Navistar ProStar+ Operation And Maintenance Manual Download

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Maintenance Intervals and Specifications

Component

Component Vendor / Lubrication Type

Viscosity

Applicable Temperatures

Steering
Intermediate
Shaft U-Joints
/ Slip Joint –
Lubricant

Fleetrite

NLGI #2 Lithium Complex Based Moly

grease P/N 991044C2 or equivalent GC/LB NLGI
#2 Multi-purpose Lithium Complex grease

Drive Shaft

U-Joint –
Lubricant

Fleetrite

Lithium Complex Based Moly grease

P/N 991044C2 or equivalent GC/LB NLGI #2
Multi-purpose Lithium Complex grease

Clutch

Release
Bearing /
Shafts / Fork
– Lubricant

Fleetrite

Lithium Complex Based Moly grease

P/N 991044C2 or equivalent GC/LB NLGI #2
Multi-purpose Lithium Complex grease

Cooling System

Extended Life
Coolant

For MaxxForce

and Navistar

engines: Shell

Rotella

Ultra Extended Life Coolant

For Cummins

ISX15 engine: Shell

Rotella

Extended Life Coolant

See Engine Operation
and Maintenance
Manual

Transmission

263

Summary of Contents for ProStar+

Page 1: ...EPA 10 2013 HD OBD US Canada Mexico June 2015 ProStar Operation and Maintenance Manual Navistar Inc 2701 Navistar Drive Lisle IL 60532 USA 2015 Navistar Inc All rights reserved All marks are trademark...

Page 2: ...e 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 e g International Dealer who may ne...

Page 3: ...t information for this vehicle or engine VEHICLE IDENTIFICATION NUMBER VIN ENGINE Feature Code Serial Number FRONT AXLE Feature Code Serial Number REAR AXLE Feature Code Serial Number TRANSMISSION Fea...

Page 4: ......

Page 5: ...duction 13 Available Models 13 Vehicle Identification 16 Vehicle Identification Number VIN 16 Feature Codes 16 Engine Serial Number 16 Line Set Ticket 17 Exterior Components 18 Front View ProStar Not...

Page 6: ...lination Zone Set Procedure 61 Compass Directional Calibration Procedure 64 Integral Digital Display Detailed Information 66 Switches 80 Headlights 80 Daytime Running Lights DRL 80 Lights On With Wipe...

Page 7: ...Control 115 Remote Power Inverter Panel 115 Windows 116 General Information 116 Bunk Restraint System 117 General Information 117 Adjustable Belts 117 Restraint Webbing System 117 Lower Bunk 119 Gene...

Page 8: ...ontrol and Shedding ELCS 149 Engine 149 Charge Air Cooler 150 Electronic Engine Controller 150 Engine Brake 150 Engine Brake With Allison Transmissions 151 Engine Brake With Eaton AutoShift UltraShift...

Page 9: ...Regeneration Inhibit Switch 182 Brakes 182 General Information 182 Downhill Operation 182 Air Brakes 183 General Information 183 Air Gauge Low Air Pressure Beeper and Warning Indicator 183 Reservoir...

Page 10: ...Differential 207 Brakes 208 General Information 208 Air Brakes 208 Inspection and Adjustment 208 Air Dryer 210 General Information 210 Desiccant Filter 210 Purge Valve 210 Heater 211 Air Reservoir Ta...

Page 11: ...egeneration 232 Cleaning 232 Drive Shafts 232 Suspension Air and Steel Springs 233 Front Suspension 233 Rear Suspension 233 Steering 234 General Information 234 Tightening Steering Intermediate Shaft...

Page 12: ...7 Transmission 258 Rear Axle Unit Refill Capacities 260 Lubricant and Sealer Specifications 261 Torque Specifications 266 U Bolt Nut Torque Chart 266 Disc Wheel Nut Torque Chart 267 Fuse Charts 267 Ty...

Page 13: ...ed 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...

Page 14: ...iscuss the details of the difficulty In most instances any problem can be resolved to your satisfaction by the owner or manager in charge Contact Closest Navistar Inc Regional Sales Office Addresses o...

Page 15: ...sh 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 sh...

Page 16: ...eadlights 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 pr...

Page 17: ...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 20401 http gpo gov Noise Emissions Wa...

Page 18: ...il sump shield or transmission enclosures 5 Changes in hardware software calibration or programmable parameters that increase engine operating speed or horsepower other than those provided by Navistar...

Page 19: ...vehicle to fail to conform to the GHG requirements during the applicable supplemental warranty period GHG Emission Control System Warranty Period The GHG emission control system warranty period begin...

Page 20: ...ponents Please refer to applicable regulations for allowable and prohibited modifications Reporting Safety Defects U S Registered Vehicles If you believe that your vehicle has a defect that could caus...

Page 21: ...afety 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 y...

Page 22: ...wheel locks Steering column collars Theft deterrent decals Wheel locks Window etching Mechanical or electronic steering locks that restrict the steering shaft U joint which are easy to use and provid...

Page 23: ...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 opti...

Page 24: ...Foreword 12...

Page 25: ...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 th...

Page 26: ...Model Description 6 x 4 Day Cab with Full Aero Package 4 x 2 Short Sleeper 56 Inch 4 x 2 Short Sleeper 56 Inch with Full Aero Package 6 x 4 Short Sleeper 56 Inch 14...

Page 27: ...Model Description 6 x 4 Short Sleeper 56 Inch with Full Aero Package 4 x 2 Long Sleeper 73 Inch 4 x 2 Long Sleeper 73 Inch with Full Aero Package 6 x 4 Long Sleeper 73 Inch 15...

Page 28: ...s 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 num...

Page 29: ...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...

Page 30: ...ge Door 4 External Hook Ups for Telephone and TV 5 External Electrical Hook Up Shore Power 6 Chassis Skirt Rear 7 Chassis Skirt Front 8 Fuel Cap 9 External Hook Up for Block Heater 10 Side Marker Turn...

Page 31: ...one and TV 5 External Electrical Hook Up Shore Power 6 Fuel Cap 7 Chassis Skirt Rear 8 Chassis Skirt Front 9 Diesel Exhaust Fluid DEF Tank Cap 10 Access Panel 11 External Hook Up for Block Heater 12 S...

Page 32: ...Model Description Back View Identical for All ProStar Models 1 Grab Handle 2 Gladhand Storage Bracket 3 Work Lights 4 Luggage Door 5 Fuel Cap 6 In Transit Heat Optional 20...

Page 33: ...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 M...

Page 34: ...ening 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...

Page 35: ...cally lock when shut Chassis Skirts The optional chassis skirts on the International ProStar Series trucks are available to provide improved aerodynamics NOTE If your vehicle is equipped with the new...

Page 36: ...ons Chassis Skirt Removal 1 Chassis Skirt 2 Keeper Bracket 3 Locking Handle in Unlock Position 1 Locate the locking handle at the rear inside of the chassis skirt 2 Release the locking handle from the...

Page 37: ...n 4 Secure the locking handle in the keeper bracket NOTE If vehicle is ordered with the optional No Idle Solution the rear passenger side chassis skirt that covers additional batteries will remove and...

Page 38: ...Model Description 26...

Page 39: ...sure your vehicle is ready to operate conduct a pre trip inspection at the beginning of each work period This section gives the operator suggested guidelines to be used in performing tractor and trail...

Page 40: ...releasing to activate this feature 3 The exterior light check will now cycle all vehicle lights except the backup light s The test flashes the exterior lights on and off in three 2 second cycles The f...

Page 41: ...b mounting brackets and tilt hood latches 2 Batteries and Cables Check that batteries are secured and cases are not broken or leaking Ensure cables are free from damage Tops of batteries and terminals...

Page 42: ...nd Cables Check that batteries are secured and cases are not broken or leaking Ensure cables are free from damage Tops of batteries and terminals must be clean and free from foreign material Replace b...

Page 43: ...top of globe which is an indication that the filter is due for replacement and drain into cup periodically Inspect for presence of water and drain water as necessary Check for leaks 4 Oil Level Use di...

Page 44: ...tire service help Mounting and demounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment NOTE Retread tires are not recommended for use on ste...

Page 45: ...ning and Drum With brakes released check to see that brake linings where visible are not worn excessively thin less than 1 4 inch 6 mm or contaminated by lubricant 9 Tire Check tread depth tire inflat...

Page 46: ...They should be clean operational and the proper color 3 Grille Inspect for damage and security Check bug screen for damage and cleanliness 4 Headlights Lenses should be clean If equipped check daytim...

Page 47: ...and equipment WARNING To prevent property damage personal injury and or death do not operate vehicle if there is loss of steering or suspension which could cause loss of vehicle control NOTE Retread...

Page 48: ...rn damaged loose or missing components 8 Brake Chamber and Hoses Check to see that the brake chambers are not cracked or damaged and are securely mounted Check for broken loose or missing parts Check...

Page 49: ...ion 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 proper airflow th...

Page 50: ...g brake system fuel system power steering system and electrical system Heat damage to hoses wires may cause vehicle malfunction 1 Cab Structure Check body panels such as doors fairings air shield and...

Page 51: ...ctual vehicle 1 Drive Shaft Ensure that all shaft couplings are secure 2 Exhaust System Check to see that all component parts are securely mounted and no cracks holes or severe dents are visible Evide...

Page 52: ...couplings Check to see that the brake chambers are not cracked or dented and that they are securely mounted Check for broken loose or missing parts 2 Slack Adjuster Check slack adjuster and chamber pu...

Page 53: ...Suspension Check condition of spring for cracks breaks or shifting Inspect spring hanger fasteners shackles U bolts and nuts for wear damage and tightness 8 Torque Rods and Shock Absorbers Check to se...

Page 54: ...lights should be clean not broken and RED in color 2 Frame Check for cracks or bends in frame Make sure there are no loose cracked bent broken or missing crossmembers or crossmember fasteners 3 Mud fl...

Page 55: ...oximately 90 degrees when brakes are applied 3 Brake Lining and Drum With brakes released check to see that brake linings where visible are not worn excessively thin less than 1 4 inch 6 mm or contami...

Page 56: ...ngs 10 Air Suspension if equipped Check for air leaks loose components and damage to air bag Inspect ride height valve and linkage for damage Air Lines and Wiring Check air lines and electrical wiring...

Page 57: ...k to see that oil pressure is building to a normal level Engine oil pressure gauge should begin a gradual rise to normal operating range 5 Low Air Alarm The low air pressure alarm may sound immediatel...

Page 58: ...stall wheel chocks if necessary Push in parking brake and start engine b Check for air compressor or governor cut out pressure at 125 135 psi 862 931 kPa Shift into a low gear and gently pull against...

Page 59: ...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...

Page 60: ...ge Switch and Optional Hi Lo Splitter Switch 7 Push Button Gear Selector for Optional Automated Manual Transmission 8 Ignition Switch 9 Control Switches 10 Tilt Telescoping Steering Column Overhead Co...

Page 61: ...odometer transmission gear indication and compass heading and outside temperature displays This instrument panel gauge cluster displays the crucial operational functions of the vehicle The following...

Page 62: ...tains 25 individual LED warning indicators These indicators are used to monitor vehicle operation and indicate a WARNING or STOP condition These warning indicators are driven by the software in the in...

Page 63: ...Lamp AWL illuminates when the vehicle needs to be serviced at the first available opportunity This lamp may be associated with information found in Exhaust Aftertreatment section 5 RSL The Red Stop L...

Page 64: ...mal conditions and exhaust gases are at extremely high temperatures 14 Diesel Particulate Filter DPF status indicator Illuminates YELLOW Solid or Flashing to indicate the need to regenerate the Diesel...

Page 65: ...e instrument panel gauge cluster to help monitor the vehicle while in service Most gauges have in gauge warning indicators that turn on if the gauge pointer moves into an out of acceptable range condi...

Page 66: ...ngine can be operated between idle speed and high idle speed without damage but should not be allowed to over speed such as when going downhill 31 The speedometer indicates the vehicle speed in miles...

Page 67: ...5 BEEPS Instrument panel gauge cluster warning indicator illuminates Voltmeter gauge out of range reading 5 BEEPS Instrument panel gauge cluster warning indicator illuminates Engine oil pressure gauge...

Page 68: ...ensor fault REPEATING SINGLE BEEP Instrument panel gauge cluster warning indicator illuminates Red Stop Lamp illuminates REPEATING SINGLE BEEP Indicates what system is requesting the Red Stop Lamp Ele...

Page 69: ...tors Blank cover plates will be used in spaces that do not have direct drive warning indicator installed at those locations Item No Item Color Description 39 YELLOW Luggage door is ajar 40 BLANK Not u...

Page 70: ...ected quadrant parameter if the parameter can be reset The selected quadrant is identified by a vertical bar located in the far right of quadrant In Quadrant 1 the odometer screen can be toggled betwe...

Page 71: ...l Engine Hours Trip Hours Machine PTO A or B Hours Machine Trip PTO A or B Hours Engine PTO Hours Engine PTO Trip Hours Instantaneous Fuel Economy Trip Average Fuel Economy Machine PTO Fuel Used A or...

Page 72: ...g is obtained from the temperature sensor General Text and Warning Messages The operator of the vehicle can make adjustments to the sleeper temperature and or sleeper blower speeds by using the SLPR T...

Page 73: ...e Compass Compass Declination Declination Zone and End Calibration NOTE The Declination Zone for the location where the Compass Calibration procedure is being performed must be set first and thereafte...

Page 74: ...Controls Features Declination Zone Map 62...

Page 75: ...ne number is displayed Refer to Declination Zone Map to determine the proper number for the current geographic location NOTE If no Declination Zone number is selected within 15 seconds the display wil...

Page 76: ...the display control knob until this message appears 3 Press and HOLD the display control knob until the End Calibration command is displayed NOTE IF the End Calibration command will not show up turn O...

Page 77: ...mpass calibration Turn the vehicle ignition key OFF and then restart the vehicle Wait 10 seconds for the compass to complete its self test Drive the vehicle in a circle and note the compass readings I...

Page 78: ...ed Display Format 100 000 0 TRIP MILES TRIP KM Trip Odometer The trip odometer displays a record of the elapsed distance traveled since the last reset NOTE The trip hours and trip miles are independen...

Page 79: ...l provide a record of the total accumulated Machine PTO hours while PTO function A or B is engaged Display Format 100 000 0 PTO HOURS A PTO HOURS B Machine Trip PTO A or B Hours This display will prov...

Page 80: ...nt from the engine The display shall be in miles per gallon or liters per 100 kilometers corresponding to the units selected while in the odometer mode Display Format 30 0 INST MPG INST L 100KM Trip A...

Page 81: ...at 100 000 0 PTO GAL A PTO GAL B PTO L A PTO L B Machine PTO Trip Fuel Used A and B The display value shall be the calculated Machine PTO Trip Fuel Used Display Format 100 000 0 PTO TRP GAL A PTO TRP...

Page 82: ...uel Used The display value shall be the calculated Trip Idle Fuel Used Display Format 100 000 0 TRP IDL GAL TRP IDL L Axle Load Indication The instrument panel gauge cluster shall display an approxima...

Page 83: ...s the following graphic With L low on the left and H high on the right the graph is shown by bars each representing a 10 increase decrease in soot level The instrument panel gauge cluster displays the...

Page 84: ...displayed during a parked regeneration No No Load Shedding Message is displayed when electrical load control and shedding feature is implemented Yes No Washer Fluid Low Indicates low washer fluid lev...

Page 85: ...is clogged Yes No Check Brake Switch Yes No Check Exterior Lamps Yes No Engine Control Shutdown Yes No Check Trailer Lights Yes No Engine Control System Error Yes No Parkd Regen Required Indicates tha...

Page 86: ...stem turns on the Amber Warning Lamp while conditions for HV Batt Off Line message are not met Yes Amber Warning Lamp Low Engine Oil Level Message is displayed when engine oil level is less than or eq...

Page 87: ...e Message is displayed when transmission oil needs changed Not available with all transmissions Yes No Trans Oil Filter Message is displayed when transmission oil needs changed Not available with all...

Page 88: ...displayed when instrument panel gauge cluster receives signal from the Retarder Driveline requesting the Amber Warning Lamp Yes Amber Warning Lamp Gen Rtrd Flt Message is displayed when instrument pan...

Page 89: ...ibration Ended Message is displayed when vehicle speed is less than 2 mph 3 km h and the operator has requested Calibrate Compass in the current ignition cycle No No Declination Zone Message is displa...

Page 90: ...haust Fluid DEF quality problem has been present for 1 hour or longer Engine performance is limited No Amber Warning Lamp DEF Quality Derated 5mph Diesel Exhaust Fluid DEF quality problem has been pre...

Page 91: ...e and Compass Heading is displayed in Quadrant 3 Typical displays for Temperature and Compass Heading are listed in the following table The display provides both the outside ambient temperature and th...

Page 92: ...n and the drivers door is open The headlights are operated in a variety of modes Daytime Running Lights DRL The Daytime Running Lights feature provides for low beam headlights at 75 brightness wheneve...

Page 93: ...n is pressed Courtesy Lights Either the driver or the passenger door activates the door mounted courtesy lights to add light when getting in or out of the truck Item No Item Description 37 Used to eit...

Page 94: ...ase idle RPM 2 HEADLIGHT INT Used to momentarily turn off interrupt the headlights when pressed 3 RESUME ACCEL Used to resume the desired speed set on the cruise control or accelerate to a higher desi...

Page 95: ...with a loose surface These conditions may cause wheel slippage and loss of vehicle control a Press the ON position of the ON OFF steering wheel control b Bring the vehicle to the desired operating sp...

Page 96: ...ailer Brake Lever This lever is used to apply and release the brakes to the trailer Multi function Switch The multi function turn signal switch is mounted on the left side of the steering column below...

Page 97: ...p the fluid reservoir filled with Fleetrite Windshield Washer Solvent or equivalent 6 Lo High Beam When the turn signal stalk is pulled past the click position lights will switch to Hi Beam position W...

Page 98: ...Controls Features Center Dash Panel Wing Panel 86...

Page 99: ...es equipped with Selective Catalytic Reduction SCR system Provides reading of transmission lubricant temperature in degrees Fahrenheit F Switches Up to 23 optional switches can be located in the cente...

Page 100: ...OCK This switch is used to lock together the front and rear axle of a tandem for improved traction at low speeds on low traction surfaces 13 SUSP DUMP This switch allows the operator to release the ai...

Page 101: ...n vehicle has single locking differential for improved traction on poor surfaces at low speeds DIFF FR AXLE LOCK Locks forward rear drive axle differential when vehicle has 6x4 independent locking dif...

Page 102: ...er pin control 24 SPARE ON Spare switch provided for customer usage of additional options 25 ENAB DATA LOG When enabled allows the driver to log the last 5 seconds of data group s operational paramete...

Page 103: ...reen 27 Auxiliary Power Connectors 28 Cup Holder Ashtray 29 Ignition 30 Cigarette Lighter 31 Accessory Power Outlet 32 Manual Transmission Shift Lever 33 Dash Electronic Touchscreen optional 34 Air Br...

Page 104: ...prove A C system performance If the valves are shut off in cab temperature adjustment may become limited In addition when shutoff valves are closed defrosters will produce only cold air Item No Item D...

Page 105: ...is mode all airflow is directed to the panel air outlets Fresh outside air is used to cool the vehicle in this mode The A C compressor turns on and off automatically as needed when in this mode Bi Lev...

Page 106: ...rflow is directed to the defrost and side de mist air outlets and fresh outside air is circulated inside the vehicle The A C compressor turns on and off automatically as needed when in this mode to re...

Page 107: ...eaned by using a power washer with a soap solution Keep the spray head at least 6 inches away from the filter to avoid damage Rinse thoroughly NOTE If your air conditioning performance seems lower tha...

Page 108: ...the Base System plus it supports Wi Fi connectivity and has more memory and processing power than the Base Vehicle Infotainment System These upgrades allow the Premium system to have an internet brows...

Page 109: ...interference received including interference that may cause undesired operation Changes or modifications not expressly approved by the party responsible for compliance could void the user s authority...

Page 110: ...ing the Door To lock push the lock unlock button on the lock symbol in the door control panel located by the vent window Pressing the lock unlock button on the lock symbol once locks both cab doors Un...

Page 111: ...ld either Up or Down direction on the passenger side AUTO window control For one touch windows down operation press and release the window control in the Down direction The window will then go to the...

Page 112: ...rs and other instrumentation to maintain safe operation A vehicle equipped with the Bendix Wingman Advanced Collision Warning System should be operated in the same safe manner as if the system were no...

Page 113: ...Object audible and visual alerts that provide the driver up to a 3 0 second alert when a metallic object s may be blocking lane of travel Adaptive Cruise Control with Braking When cruise control is on...

Page 114: ...d with the Bendix Wingman Fusion System should be operated in the same safe manner as if the system were not installed The system is not a substitute for normal safe driving procedures It will not com...

Page 115: ...oves up to twice as much vehicle speed as current collision mitigation systems Stationary Vehicle Braking can automatically alert the driver up to 3 5 seconds before impact and apply vehicle brakes if...

Page 116: ...r Wabco OnGuard Collision Safety System should be operated in the same safe manner as if the system were not installed The system is not a substitute for normal safe driving procedures It will not com...

Page 117: ...tives for driving more efficiently This is accomplished by measuring the driver s habits based on fuel economy time at idle or both Rewards include higher maximum vehicle speed and higher cruise contr...

Page 118: ...Controls Features 106...

Page 119: ...142 cm short sleepers 73 in 185 cm long sleepers Main Features The sleeper compartments are designed to accommodate different needs and your sleeper may or may not be equipped with all the features l...

Page 120: ...6 Tower Cabinet 7 Lower Bunk 8 Under Bunk Storage Area 9 Refrigerator Cabinet or Dresser Cabinet 10 Upper Bunk Common features on the International ProStar Series 73 in 185 cm long sleeper model with...

Page 121: ...provided at the head of the upper bunk Depressing the switch on the housing will turn the reading light on and off Floor Lights There are two red floor lights located under the lower bunk included wi...

Page 122: ...ons for up to six switches 2 Climate Controls Manual heater ventilation and air conditioning HVAC Controls 3 Power Receptacle Standard 12V power socket 4 Radio Remote Control Can be used to control th...

Page 123: ...light on or off Press on the bottom of the switch to turn the floor lights on or off Engine Control Switch WARNING To prevent property damage personal injury and or death never start the engine unles...

Page 124: ...f the LED is off the system has not been enabled If the LED is steady on the system has been enabled and the automatic start stop of the engine will occur when the conditions are met bunk switch is pr...

Page 125: ...fter each run cycle 7 Horn will sound twice before the engine starts 8 To disable depress and release auto start stop switch on the instrument panel Manual Start Stop Mode 1 To enable perform Steps 1...

Page 126: ...low speed if the rear blower switch is in the Off position Electronic Climate Controller NOTE If sleeper air conditioning is desired and the main cab blower is not enabled the air conditioner will not...

Page 127: ...esigned to reduce cab condensation while limiting the electrical load on the vehicle the operation of the module is 630 seconds ON 280 seconds OFF and then 400 seconds ON 280 seconds OFF This cycle is...

Page 128: ...e inverter is overloaded or DC voltage is too low No light indicates that no fault exists For more information on the remote power inverter panel refer to the Power Inverter Manual Windows General Inf...

Page 129: ...ted The description and recommended usage of the two available restraint systems for sleeper berth areas are as follows Adjustable Belts This two belt system is standard with the sleeper lower bunk To...

Page 130: ...4 The restraint webbing system is designed to be held up away from the reclining bunk occupant by the adjustable side latch plates on each side of the restraint webbing system Insert two side latch p...

Page 131: ...2 Gas Shocks The lower bunk is fitted with two gas shocks to aid in opening closing and supporting the bunk in the opened position 3 Lights The lower bunk has two automatic lights that turn on as the...

Page 132: ...out of the way Brackets are located on each side wall to hold the bunk in the down position and a latch is located on the passenger side to hold the bunk or release it from its stowed position Access...

Page 133: ...left foot on the top step while maintaining a firm grip on the front edge of the airline cabinet with your right hand and the front bunk rail with your left hand 3 Release your right hand from the fro...

Page 134: ...y to the left swinging your left leg down and placing your left foot on the top step Item 4 Release the front bunk rail with your right hand and grasp the front edge of the airline cabinet 3 Grab the...

Page 135: ...r a projectile can cause an accident NOTE The following will describe and illustrate the standard cabinets and their storage functions for the International ProStar Series long sleeper Your vehicle ma...

Page 136: ...until the lift release handle locks the drawer shut 4 Door Lock The door lock prevents the door from opening while in motion To unlock push the door lock to the left To lock the door push the door loc...

Page 137: ...he dresser cabinet serves as a desktop 2 Release Knob A release knob is used to open the work table To open depress the knob to extend it from the work table then pull the work table open To close the...

Page 138: ...Pocket This provides a storage area for books magazines and maps 6 Dresser Cabinet The dresser cabinet is available on select International ProStar Series long sleeper models and is located behind the...

Page 139: ...rea for books magazines and maps 3 Door The optional door is provided on select International ProStar Series sleeper models Some models are fitted with no door or a snap on cloth curtain 4 Lift Releas...

Page 140: ...ng the rear wardrobe in the opened position 3 Door The door is provided on select International ProStar Series sleeper models Some models are either fitted with no door or a snap on zipper cover 4 Han...

Page 141: ...rations of one two or three cabinets on each side of select International ProStar Series sleeper models 2 Door Each airline cabinet is provided with its own pull down door to secure stored items 3 Int...

Page 142: ...ernational ProStar Series sleeper models and is used for converting 12 volt DC current to 120 volt AC current so that devices such as a refrigerator TV VCR microwaves and hair dryers can be used withi...

Page 143: ...t property damage personal injury and or death do not operate the truck in the possible presence of flammable vapors unless both a complete hazard analysis is performed and necessary additional safety...

Page 144: ...G To prevent property damage personal injury and or death when parking your vehicle do not leave transmission in gear Always use parking brake When parking on a grade install wheel chocks and turn fro...

Page 145: ...l injury and or death do not ride in the vehicle cargo area or on the outside of the vehicle Ride only in designated seating positions or sleeper berth with seat belts or bunk restraints fastened and...

Page 146: ...djust the seat cushion and seat back for a comfortable driving position In the event of a collision a correct driving position maximizes the effectiveness of the safety belt Tether straps are installe...

Page 147: ...he seat belt must be free to slide through the tongue allowing the belt tension to equalize across hips and chest The retractor is a locking type that allows the seat belt to come out and to adjust fo...

Page 148: ...y cause a weakening of the webbing Clean the belts occasionally with mild soap do not use cleaning solvents or abrasives The entire seat belt assembly should be inspected periodically for corrosion we...

Page 149: ...eats and seating systems may not compensate completely for severe road conditions Ensure that head clearance will be maintained during all road conditions as the seat may move up and decrease the avai...

Page 150: ...ture NOTE This feature operates from the truck air supply and does not turn off automatically when the truck is shut down To avoid depleting the air tank s during shutdown periods make sure the Back C...

Page 151: ...If your vehicle has an optional battery disconnect switch be sure that it is in the On position This switch is cab mounted or mounted on the battery box NOTE Automated manual transmissions must be in...

Page 152: ...operation rotate the key clockwise to the OFF position After the Engine Starts NOTE For additional information see Engine Operation and Maintenance Manual Do not increase engine speed until the oil pr...

Page 153: ...dlights and all accessories 4 Idle a hot engine for 2 5 minutes to allow the turbocharger to cool 5 Rotate the key counterclockwise to the OFF position and remove key from the ignition switch Emergenc...

Page 154: ...mally present around the battery 8 With the engine running on the booster vehicle allow the discharged batteries to charge for at least 5 minutes 9 Attempt to start the discharged vehicle 10 Reverse a...

Page 155: ...prevent property damage adhere to this Caution Because diesel engines are highly efficient they use very little fuel while idling As a result idling in cold weather will not heat the engine to its no...

Page 156: ...conditions exist the use of winter fronts or other air restrictive devices mounted in front of the radiator is not recommended on International ProStar Series vehicles which are equipped with engine...

Page 157: ...ing Be alert to any change feel in steering when driving This change or feel includes increased steering effort unusual sounds when turning excessive wheel play or pulling to either side If any of the...

Page 158: ...cked position with your left hand Make certain the steering wheel is in the proper position and the column is locked General Information Start the vehicle in motion by utilizing the highest gear speed...

Page 159: ...ill then charge at idle If the vehicle is to be warmed up prior to beginning operation the operator should observe the voltmeter for charging indication before leaving the vehicle Battery WARNING To p...

Page 160: ...echarge WARNING To prevent property damage personal injury and or death DO NOT check battery condition by shorting flashing across terminals When working around the terminals and battery use extra car...

Page 161: ...compartments are protected by either fuses or circuit breakers The power distribution center is located within the instrument panel glove box area on the passenger side of the vehicle Electrical Load...

Page 162: ...ng cooler intake air is denser than uncooled air and will allow additional fuel to be injected for greater power while helping to reduce emissions Electronic Engine Controller Each vehicle contains an...

Page 163: ...rmation on the engine braking system Engine Brake With Allison Transmissions When the Transmission Control Module TCM detects the engine brake has been enabled it commands use of a preselected shift s...

Page 164: ...on process and other engine functions The ECM also communicates with the Body Controller BC and alerts it to out of range operating conditions The BC in turn generates engine function indicators and w...

Page 165: ...rescribed frequency some monitors run continuously while some run a specific ratio against the number of drive cycles The operator will be alerted to emissions or other system problems when the Malfun...

Page 166: ...uring the unloaded cycle As the compressor reaches approximately 130 psi 896 kPa the air governor will through various methods stop the air compressor from pumping pressurized air to the air system Wh...

Page 167: ...level This will ensure the oil is level in the oil pan and the circulated oil has had a chance to return to the pan It is not necessary for the oil to be hot to obtain an accurate reading When checki...

Page 168: ...n engine performance As little as 2 volume gasoline mixed with diesel fuel will create a flammable explosive mixture in the fuel tank vapor space which will pose an extreme fire explosion hazard durin...

Page 169: ...not permit any other person to engage in such activities as would be likely to result in fire or explosion Reserve Fuel No extra supply of fuel for the propulsion of the vehicle or for the operation o...

Page 170: ...rify that the transmission fluid level is correct and that the engine temperatures are within normal limits If the high transmission or engine temperatures persist stop the engine and contact your nea...

Page 171: ...sition to the 6th gear position 1 When operating off highway or under adverse conditions always use the lowest gear when starting to move the vehicle 2 For all normal conditions use the highest gear t...

Page 172: ...or smoothly to start the upgrade at full power then downshift as needed to maintain vehicle speed Never hold a vehicle on a hill with the clutch To hold on a hill with the clutch requires that the clu...

Page 173: ...Easy Pedal EP clutches If non self adjusting clutches are used in this application it is important that clutch adjustments be maintained Adjustment intervals should be every 20 000 miles 32 000 km Wh...

Page 174: ...e transmission into either first or reverse gear If the transmission does not go into first gear or reverse tooth butting may be occurring Slowly release the clutch pedal while applying light pressure...

Page 175: ...o not have a clutch pedal For operating instructions refer to the Allison Transmission Operator s Manual Hill Start Aid Hill Brake Optional Some transmissions are equipped with an optional hill brake...

Page 176: ...osition CAUTION To prevent vehicle and or component damage engage the PDL only when stopped or moving at low speed Never try to engage the PDL while the wheels are spinning as this may result in shock...

Page 177: ...anually shifted from the vehicle cab By actuating the switches mounted on the instrument panel the driver can independently lock or unlock the forward rear and or rear rear axle differentials when the...

Page 178: ...ition and the air tanks have sufficient pressure to fill the suspension When the ignition switch is turned off power to the solenoid will be removed therefore the suspension will remain in the state l...

Page 179: ...tion depends on engine speed load and altitude therefore it differs from vehicle to vehicle CAUTION To prevent property damage Navistar Inc requires the use of Diesel Exhaust Fluid DEF that meets or e...

Page 180: ...vehicle The sound may last for about 60 seconds Low DEF Level WARNING To prevent property damage personal injury and or death maintain the adequate Diesel Exhaust Fluid DEF level to avoid a loss of en...

Page 181: ...VISOR FOR INFO and DEF LOW REFILL SOON Initial Warning normal engine operation DEF level is 10 or lower 2 Flashing 1 Beep Scrolls between SEE VISOR FOR INFO and DEF LOW REFILL SOON Initial Warning nor...

Page 182: ...age Vehicle Conditions Operation 4 Flashing Solid 1 Beep Scrolls between SEE VISOR FOR INFO DEF LOW ENG DERATED 40 and WARN ENGINE Engine performance is LIMITED DEF level is 0 5 Flashing Solid Solid 1...

Page 183: ...normal engine operation DEF level is 5 6 or lower 2 Flashing 1 Beep DEF LOW REFILL SOON Initial Warning normal engine operation DEF level is 2 2 or lower 3 Flashing Solid 1 Beep DEF LOW ENG DERATED 40...

Page 184: ...and vehicle speed and may cause an accident If incorrect liquid is in the DEF tank or if some other fault is detected within the SCR system the Amber Warning Lamp or Malfunction Indicator Lamp will i...

Page 185: ...NGINE Initial Warning fault code has been set 2 1 Beep Scrolls between DEF QUALITY DERATED 25 and WARN ENGINE Engine performance is derated by at least 25 3 1 Beep Scrolls between DEF QUALITY DERATED...

Page 186: ...eration 1 None DEF QUALITY SERVICE SOON Initial Warning fault code has been set 2 None DEF QUALITY ENG DERATE Engine performance is progressively derated by at least 25 3 1 Chime DEF QUALITY ENG DERAT...

Page 187: ...h Cummins ISX15 Engines Level Indication Audible Alarm Vehicle Conditions Operation 1 or 1 Beep Initial Warning fault code has been set 2 or 1 Beep Engine performance is derated by at least 25 3 or 1...

Page 188: ...System Fault For Vehicles Equipped with Cummins ISX15 Engines cont Level Indication Audible Alarm Vehicle Conditions Operation 4 or and 1 Beep Engine performance is derated by 40 Vehicle speed is lim...

Page 189: ...n Audible Alarm Vehicle Conditions Operation 1 1 Beep Initial Warning fault code has been set 2 1 Beep Engine performance is derated by at least 25 3 1 Beep Engine performance is progressively derated...

Page 190: ...requirement to shut the engine off and not restart it until the DPF has been serviced by a technician It is important to perform a Parked Regeneration when required Failure to do so could be mission...

Page 191: ...tween SEE VISOR FOR INFO and PARKED REGEN REQUIRED Exhaust filter regeneration required Drive on highway at highway speeds or start Parked Regeneration to prevent loss of power 2 All Flashing None Scr...

Page 192: ...al injury or death Pull vehicle safely off roadway and start Parked Regeneration to prevent loss of engine power Exhaust System Temperature is HOT WARNING To prevent property damage personal injury an...

Page 193: ...t RPM PARKD REGEN ACTIVE will be displayed in the information display and the switch indicator will illuminate when the cycle is started If the indicator is blinking check to be sure that all conditio...

Page 194: ...ration WARNING To prevent property damage personal injury and or death do not attempt to gear down if the engine is at or near maximum speed RPM Under these conditions it will be impossible to shift i...

Page 195: ...secondary brake system In the event air pressure loss occurs in one system the remaining system continues to provide braking action When a failure is detected the air dryer is provided with a limp hom...

Page 196: ...and requires no manual assistance or control lines from other sources The reservoir should be drained and the valve should be examined periodically to ensure that the drain passage is not obstructed...

Page 197: ...s nut is tightened to compress cage the spring and release the brake Remove release stud assembly from carrying pocket Apply a light coat of antiseize to the threads of the release stud to avoid any u...

Page 198: ...the tractor and trailer are parked Air pressure may leak from the system and the vehicle could roll away The trailer brake hand control is used to apply the trailer service brakes independently of the...

Page 199: ...Normal Running Out In Bobtail Sliding Fifth Wheel Adjustment Sliding Trailer Tandems Adjustment The PARKING BRAKE valve YELLOW knob controls the spring brakes on the tractor and when pulled out simult...

Page 200: ...d be noted that there is a noticeably different brake pedal feel on tractors with this feature while operating in the bobtail mode Higher brake pedal efforts will be experienced by the driver than whe...

Page 201: ...ter rings used by axle mounted sensors to transmit wheel speed information to the ABS electronic control unit located inside the cab The control unit monitors and compares all wheel speed inputs to de...

Page 202: ...raction Control is an integrated addition to the ABS This system utilizes input from the individual wheel sensors to determine if drive axle wheel slip is occurring during vehicle acceleration If driv...

Page 203: ...l vehicle stability by automatically reducing vehicle speed under certain conditions Drivers operating a Stability Control equipped vehicle should employ safe driving practices and assume no additiona...

Page 204: ...steering input and intervene if a yaw correction is needed The sensor also provides the earliest indication of an increase in lateral acceleration that might cause a potential roll event A steering a...

Page 205: ...asing the parking brake CAUTION To prevent property damage observe the following Due to many variables that exist in towing positioning and lifting towing is the sole responsibility of the towing oper...

Page 206: ...ks are inserted directly into the front suspension bracket when in use and can be conveniently stored in the cab when not in use Tow hooks provide a convenient attachment point from which to recover t...

Page 207: ...o prevent loss of axle lubricant and entrance of contaminants If axle shafts are not removed removal of propeller shafts at rear axle will be required Towing Vehicles With Driver Controlled Differenti...

Page 208: ...DIFF LOCK shift collar to fall slightly and block or temporarily resist axle shaft reinsertion 3 Install right side and left side axle shafts as follows a Place gaskets on wheel hub studs b Push righ...

Page 209: ...when connecting disconnecting or loading the trailer The vehicle speed must be below 5 mph 8 km h before the switch will operate the valve When connecting to a trailer switch the SUSP DUMP switch loc...

Page 210: ...lock it once the desired position is attained To unlock the fifth wheel press in the top portion of the switch The switch indicator will illuminate steadily when the fifth wheel is unlocked NOTE The f...

Page 211: ...peration of all trailer lights and correct faulty lights Un Hook 1 Try to keep tractor and trailer in straight line 2 Apply tractor and trailer parking brakes 3 Lower trailer landing gear making sure...

Page 212: ...tinuous tone alarm shuts off before the repetitive beep is heard jaw unlocking was incomplete Fifth Wheel Jaw Monitoring The optional fifth wheel jaw monitoring feature is an electronic jaw lock indic...

Page 213: ...valent to International service parts As with any vehicle care should be taken to avoid being injured when performing maintenance or repairs or making any checks Improper or incomplete service could r...

Page 214: ...AUTION To prevent damage to electrical components during electric welding operations follow these cautions Prior to electric welding disconnect any negative and positive battery cables that connect th...

Page 215: ...quency of lubrication intervals Thorough lubrication and maintenance at the specified intervals will ensure Outstanding Life Cycle Value and will reduce overall operating expense In some types of oper...

Page 216: ...ich can be done without tools or by cleaning the filters HVAC Filters NOTE There are three possible cab HVAC filter configurations top access side access and front access HVAC filter housings Side Acc...

Page 217: ...ntake housing 3 Install new filter into air intake housing 4 Close and secure filter access door by turning screws clockwise one quarter turn Recirculation Filters The recirculation filters are mounte...

Page 218: ...lt nuts after the first 1 000 miles 1 600 km and every 36 000 miles 58 000 km thereafter Observe the following when checking the front axle for damaged binding or worn parts and adequate lubrication K...

Page 219: ...094 km will generally show if tires are wearing normally Rapid outside shoulder wear on both tires indicates too much toe in Rapid inside shoulder wear on both tires indicates too much toe out Excessi...

Page 220: ...rts or assemblies Clean brake parts and assemblies in the open air During disassembly carefully place all parts on the floor to avoid getting dust into the air Use an industrial vacuum cleaner with a...

Page 221: ...onditions If you are uncertain of the proper schedule and procedures for your vehicle contact your International dealer Periodic checking of push rod travel or brake adjustment is essential for good b...

Page 222: ...ge and a filter which is serviced as an assembly Moisture from the air collects on the desiccant and is automatically discharged Life and performance of the air dryer depends on usage air humidity lev...

Page 223: ...een expelled Drain the wet tank daily at the end of each trip to purge collected water and prevent ice formation inside the tank when the vehicle is shut off in cold weather If you are unsure which ta...

Page 224: ...eaner to remove loose dust and dirt from upholstery and floor Vinyl and woven plastic upholstery can be washed with warm water and mild soap Remove soap residue and wipe dry If commercial cleaners are...

Page 225: ...the vehicle chassis is lubricated to ensure smooth clutch activation and long life All new International ProStar vehicles use non asbestos clutch linings However exposure to excessive amounts of clut...

Page 226: ...stem Do not mix different types of brake fluid The wrong fluid will damage the rubber parts of the system causing loss of clutch function CAUTION To prevent vehicle and or engine component damage do n...

Page 227: ...charged Use of a Midtronics 55 Amp Power Supply Smart Battery Charger Model Number PCX550 Part Number PSC550CCKIT or equivalent available through your International dealer is recommended Cold batterie...

Page 228: ...rminal corrosion and for cleaning the top of the battery Brighten the contact surfaces with steel wool apply a light coat of lubricant sealing grease such as Fleetrite 472141 C1 or equivalent or a spr...

Page 229: ...he batteries and prevent a stranded vehicle The test will check for alternator amperage output starter current draw and battery amperage capacity This type of testing will detect weaknesses that may n...

Page 230: ...he fuse panel cover in the cab the schematic on the fuse cover in the luggage compartment or the Fuse Panel Schematic located in SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS of this manual for f...

Page 231: ...s where road salt is used the inspection consists of disassembling the joints of each metal component and inspecting for salt buildup that can cause particles to flake off and enter the engine combust...

Page 232: ...ice Air Cleaner Element Service This vehicle comes with a selection of two air cleaner options The first option is a single element The second option is a dual element air cleaner that is available fo...

Page 233: ...at can enter the clean side of the piping to the turbocharger 1 Lift and hold the locking tab located at the 2 o clock position Rotate the cover counterclockwise in direction of unlock symbol on cover...

Page 234: ...unching If any of the mentioned conditions exist obtain and install an alternate new air filter element from your International dealer 5 Carefully install the new air filter element into the air clean...

Page 235: ...n gauge Repeat above except close gauge connection airtight Engine airflow too low to generate a restriction reading Turbocharged engines must be full load to pull full engine airflow Air cleaner elem...

Page 236: ...ure has been released the pressure cap may be removed WARNING To prevent property damage personal injury and or death do not exceed the pressure rating on the deaeration tank cap Ensure that the press...

Page 237: ...Maintenance Intervals and Specifications and demineralized or distilled water into the deaeration tank A 50 50 coolant mixture will achieve a 34 F 37 C freeze point A 53 47 coolant mixture will achie...

Page 238: ...with water of the proper coolant concentrate refer to Lubricant and Sealer Specifications in section Maintenance Intervals and Specifications and demineralized or distilled water into the deaeration t...

Page 239: ...long term cost of operation Coolant Concentration Freeze Point Cooling systems should be checked twice a year to ensure proper coolant water concentrations A 53 47 coolant water mixture from the facto...

Page 240: ...onths or more frequently if fuel quality or type of fuel dictates Since Ultra Low Sulfur Diesel ULSD fuel tends to absorb more water and engines are operating at higher temperatures microbe growth in...

Page 241: ...acks and holes Fan speed ratio should not be changed and fan spacer dimensions and position should not be altered Inspect for proper operation of fan clutch making sure that the fan is disengaged when...

Page 242: ...Maintenance Instructions Maintenance Record Noise Control Chassis Model Vehicle Identification Number Maintenance Performed Maintainer Name Location Date 230...

Page 243: ...Maintenance Instructions 231...

Page 244: ...as indicated by the instrument panel gauge cluster warning indicators See the Parked Regeneration Procedure in SECTION 6 OPERATION Cleaning If on vehicle regeneration is unsuccessful at removing soot...

Page 245: ...perating under load for 1 000 miles 1 600 km or six months whichever comes first the U bolt nuts must be re torqued 2 Thereafter the U bolt nuts must be re torqued every 36 000 miles 58 000 km Re torq...

Page 246: ...drag link Check that pitman arm steering arm at steering gear mounting is tight and locked Check system for leaks or hose chafing Maintain proper power steering fluid levels Regularly inspect steering...

Page 247: ...and finger It must be large enough to stay completely in the shallow groove in the top edge of the reservoir prior to cap installation Replace cracked or damaged O rings Refer to SECTION 8 MAINTENANCE...

Page 248: ...To prevent property damage personal injury and or death Do not mix stud piloted wheels or fasteners with hub piloted wheels or fasteners Mixing wheel types may cause premature wheel failure Do not ch...

Page 249: ...kPa pressure range To minimize rim corrosion it is particularly important to keep moisture from the inside of tires and proper selection of air compressor equipment proper air line routing and the us...

Page 250: ...any cut that is large enough to grow in size and depth Any nail or puncturing object If any stone or object is held by a tread groove and is starting to drill into the tread base remove the object Pr...

Page 251: ...o the steer axles or run out to retread stage on the rear axle Another rotation possibility for fleets with rib tires in all wheel positions is to break in the new steer tires in the drive axle positi...

Page 252: ...und condition Wear Radial tires can exhibit three types of normal wear patterns even erosion or chamfer Even Wear is a sign that the tire is being properly used and maintained Erosion Wear has also be...

Page 253: ...Nut Maintenance and Installation WARNING To prevent property damage personal injury and or death always follow these instructions when mounting tires on wheels Only personnel that have had proper trai...

Page 254: ...ilures WARNING To prevent property damage personal injury and or death when installing the tire and rim assembly on disc brake equipped axles make sure the tire valve stem clears the brake caliper The...

Page 255: ...nsure that the wheel is resting on the pilot pads and is against the brake drum 6 Hand start all wheel nuts to avoid cross threading 7 Starting with the nut at the 12 o clock position and using the ap...

Page 256: ...Original Equipment Transmission Manufacturer for specific service instructions and recommendations required capacities and transmission fluids Check lubricant level With the vehicle on level ground ve...

Page 257: ...tions These intervals may be expressed in miles kilometers hours of operation and or months of operation It is important to note that in high duty cycle types of operation and or where operating condi...

Page 258: ...Chart Notes NOTE 1 A hand pumped grease gun should be used for optimal grease distribution within the component joint NOTE 2 Kingpin thrust bearings must be lubricated through the lower kingpin grease...

Page 259: ...INSPECTION GUIDE DAILY Wheel Bearing Oil Type Check Level A B Suspension Fasteners Components Check A B Tie Rod Ends Lubricate NOTE 1 A B Drag Link Ends Lubricate NOTE 1 A B Kingpins and Bushings Lubr...

Page 260: ...0 000 miles 160 000 km 12 Months Rear Axle Wheel Ends Inspect for leaks lube level condition and check end play with dial indicator 100 000 miles 160 000 km 12 Months Also at brake lining service If w...

Page 261: ...applicable A B Note Install grease slowly with hand pump at low pressure Power grease guns may blow out dust seal Steering Intermediate Shaft U Joints Slip Joint Lubricate A B Steering Intermediate S...

Page 262: ...ck A B Air Dryer Heater Purge Valve Check A B Air Compressor Discharge Line Check for Blockage A B Brake Shoes NOTE 3 As Required Air Brakes Air Dryer Desiccant Replace NOTE 3 250 000 miles 400 000 km...

Page 263: ...for Loose Connectors A B Fuel Water Separator Drain Water Dirt A B Non Davco Fuel Water Separator Filter Replace A B Davco Fuel Water Separator Filter Replace A B For Maxxforce and Navistar Engines A...

Page 264: ...5 years Transmission Filter Replace Refer to Transmission Manual Transmission Transmission Fluid Mineral Replace Refer to Transmission Manual Wear and Condition Check A B Wheel Stud Nuts Retorque A B...

Page 265: ...s Lubrication and Maintenance Interval Recommended Synchronized Intervals cont System Item Intervals Special Interval 3 miles km hours months Tire Pressure Check Tire Wear Check Daily A B Tires Low Ai...

Page 266: ...utch cross shafts These fittings reduce service time by providing convenient access to clutch cross shaft bushing grease zerks Grease may be applied through two remote mounted grease zerks mounted to...

Page 267: ...ing Intermediate Shaft 3 Front S Cams and Slack Adjusters 4 Kingpin Bushings and Thrust Bearings 5 Tie Rod Ends 6 Steering Drag Link Ends 7 Clutch Cross Shafts and Release Bearing 8 Drive Shaft U join...

Page 268: ...d Bottle 3 Front Axle Oil Filled Hubs 4 Hydraulic Clutch Reservoir 5 Drive Axle Oil Fill Level Check Plug 6 Diesel Exhaust Fluid DEF Tank on vehicles equipped with Selective Catalytic Reduction SCR sy...

Page 269: ...icant amount of the rinse water will remain in the system In this case refilling with a mixture with a higher percentage 60 66 of coolant concentrate is advised in order to achieve a final mixture clo...

Page 270: ...and transmission oils Description Transmission Type Feature Code Eaton Fuller 9 Speed Manual 13GPL 13GSR Allison Automatic TC10 10 Speed Automated 13AWD Eaton Fuller 10 Speed Manual 13GAH 13GAP 13GHJ...

Page 271: ...nual 13GXM 13GXL 13GXN 13GXP 13GXR 13GXS 13GXT 13GXU Eaton Fuller 13 Speed Manual 13GKJ 13GRE 13GJS Eaton Fuller 13 Speed UltraShift 13GSV 13GSW 13GSX 13GUX 13GUY Eaton Fuller 15 Speed Manual 13GHY Ea...

Page 272: ...014GYL 0014GYA 0014GYE 0014GXX 14GXY 12 21 25 8 9 51 20 10 6X4 TANDEM AXLE Forward Rear Description Code Liters Pints Liters Pints Dana Spicer AdvanTEK D40 156 D40 156S D40 156D D40 156DS D40 156H D40...

Page 273: ...able Temperatures Non driving Front Axle Mineral Oil 75W 75W 80 75W 90 75W 140 80W 90 80W 140 85W 140 40 F to 15 F 40 C to 26 C 40 F to 80 F 40 C to 27 C 40 F to 100 F 40 C to 38 C 40 F and above 40 C...

Page 274: ...Eaton Dana and Meritor Easy Steer axles With chassis load on axle force grease through thrust bearings then with axle lifted clear of floor force grease between kingpin and bushing surfaces Engine Eng...

Page 275: ...icant Fleetrite Lithium Complex Based Moly grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease Clutch Release Bearing Shafts Fork Lubricant Fleetrite Lithium Complex Ba...

Page 276: ...PI CJ or CI Gear Oil API GL 1 SAE 90 Meritor only SAE 80 Meritor only SAE 50 SAE 40 SAE 30 Above 10 F 12 C Above 10 F 12 C Above 10 F 12 C Above 10 F 12 C Below 10 F 12 C Transmission Oil Synthetic Oi...

Page 277: ...Axle Rear Drive Axle s Synthetic Emgard FE and Emgard XFE Synthetic Lubricant 75W 90 All Temperatures Electrical Terminals Lubricant Sealing Grease Fleetrite 472141 C1 Connectors Dielectric Grease NY...

Page 278: ...TP and 14ATR 260 300 353 407 14TBJ 20 000 lb 9 070 kg Capacity International Air Suspension IROS for all other axles 370 400 502 542 14UNL 14UNM 14UNN 14UNS 14UNT and 14UNU 40 000 lb 18 140 kg Capacit...

Page 279: ...T Torque Lug Nut Size Lug Nut Type Socket Size lb ft N m 22 mm 2 piece 33 mm 450 500 610 678 NOTE Do not use lubrication on dry threads Where excessive corrosion exists a light coat of lubricant on th...

Page 280: ...Maintenance Intervals and Specifications Typical Interior Fuse Panel Layout NOTE F11 D Wabco Bendix both will use 10 amp fuse instead of 5 amp fuse 268...

Page 281: ...Distribution Module PDM Fuse Panel Layout On certain ProStar models you can find a Power Distribution Module PDM under the hood in the driver s side It is mounted on the air cleaner bracket and is im...

Page 282: ...the PDM in this location it means that your vehicle has in line fuses instead of a PDM fuse panel The following illustration shows the typical layout of the fuse panel in the under hood PDM CAUTION To...

Page 283: ...B not in use 6 2C Eaton clutch 40A 7 2D not in use 8 2E ECM 25A for Navistar s engines 30A for Cummins ISX15 engines 9 3A not in use 10 3B aftertreatment PDM for vehicles equipped with SCR system 30A...

Page 284: ...ome Lamp GE211 2 Accent Lamps GE211 2 Under Bunk Lamp GE211 2 Cab Floor Lamp GEW5W Sleeper Floor Lamp GEW5W Sleeper Reading Lamp GE912 LED Cab Map Lamp See Dealer Door Lamps GEW5W Clearance Marker Lam...

Page 285: ...ncandescent GE3156 Filter List Filter part numbers and or specifications may change during the lifecycle of this vehicle Current information on the appropriate chassis and engine filters for your vehi...

Page 286: ...Maintenance Intervals and Specifications 274...

Page 287: ...aler These service resources are also available via the Internet by an annual subscription to the Service PortalSM Web site or via the OnCommand Service Information DVD Information on the Service Port...

Page 288: ...th America s leader in truck manufacturing is also North America s leader in warranty value Published Service Contracts for Performance PM Service designed to ensure the lowest possible cost of owners...

Page 289: ...ide Access HVAC Filter 204 Sleeper HVAC Filter 206 Air Dryer 186 210 Desiccant Filter 210 Heater 211 A CONT Air Dryer cont Purge Valve 210 Air Gauge Low Air Pressure Beeper and Warning Indicator 183 A...

Page 290: ...rake Application 184 Brakes 182 208 ABS Connections and Sensors 211 Air Brakes 183 208 B CONT Brakes cont Air Gauge Low Air Pressure Beeper and Warning Indicator 183 Brake Application 184 Inspection a...

Page 291: ...ification 95 Gauges 87 Switches 87 Charge Air Cooler 150 C CONT Charge Air Cooler and Radiator Core Inspection and Cleaning 224 Inspection and Cleaning 224 Chassis Lubrication 203 Chassis Skirt Instal...

Page 292: ...ilters 257 Crankcase Ventilation Filter 228 Cruise Control 83 Customer Security Guide for International Trucks 9 D Dash Components 48 Daytime Running Lights DRL 80 DEF Contamination or SCR System Faul...

Page 293: ...ternator 147 E CONT Electrical cont Auto Start Stop System Battery Cables 216 Batteries 215 Battery 147 BATTERY ON Indicator 148 Circuit Breakers Fuses and Fusible Links 149 Electrical Charging and St...

Page 294: ...ures 152 Engine Fluids and Contaminated Material 219 E CONT Engine Idle Shutdown Timer Optional 144 Engine Idling 143 Engine Noise Shields Blankets 229 Engine Oil 155 Engine Performance Problems 155 E...

Page 295: ...207 Inspection and Lubrication 206 Normal Maintenance 207 F CONT Front of Tractor 34 Front Suspension 233 Front View ProStar Equipped with Selective Catalytic Reduction SCR System 19 Front View ProSt...

Page 296: ...with Cummins ISX15 Engines Table 169 I CONT Indicators aboutLow DEF level For Vehicles Equipped with Navistar N13 engines Table 171 Inspection 238 Inspection and Adjustment 208 Inspection and Cleanin...

Page 297: ...n and Maintenance Interval Chart Symbols Key 246 Lubrication and Maintenance Intervals 245 Maintenance Intervals 245 Lubrication Points 234 Luggage Box Access 23 Driver and Passenger Side 23 M Main Fe...

Page 298: ...ock 165 Locking or Limited Slip Differentials 163 O CONT Operating Instructions cont Tandem Axle Power Divider Lock PDL Control 164 Rear Suspension 166 Air Suspension System Faults 166 Rear Air Ride S...

Page 299: ...Panel Lighting 80 Park Lights 80 Parked Regeneration Procedure 181 Parking Brake 184 Parking Brake Alarm 185 Parking Brake Reset 185 Parking Brake Alarm 185 P CONT Parking Brake Indicator 188 Parking...

Page 300: ...on Is Advisable 239 S Safety Recalls and Authorized Field Changes 9 Scheduled Maintenance 219 Seat Belts 133 Care of Seat Belts 136 Operation 135 Seats 137 Selective Catalytic Reduction System If Equi...

Page 301: ...stable Steering Column 146 Lubrication Points 234 S CONT Steering cont Power Steering 235 Tightening Steering Intermediate Shaft Joint Bolts 234 Steering Column and Switches 84 Steering Wheel Controls...

Page 302: ...ooks 194 Towing Vehicle With Front Wheels Suspended 195 Towing Vehicle With Rear Wheels Suspended 196 Towing Vehicles With Driver Controlled Differential Lock 195 Installing Axle Shafts 196 Removing A...

Page 303: ...on Fluid Temperature 158 Cold Weather 158 High Fluid temperature 158 Transmission Fluid 157 Transmission Fluid Temperature 158 Cold Weather 158 T CONT Transmission Fluid Temperature cont High Fluid te...

Page 304: ...icles Equipped with Cummins ISX15 Engines Table 175 W CONT Warnings of SCR System Fault For Vehicles Equipped with Navistar N13 Engines Table 177 Washing and Waxing 211 Wear 240 Irregular Wear 240 Whe...

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