from Interior.....................................85
AutomaticDoorLock Function...................... .........86
Windows.......................................................86
Manual Operation.............................................86
Power Operation..............................................86
Window Lockout Function....................................86
Mirror Controls.................................................86
Vent Window................................................ ...87
Driver Reward......................................................87
Section 5 – Operation
Operation Safety...................................................89
Cab Controls...................................................90
SeatBelts.............................. .............................91
General..................................... ....................91
Operation.......................................................92
CareofSeatBelts. ............................................93
ii 3879634R1
Table of Contents
Seats................................................................93
Extended Cab Bunk (Optional)..............................93
StartingProcedures................................................94
Engine Starting................................................94
Afterthe EngineStarts........................................95
Engine ShutDown.............................................95
Shut-Down Warning Indicator Or Beeper...................95
Engine IdleShutdownTimer (Optional).....................96
System Operation.............................................96
TheftDeterrent System(Optional)..........................96
TheftDeterrent Code EntryProcedures....................97
EmergencyStarting Using Jumper Cables...............100
ColdWeather.................................................100
ColdWeather Starting........................... ............101
Cold Weather Operation....................................101
Winter/Engine Intake Operation............................101
Engine Idling ....................................... ..........101
Winter Front Usage..........................................102
Hot Weather Operation......................................102
Starting A Turbocharged Vehicle On A Grade............102
Proper Starting Procedure..................................102
OperatingInstructions......................... ...................103
Steering.................................... ...................103
Tilt SteeringColumn............... ..........................103
Adjustable Tilt/Telescoping Steering Column.............104
General.......................................................104
Electrical.............. ................................... .....105
Electrical System...... ......................................105
Alternator.....................................................106
Ammeter................ ................................... ...106
Battery........................................................106
Battery Disconnect Switch..................................107
CircuitBreakers, Fuses, and Fusible Links... ............107
Engine........................................................108
Charge Air Cooler...........................................108
Engine Brake, Retarder (Optional).........................108
Engine Brake SystemOperation...........................109
Operational Modes..........................................109
MaxxForce® 11 and 13 Engine Brake With Eaton
AutoShift®/UltraShift® Transmissions Special
Driver Instructions...........................................109
Automatic TransmissionOperation. .......................110
ABS Operation...............................................110
MaxxForce® Engine Features..................... .........110
Certified Clean Idle.................................. .........111
Self Diagnostics..............................................111
Engine Warning/Protection System (EWPS)..............111
Optional Coolant Warning Level System – 3 Way
(08WWJ)...................... ................................112
Optional Engine Protection System – 3 Way(08WPP)...112
Air CompressorCycling.....................................112
Cooling System..............................................113
Antifreeze.....................................................114
Engine Oil.....................................................114
Engine Performance Problems.............................115
Fuel.......................................................... ..115
Ultra Low Sulfur Diesel Fuel Requirements...............115
Unacceptable FuelBlends..................................115
Hazards of DieselFuel/GasolineBlends..................115
Additional UnsafePractices.................................115
Fuel and Lubricant Additives...............................116
Fueling Procedures..........................................116
Fueling Precautions.........................................116
Reserve Fuel.................................................116
3879634R1 iii
Table of Contents
Exhaust Diesel Particulate Filter Regeneration...........117
Parked Regeneration Procedure...........................119
RegenerationInhibit Switch.................................119
Two-Position Regeneration Inhibit Switch.................120
Three-Position Regeneration InhibitSwitch...............120
Transmission.................................................120
Manual Transmissions......................................120
Engagingthe Clutch................... ......................120
Clutch Brake (Vehicles with Nonsynchronized
Transmission) – VehicleNot Moving.......................121
Double Clutch Procedures, Nonsynchronized............121
Clutch Precautions..........................................122
Shiftingwith Synchronized Transmission.................122
Shifting withNonsynchronized Transmission.............122
Operation of the Eaton AutoShift® Transmission
and Shifter...................................................122
Eaton UltraShift® Transmissions (Optional)..............123
Automatic Transmissions...................................123
Allison Transmissions.......................................123
Allison Transmission with “P” – (Park) Park Pawl
Mechanismor“PB” – Parking Brake Position............123
Parking TheVehicle.........................................124
Preparing to Drive the Vehicle .............................125
Manual ParkingBrake ......................................125
Air Parking Brake or Power Parking Brake...............125
Operation of the Alliso n Generation IV Gearshift
Controls ......................................................125
Allison Generation IV T-Bar Gearshift Control............126
Torque Lock..................................................126
Operation of the Allison Generation IV Push-button
Shift Selector ................................................127
Operation of theColumn-Mounted Shifter................128
Main Transmission Controls................................128
Backup Alarm................................................129
Auto Neutral..................................................129
Power Take OffControl.... .................................131
Automatic Transmission Operating Temperature..... ....131
Rear Drive Axles ............................................132
Locking Differentials.........................................132
Tandem Axle Power Divider Lock (PDL) Control.........132
Driver-Controlled Differential Lock.... .....................133
Controlled Traction Differential.............................134
Locking Differential (Optional)..............................134
Two Speed RearAxle.......................................135
Axle Shift Only...............................................135
Split Shifting.. ................................ ................136
Axles and Suspensions.....................................136
GrossWeight (Axle – Vehicle)..............................136
AxleOperatingTemperature... .............................136
Front Axle (4X4,6X6)......... ..............................136
TransferCase................................................137
Operation.....................................................137
International® Ride Optimized Suspension (IROS)
(Optional).....................................................139
Air Suspension Dump (ASD) Switch (Optional)..........139
Air Suspension System Faults.............................140
Axle and Suspension Conversions........................140
Lift Axle Options..................................................140
Lift Axle Locations...........................................141
Lift Axle Types...............................................141
LiftAxleControls.................................... .........142
Lift Axle System Operation.................................145
Brakes.............................................................147
Downhill Operation..........................................147
iv 3879634R1
Table of Contents
Air Brakes....................................................148
Air Gauge, Low Air Pressure Beeper and Warning
Indicator.......................................................149
Brake Application............................................149
Parking Brake................................................149
Parking Brake Reset..... ...................................150
Reservoir Moisture Draining................................151
Air Dryer......................................................151
Trailer Brake Hand Control.................................151
TrailerAir Supply andParking Brake Modular Controls...152
ParkingBrake Indicator ....................................153
Parking Brake Alarm..... ...................................153
Antilock Brake System (ABS)..............................153
ABS Operation...............................................154
ABS Self-Check............................................ ..154
AntilockDriving Tips........................ .................155
Air Brake Bendix® ABS-6 ..................................155
CoreABS Functions ........................................155
TractionControl (IfEquipped)..............................156
ATC System Check....................... ...................156
ATC OFF ROAD or MUD/SNOWSwitch..................156
Stability Control Systems – Bendix® ESP................157
Bobtail Proportioning System...................................158
Towing Instructions...............................................158
Towing Vehicle with Front Wheels Suspended...........159
Towing Vehicles with Driver Controlled Differential
Lock...........................................................160
Removing Axle ShaftsBefore Towing.....................160
Installing Axle Shafts........................................160
Towing Vehicle with Rear Wheels Suspended......... ...161
Tractor-Trailer Connections.....................................161
Connecting/DisconnectingaTrailertoa Vehiclewith
Air Suspension. ................................... ...........162
Fifth Wheel Operation.......................................162
Fifth Wheel Slide Switch (Optional)........................162
Hook-Up......................................................163
Un-Hook......................................................163
Section 6 – Maintenance Instructions
Introduction....... .................................................165
Maintenance Guidelines.........................................165
Supporting Your Vehicle for Service............................167
Chassis Lubrication..............................................167
Air Conditioning Service Checks..................... ...........168
HVAC Filters..................................................168
SideAccessHVAC Filter........... .........................168
FrontAccess HVAC Filter...................................169
Recirculation Filters.........................................169
Axles..... .................................... ......................170
FrontAxle.....................................................170
Inspection andLubrication..................................170
Normal Maintenance........................................170
Alignment..... ....................................... .........171
Front DriveAxle andTransfer Case(Optional) ......... .171
Inspection andLubrication..................................171
Rear Axle – Inspection and Lubrication...................171
Lift Axle System......... .........................................171
Brakes.............................................................172
General Information.........................................172
Air Brakes....................................................173
Inspection and Adjustment.................................173
Air Dryer......................................................174
3879634R1 v
Table of Contents
General Information.........................................174
Desiccant Filter........................................ ......175
Purge Valve..................................................175
Heater.........................................................175
Air Reservoir/Tanks MoistureDraining....................175
ABS Connections and Sensors............................176
Cab.................................................................176
CareofVehicle...............................................176
Washing and Waxing........................................176
Bright Metal Care............................................176
Upholstery Care..............................................176
Exposed Rubber and Unpainted Plastic Parts..... .......176
Clutch........................................... ...................177
PedalFree-Travel....................... .....................177
Electrical.................................. .........................177
Batteries .....................................................177
Battery Cables........ .......................................178
Electrical Chargingand Starting System Test............178
Terminal Inspection-Cleaning-Corrosion Protection......178
Accessory Feed Connections..............................179
Fuses and Relays. ..........................................179
Engine.............................................................179
General.......................................................179
Engine fluids andcontaminatedmaterial..................180
ScheduledMaintenance....................................180
Air Induction System........................................180
Air Restriction Gauge........................................181
Air CleanerElement Service...............................182
Troubleshooting........................................... ...184
Charge Air Cooler And Radiator Core Inspection
And Cleaning.................................................185
Inspection andCleaning....................................185
Cooling System..............................................185
Coolant Level..................................... ...........185
Filling Instructions...........................................186
Filling Instructions (MaxxForce® 11 and 1 3 Engines)...187
Coolantand OptionalCoolant Filter.......................188
AntiFreeze................ ....................................189
Fan Clutch............................. .......................189
Fuel System..................................................189
Fuel Tank Draining and Cleaning..........................189
Frame.... .............................. .......................190
Tow Hooks, TowPins,and PintleHooks..................190
NoiseEmissions–Exterior. ................................ .....190
Instructionsfor Proper Maintenance.......................190
Air Intake System............................................190
Body...........................................................190
Cooling System..............................................190
Engine Noise Shields/Blankets.............................191
Exhaust System..............................................191
Diesel ParticulateFilter (DPF)..................................191
Regeneration...................................... ...........191
Cleaning......................................................191
Transmission................................................... ...191
Neutral Start Switch.........................................191
Manual/Automated Manual Transmissions...............191
Automatic Transmissions...................................192
Drive Shafts.......................................................192
Suspension(Air and Steel Springs)............................192
Steering............................................................192
General Information.........................................192
TighteningSteeringIntermediate Shaft JointBolts.......193
LubricationPoints........... .................................193
PowerSteering...............................................194
vi 3879634R1
Table of Contents
Tires...................................................... ..........194
Tire Warnings................................................194
Tire Maintenance............ ................................195
Checking Inflation............................................196
Underinflation................................................196
Inspection.....................................................196
Loads.........................................................197
Dual Tires Matching.........................................197
Dual Tires Mixing. ...........................................197
Rotation.................................... ...................197
RotationIs Advisable..... ...................................197
Tire Replacement............................................198
Wheeland Tire Balancing..................................198
Wear..........................................................198
Irregular Wear........ ........................................199
Use of Tire Chains...........................................199
Wheels.............................................................199
Wheel and Wheel Nut Maintenance and Installation.....199
WheelNut Torque Maintenance............................200
Hub-Piloted Wheel Installation Procedures...............200
Section 7 – Maintenance Intervals And
Specifications
Lubrication and Maintenance Intervals ........................203
Maintenance Intervals........................ ...............203
Lubrication and Fluids Charts...................................211
Components RequiringLubrication........................212
Components Requiring Fluid Check and Fill..............213
Unit Refill Capacities.............................................214
Front DriveAxles............................................214
Rear Axle Unit Refill Capacities............................214
Cooling System Refill Capacities................... .......216
Crankcase and Oil Filters...................................216
PowerSteeringSystems.................. ..................216
TransferCase................................................216
Transmission.................................................217
Tire and Rim Combinations.....................................218
ApprovedTireand Rim Combinations.....................218
Lift Axle System......... .........................................219
Torque Specifications............................................219
Disc Wheel Torque Chart............. ......................219
U-Bolt Nut Torque Chart....................................221
Spring U-Bolt Checks.......................................223
Lift Axle Torque Charts......................................223
Fuse Charts.......................................................224
WorkStar®Series Light Information............................225
Filter List...........................................................225
Section 8 – Customer Assistance
Service Information...............................................227
International TruckWarranty Program.........................227
Section 9 – Index
Index.... ....................................... ....................229
3879634R1 vii
Table of Contents
viii 3879634R1
SECTION 1 — FOREWORD
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 sys tems, can adversely a ffect the qua lity and reliability
of your vehicle. Such mo difications 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.
Studythismanualcarefully. Donotoperateyour vehicle until you
are completely fa miliar with the conte nts 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 y ou 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 matte rs 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.
3879634R1 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 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
Codenumbers are the basis for identifying the componentsused
on International trucks. They are used by s ales personnel to
orderthe 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 lette rs.
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 ToReturn Line Set Ticket ToVehicleAfter 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 oc curring 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 3879634R1
Foreword
NOTE: Washing Instruc tions- Wash the vehicle with war m 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 veh icles 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 exposed primedorraw
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
modelsand bus chassis, -40°F (-40°C)is standard for heavy
duty models].
5. Cover open ends of vertical exhaust s tack(s).
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
Unitsin 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. Startandrunthevehicleat 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.
6. Drain air brake reservoirs and close the drain cocks.
7. Lubricate all exposed tran smission, auxiliary transmission
and PTO shift rails.
3879634R1 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
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
thoseactspresumedtoconstitutetamperingaretheactslisted
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
4 3879634R1
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 NHTS A 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 Investiga tionsand Recalls,
you may call 1-800-333-0510 or write to: Transport Canada,
ASFAD, P la ce 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 N ational Highway Traffic Safety Administration
3879634R1 5
Safety Recalls and Authorized Field Changes
Safety Recalls and Authorized Field C hanges are two
campaigns that are used to notify owners of modifications
Foreword
that may involve their vehicle. If you receive such notification,
PLEASE FOLLOW ALL INSTRUCTIONS PROVIDED IN THE
CUSTOMER LETTER. If your vehic le 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 fro m 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 wind ows com ple tely.
• Park in well-lit areas.
• Drop a business card with yourname on it betweenthe glass
and doorframe. This can aid in identifyingthe 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.
•Postadriver has no cash sign on your door to discourage a
robbery.
• Permanently m ountyour CBradio o r remove it when you will
be away from your truck.
6 3879634R1
Foreword
• Do not discuss where your vehicle is located when you are
not on the road.
• D o not share information about y our 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 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:
Layer 3: Vehicle Immobilizer
A. Fuse cutoffs
B. Kill switches
C. Starter, ignition, and fuel disablers
D. Fuel cutoff switch
3879634R1 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 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
ontheLineSetTicket. IfinstalledbyaTEM,youshould
receive an operating guide and/or training for the specific
functions provided. Familiarize yourself w ith 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.
8 3879634R1
SECTION 2 — MODEL DESCRIPTION
Model Description
Introduction
The WorkStar® Series Truck is available in a variety of models,
including the WorkStar® Series Deluxe and the WorkStar®
Series Premium. The WorkStar® Series is av aila b le in three
cab models, including the standard cab, extended cab, and the
crew cab.
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 m anual are represented as accurately as possible. Models
covered are shown on the following pages.
Available Models
4x2
The 4x2 configuration includes these models 7300, 7400, 7500,
7600.
3879634R1 9
Model Description
4x4
6x6
The 6x6 configura
The 4x4 configuration includes these models 7300, 7400, 7500.
6x4
The 6x4 configuration includes these models 7400, 7500, 7600.
10 3879634R1
tion includes these models 7400, 7500.
Model Description
Available Cabs
The WorkStar® Series Truck is available with a standard cab,
extended cab, or crew cab. Each cab has its own unique
features and uses.
Standard Cab
Extended Cab
Crew Cab
3879634R1 11
Model Description
Vehicle Identification
Vehicle Identification Number (VIN)
TheVehicleI
side door. Th
ordering rep
Feature Code
FeatureCodesare the basis for identifyingthecomponentsused
on International trucks. They are used by s ales personnel to
orderthe truck, by manufacturing to build that truck, and by parts
dentification Number (VIN) is located on the driver
e VIN and model description are necessary when
lacement parts or service manuals.
s
personnel to service the truck. Many items in this manual are
identified by codes.
Feature Codes are a combination of numbers and/or letters.
These codes are listed on the Line Set Ticket, which is
sometimes known as the vehicle specification card or code
sheet.
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 the Line Set Ticket to the vehicle after
obtaining parts.
Each vehicle is provide d 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.
12 3879634R1
Exterior Components
1. Headlight
2. Door Latch
3. Fuel Cap
4. Side Marker/Turn Light
Model Description
5. Bumper
6. Fog Light
1. Glad Hand
2. Work Ligh
3. Side Mark
4. Fuel Cap
5. Taillight
3879634R1 13
Storage Bracket
t
er/Turn Light
s
Model Description
CabEntryandExit
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
warningcouldcauseyoutosliporfallandcould
result in personal injury or death.
Tilt Hood
WARNING
To prevent personal injury or death, never put
any part of your body beneath a raised hood
unless the hood is all the way forward in its
range of motion and is fully settled in the over
center position.
Raising the Hood
1. Before opening the hood, make sure that there is enough
room in front of the vehicle for the hood to open completely
without pinning or pinching yourself between the hood and
any other structures.
2. Release the latches on both sides of the cowl.
3. Graspthe hood handle and pullthehood forward over center
and allow it to settle into the raised position.
4. Make certain that hood is resting in the open position before
releasing hood.
Lowering the Hood
1. Make sure that the hood has no tools/parts/people in its path
of motion.
2. Grasp the hood handle and push the hood backward over
center and allow it to settle into lowered position.
3. Engage latches at both sides of cowl.
14 3879634R1
SECTION 3 — INSPECTION GUIDE
Inspection Guide
Introduction
General Information
WARNING
To prevent property damage, personal injury or
death when servicing the vehicle, park on a flat
level service, set the parking brakes, turn the
engine off, and chock the wheels.
WARNING
Exercise care when w orking on vehicles with
running engines that are equipped with an
automatic fan clutch. The fan engages when
engine coolant reaches a predetermined
temperature or the refrigerant pressure (if
equipped with air conditioning) reaches a
predetermined setting. The fan will start with
no advance warning. Failure to observe these
precautions could result in vehicle damage,
personal injury, or death.
WARNING
If vehicle is equipped with an automatic
transmission, have a qualified technician
regularly check operation of transmission neutral
start sw itch . If unit starts in gear, the vehicle
may inadvertently move, which could result in
property damage, personal injury, or death.
To be sure your vehicle is ready to operate, conduct a pre-trip
inspection at the beginning of each work period. This section
givestheoperatorsuggestedguidelinestobeusedinperforming
tractor and trailer pre-trip inspections. Safety is the most
important and obvious reason for doing a pre-trip inspection.
Depending on the optional features of the vehicle being used
and any possible aftermarket items installed on the vehicle,
these guidelines should be modified to include other necessary
inspection points. Follow the steps in this section and check
them off to assure a proper vehicle inspection procedure. The
pages in this section may be reproduced locally and used on a
regular basis.
If any component or system does not pass this inspection, it
must be corrected before operating the vehicle. Take your time
going through the pre-trip inspection. Remember that a careful
pre-trip inspection saves time by eliminating unscheduled stops
to correct a faulty item.
3879634R1 15
Inspection Guide
Vehicle Inspection
Preparation
NOTE: Perform the following procedures prior to conducting the
pre-trip inspection.
• Apply parking brakes.
• Turn on parking lights and hazard lights.
• Unhook the hood latches and raise the hood.
• Check under the vehicle for oil, fuel, coolant leaks, or other
signs of damage.
• Use pullcablesoropendraincockstoallowairtankstoexpel
any existing water. Release pull cables or close drain cocks.
• Chock wheels on tractor and trailer, if attached.
• S tart the engine and allow the air pressure to build up to
normal operating pressure of 115 to 130 psi (793 to 896
kPa). Stop engine.
Exterior Lights Check
TheoptionalLMPcheckswitchisusedtoperformtheexterior
lights check in the following manner:
1. Place the ignition switch in the O N or ACC position,
place the transmission in (N) Neutral, and apply the
Parking Brake.
2. Press the optional LMP check switch to activate the
system.
3. The exterior light check will now cycle all vehicle lights
except the back-up light(s). The test flashes the exterior
lights ON and OFF in three, 2-second cycles. The
first 2-second period illuminates park lights (clearance,
identification, side marke r and license plate lights),
turn signal lights, low beam head lights, fog lights.
The second 2-second period illuminates park lights
(clearance, identification, side marker and license plate
lights), high beam headlights, brake lights, work lights.
The third 2-second period turns OFF all lights. This
cycle repeats until deactivated by the operator.
4. Walk around vehicle and inspect illumination of lights.
5. To cancel this feature, do one of the following: either
press the brake pedal, manually turn ON any external
light, turn the ig nition switch to OFF or CRANK,
depress the exterior light check switch, or release
the parking brake. The feature will automatically
cancel approximately 10 minutes after activation if not
deactivated by the operator.
6. Checking the backup lights requires two people and
the engine running. Depress the clutch (if applicable)
and select reverse while the second person observes
backup light operation.
16 3879634R1
Inspection Guide
Left Side Cab Area 1. Cab Structure: Check body panels such as doors,
air shield, sunshade, and cab for signs of breaks or
damage. Check condition of cab mounting brackets
and tilt hood latches.
2. Wipers: Check windshield wiper arms for proper spring
tension and wiper blades for damage.
3. Windshield: Check for damage to windshield and clean
if dirty.
4. Battery Box: Inspect for damage and secure mounting
of battery box. Remove battery box cover.
5. Batteries and Cables: Check that batteries are secured
and cases are not broken or leaking. Ensure cables are
free from damage. Topsof batteries and terminals must
be clean and free from foreign material. Replace battery
box cover.
6. Fuel Tank: Check to see that the fuel tank(s) and cap(s)
are secured and make sure there is no damage or leaks
at the tank(s) or fuel lines. Insure mounting straps are
secure and not chafing tank.
3879634R1 17
Inspection Guide
Left Engine Compartment
1. Power Steering Fluid: Verify that the fluid level is
between the Cold or Hot (as applicable) MIN and MAX
marks.
2. Coolant Level: Do not remove pressure cap unless
coolant is cool. Ensure fluid level is between the
minimum and maximum fluid level range as marked on
the plastic translucent reservoir or sight glass .
3. Brake Fluid Level (if equipped): During normal vehicle
operation and servicing, the fluid level will vary between
the “MIN” and “MAX” lines on the master cylinder
mounted “front” reservoir. Do not fill the master cylinder
to the top of the reservoir. Over filling may lead to
overflow. DO NOT add fluid above MAX line.
4. Oil Level: Use dipstick to verify that the oil level is
between the full and add marks.
5. Windshield Washer Fluid Level: Inspect the reservoir
and verify that the fluid level is not empty and has
enough fluid to accomplish the upcoming mission. If
additional fluid is required, see Lubricant and Sealer
Specifications chart, in the Specification section, for
the correct fluidtypebeforefilling. Do not use water in
freezing climates.
6. Radiator and Charge Air Cooler: Check for loose
mounting and damage. Inspect condition of all hoses
for damage, cracks, and leaks. Inspect for foreign
material on face of cooling package. Carefully brush
away collected materials without bending cooling fins to
maintain prop er airflow through cooling package.
18 3879634R1
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