Navistar WorkStar Series Operator'S Manual Download

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Model Description

Exterior Components

Headlight

Door Latch

Fuel Cap

Side Marker/Turn Light

Bumper

Fog Light

Glad Hand Storage Bracket

Work Light

Side Marker/Turn Light

Fuel Cap

Taillights

3879634R1

Summary of Contents for WorkStar Series

Page 1: ...ubject that person or entity to criminal penalties Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and othe...

Page 2: ...488 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 Commer...

Page 3: ...tacting your local International dealer It is the policy of Navistar Inc to improve its products whenever it is possible and practical to do so We reserve the right to make changes or add improvements...

Page 4: ...Operator s Manual WorkStar Series Printed in the United States of America 3879634R1...

Page 5: ...odel Description Introduction 9 Available Models 9 Available Cabs 11 Standard Cab 11 Extended Cab 11 Crew Cab 11 Vehicle Identification 12 Vehicle Identification Number VIN 12 Feature Codes 12 Engine...

Page 6: ...uise Control 69 Basic Functions of Steering Wheel Controls 70 Operational Procedures 70 Throttle 70 Stationary Variable Speed Control 12VXT 71 Stationary Pre Set Speed Control 12VXU 71 Mobile Variable...

Page 7: ...Ammeter 106 Battery 106 Battery Disconnect Switch 107 Circuit Breakers Fuses and Fusible Links 107 Engine 108 Charge Air Cooler 108 Engine Brake Retarder Optional 108 Engine Brake System Operation 10...

Page 8: ...the Allison 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 t...

Page 9: ...trolled Differential Lock 160 Removing Axle Shafts Before Towing 160 Installing Axle Shafts 160 Towing Vehicle with Rear Wheels Suspended 161 Tractor Trailer Connections 161 Connecting Disconnecting a...

Page 10: ...184 Charge Air Cooler And Radiator Core Inspection And Cleaning 185 Inspection and Cleaning 185 Cooling System 185 Coolant Level 185 Filling Instructions 186 Filling Instructions MaxxForce 11 and 13 E...

Page 11: ...rvals 203 Lubrication and Fluids Charts 211 Components Requiring Lubrication 212 Components Requiring Fluid Check and Fill 213 Unit Refill Capacities 214 Front Drive Axles 214 Rear Axle Unit Refill Ca...

Page 12: ...Table of Contents viii 3879634R1...

Page 13: ...contents of this manual Always retain this manual in your vehicle for reference If you sell the vehicle make sure the manual goes with it Assistance Guide When parts are required always provide the u...

Page 14: ...le 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...

Page 15: ...standard for medium duty models and bus chassis 40 F 40 C is standard for heavy duty models 5 Cover open ends of vertical exhaust stack s 6 Drain air brake reservoirs and close the drain cocks 7 Lubri...

Page 16: ...nmental 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 th...

Page 17: ...ct 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...

Page 18: ...ers 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 an...

Page 19: ...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 protecti...

Page 20: ...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 a...

Page 21: ...s 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 v...

Page 22: ...escription 4x4 The 4x4 configuration includes these models 7300 7400 7500 6x4 The 6x4 configuration includes these models 7400 7500 7600 6x6 The 6x6 configuration includes these models 7400 7500 10 38...

Page 23: ...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 3879634...

Page 24: ...cket 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 lo...

Page 25: ...iption Exterior Components 1 Headlight 2 Door Latch 3 Fuel Cap 4 Side Marker Turn Light 5 Bumper 6 Fog Light 1 Glad Hand Storage Bracket 2 Work Light 3 Side Marker Turn Light 4 Fuel Cap 5 Taillights 3...

Page 26: ...slip or fall and could 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 for...

Page 27: ...ay 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...

Page 28: ...ll 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 identifi...

Page 29: ...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...

Page 30: ...g 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...

Page 31: ...ck that the air dryer heater activates at temperatures below freezing With the vehicle in a cold environment and before the engine is started turn on the ignition and touch the air dryer housing It sh...

Page 32: ...d leaks and damage to power steering hoses 2 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 Ch...

Page 33: ...ame wheel end are evenly separated and that tire sidewalls are not touching one another 9 Wheel and Wheel Nuts Check for damaged or bent wheel Check to see that all wheel nuts are present and not loos...

Page 34: ...equipped check daytime running lights 4 Hood and Fenders Check hood panels and fenders for signs of breaks or damage Ensure hood opens and closes properly 5 Lighting System Lower hood and inspect par...

Page 35: ...e size of fuse or circuit breaker or change type of breaker supplied with your truck To do so could cause wiring to overheat and possibly burn resulting in a fire which could cause property damage per...

Page 36: ...e are not worn excessively thin less than 1 4 inch 6mm or contaminated by lubricant 8 Hub Check for obvious leaks on outside or inside of wheel Verify correct oil level in hub 9 Wheel and Wheel Nuts C...

Page 37: ...engine off press on all belts to test for proper belt tensioner performance 4 Radiator and Charge Air Cooler Check for loose mounting and damage Inspect condition of all hoses for damage cracks and l...

Page 38: ...damage such as transmission component damage 1 Cab Structure Check body panels such as doors fenders and cab for signs of breaks or damage Check condition of cab mounting brackets and tilt hood latch...

Page 39: ...ere are no loose cracked bent broken or missing crossmembers or fasteners 2 Exhaust System Check to see that all component parts are securely mounted and no cracks holes or severe dents are visible Ev...

Page 40: ...ly mounted Check for broken loose or missing parts 2 Slack Adjuster Check slack adjuster and chamber push rod travel When pulled by hand push rod should not move more than approximately one inch Angle...

Page 41: ...h sight glass 7 Spring 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 Shoc...

Page 42: ...t 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 fasteners 3 Mud flaps Inspect rear mud flaps and mounti...

Page 43: ...r secure 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 c...

Page 44: ...utside or inside of wheel Inspect axle flanges and wheel seals for leaks and loose mounting hardware or broken items Check lube level if equipped with sight glass 8 Spring Suspension Check condition o...

Page 45: ...sure that top surface face of the 5th wheel has a coat of grease 4 Mounting Bolts and Release Handle Look for loose or missing mounting brackets clamps bolts or nuts All locking pins must be in place...

Page 46: ...othly without any binding or irregular feel Remove foot from accelerator and make sure engine returns to idle immediately 7 Voltmeter Check the gauge to see if the alternator is charging between 12 5...

Page 47: ...IGNITION BACK ON d Without brake pedal applied note air pressure drop for one minute It should be less than 2 psi 14 kPa e Depress and hold brake pedal and make sure there is no more than a 3 psi 21...

Page 48: ...Inspection Guide 36 3879634R1...

Page 49: ...ed 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 S...

Page 50: ...tches Overhead Console This vehicle is equipped with an overhead console that provides both dome lighting and storage facilities The overhead storage capacity consists of two netted storage bins large...

Page 51: ...and an Integral Digital Display that provide odometer transmission gear indication and compass heading and outside temperature displays This instrument panel gauge cluster displays the crucial operat...

Page 52: ...Controls Features 40 3879634R1...

Page 53: ...Alert condition to the operator 4 Illuminates Yellow Used in conjunction with other Warning Indicators or General Text and Warning Messages to indicate an Alert condition to the operator 5 Illuminate...

Page 54: ...luminates Yellow when an emissions problem has occurred 16 Illuminates Red when a parking brake system malfunction has been detected If the Service Parking Brake indicator stays illuminated have the s...

Page 55: ...ne and determine cause of the gauge indication that is out of acceptable range Metric versions of the gauges and speedometer are available as an option Item No Item Description 26 Transmission Oil Tem...

Page 56: ...ndicates vehicle speed Item No Item Description 32 Fuel Level Gauge Indicates the approximate fuel level in the fuel tank If your vehicle is equipped with dual fuel tanks the fuel gauge reads the fuel...

Page 57: ...damage personal injury or death The Instrument Panel Gauge Cluster will sound an audible alarm that accompanies out of range gauge readings along with the particular gauge warning indicators The clus...

Page 58: ...iary Air Pressure Gauge out of range reading 5 BEEPS Instrument Panel Gauge Cluster warning indicator illuminates Gauge Sensor Faults 3 BEEPS Gauge pointer goes to 6 o clock position and Instrument Pa...

Page 59: ...minates in conjunction with the Optional Qualcomm satelite communication system see Qualcomm system owner s manual Integral Digital Display The Integral Digital Display is located below the speedomete...

Page 60: ...l Messages Informational Display Screens Odometer Trip Odometer Total Engine Hours Trip Hours Machine PTO A or B Hours Machine Trip PTO A or B Hours Engine PTO Hours Engine PTO Trip Hours Instantaneou...

Page 61: ...t 100 percent brightness with the headlight switch activated The park lights tail lights markers and clearance lights will be on as well Your vehicle may be equipped with an optional headlight warning...

Page 62: ...panel lighting continually press the lower portion of the rocker switch Dome Lighting The overhead dome light is used for reading and for illumination when entering and exiting the vehicle The dome li...

Page 63: ...rking lights and illuminates the instrument panel This switch functions even when ignition switch is turned OFF a warning will sound when this switch is ON and the ignition switch is OFF 52 Panel Dimm...

Page 64: ...ompass 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 thereafter the Compa...

Page 65: ...Controls Features Declination Zone Map 3879634R1 53...

Page 66: ...mber 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 will ret...

Page 67: ...isplay 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 OFF th...

Page 68: ...seconds to for the compass to complete its self test Drive the vehicle in a circle and note the compass readings If the lower left quadrant of the Instrument Panel Gauge Cluster Display shows the corr...

Page 69: ...e independently reset Display Format 100 000 0 TRIP MILES TRIP KM Total Engine Hours The Engine Hour display provides a record of accumulated engine hours and will not show any increase unless the eng...

Page 70: ...ours This display will provide a record of the total accumulated Machine Trip PTO hours while PTO function A or B is engaged Display Format 100 000 0 PTO TRP HOURS A PTO TRP HOURS B Engine PTO Hours T...

Page 71: ...play Format 30 0 INST MPG INST L 100KM Trip Average Fuel Economy The display value shall be the average fuel economy value since the last reset of the trip odometer The display shall be in miles per g...

Page 72: ...TRP L B Engine PTO Fuel Used The display value shall be the calculated Engine PTO Fuel Used Display Format 100 000 0 ENG PTO GAL PTO TRP L Engine PTO Trip Fuel Used The display value shall be the cal...

Page 73: ...10 percent increase decrease in soot level The instrument panel gauge cluster displays the last received level until a new value is received or until the instrument panel gauge cluster detects that it...

Page 74: ...hen there are active diagnostic codes Yes No Check A C Indicates a fault in the HVAC System Yes No PARKD REGEN INHIBITED Message is displayed when parked regeneration has been requested but is not per...

Page 75: ...rning Indicator Yes No Check Stop Arm Crossing Gate 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 REQUIRE...

Page 76: ...gine Message is displayed when ECM requests the Yellow warning indicator and not the Red warning indicator Yes Yellow warning indicator HV Batt Off Line Message is displayed when Hybrid system battery...

Page 77: ...n Red Stop MIL or PROTECT or the Yellow Warning indicator without the conditions to display Check Trans Trans Temp Trans Oil Life Trans Oil Filter or Trans Service Not available with all transmissions...

Page 78: ...IC 1 PAM Hybrid Service Tool Global Message is displayed when a module other than the engine requests the Yellow warning indicator Yes Yellow warning indicator Retarder Temp Message is displayed when...

Page 79: ...r has requested Calibrate Compass in the current ignition cycle No No Calibration Ended Message is displayed when vehicle speed is less than 2 mph 3 km h and the operator has requested Calibrate Compa...

Page 80: ...ust be moving to acquire an accurate temperature Quadrant 3 Display Messages Description Outside Temperature and Compass Heading Display Format Outside Temperature Reading The Outside Temperature is d...

Page 81: ...sume the desired speed set on the cruise control or accelerate to a higher desired speed When parked used to increase idle RPM Cruise Control The cruise control systems for all electronic engines func...

Page 82: ...es like an automotive cruise control 1 Press the ON position of the CRUISE THROTTLE ON OFF steering wheel control 2 Bring the vehicle to the desired operating speed above 35 MPH and then push the SET...

Page 83: ...ordered this feature can provide two different predetermined speeds which are selected with the SET CRUISE or RESUME ACCEL positions You need to know which position to use for your specific operation...

Page 84: ...h does not automatically cancel and will require manual cancellation Lane Change The turn signal lever includes a lane change feature which allows the operator to signal the intention to change lanes...

Page 85: ...the lever is held in the pulled position When the Lo Beam headlights are ON the Hi Beam lights can be made to flash if the lever is not lifted past the click or dimmer position 5 Hazard Warning Switc...

Page 86: ...al parking brake controls and auxiliary electrical power source see Vehicle Operation for operational details Refer to the Radio Operator s Manual provided with the vehicle for instructions on operati...

Page 87: ...AKE ON OFF Turns engine compression brake ON OFF ENG BRAKE 1 2 3 A three position switch that selects the amount of engine braking 1 Low 2 Medium 3 High Transmission Retarder RTARDR ON Turns ON transm...

Page 88: ...witch indicator will be ON when the ON position is selected WORK LIGHT ON This switch is used to turn the back of cab work light ON or OFF 2 Speed Axle 2 SPD LO 2 SPD HI A 2 speed switch that allows t...

Page 89: ...r ratio AIR ASSIST OFF ON Provides inflation or deflation of auxiliary air bag Engine Shutdown Override ENG OVRD ON This momentary switch when pushed to the ON position will allow the vehicle to be re...

Page 90: ...Optional Gauge Function Ammeter Gauge Provides reading of battery and alternator current in Amps Rear rear Axle Temperature Gauge Provides monitoring of temperature of axle lubricant Warning indicatio...

Page 91: ...ter Engine Intake Switch b Optional Air Horn Switch c Optional Ether Start Switch d Optional Engine Start Switch e Optional Axle Enable Switch f Optional Axle Up Down Switch g Optional Roof Auxiliary...

Page 92: ...stem performance If the valves are shut off in cab temperature adjustment may become limited In addition when shut off valves are closed defrosters will only produce cold air Item No Item Description...

Page 93: ...e In this 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 OFFautomatically as needed when in this mode...

Page 94: ...h the windows up remove the overheated air inside by driving with windows down and the air conditioner ON for one or two city blocks Air Conditioning CAUTION Failure to follow recommended service proc...

Page 95: ...uipped with optional Heater Shut Off Valve s to prevent hot coolant from circulating through the heater core s Closing the valve s during hot weather operation will improve A C system performance If t...

Page 96: ...ocks Remote Keyless Entry Operation Optional The remote keyless entry key fob is used to lock and unlock all doors from a distance of 30 feet 9 m or less Whenever the doors are locked or unlocked usin...

Page 97: ...rior or interior door handles To open the door from the interior if locked the front door will unlock when the door handle is pulled If equipped with a crew cab the rear door locks when engaged must b...

Page 98: ...driver and passenger windows Controls for these window lifts are mounted in the door control panels located by the vent windows The driver side controls regulate window operation for both driver and...

Page 99: ...onomy time at idle or both Rewards include higher maximum vehicle speed and higher cruise control speed limit Lower maximum vehicle speed or cruise control speed limits may result as a penalty for fai...

Page 100: ...Controls Features 88 3879634R1...

Page 101: ...utilized The operator is responsible for using those processes and or equipment to ensure that the diesel engine and all other components on the truck can be operated safely under the specific conditi...

Page 102: ...de open Maintain exhaust system in good operating condition Breathing exhaust gases could result in personal injury or death WARNING All vehicles have blind spots Make sure your way is clear in all di...

Page 103: ...injury or death NOTE Periodically inspect the seat belts for wear and function Replace any parts whose performance is in doubt General Safety belts must be worn by the driver and all passengers at all...

Page 104: ...a locking type that allows the seat belt to come out and to adjust for body movement 4 The seat belt will return to the retractor as the body returns to its original position The retractor will retain...

Page 105: ...Use caution and reduce speed Properly adjusted seats and seating systems may not compensate completely for severe road conditions Ensure that head clearance will be maintained during all road conditio...

Page 106: ...osition This switch is cab mounted or mounted on the battery box NOTE Automated manual transmissions must be in N Neutral and vehicles with a clutch pedal require the clutch pedal to be depressed befo...

Page 107: ...dling period should somewhat follow the size of the engine in order to avoid seals or like features of an engine being damaged by rising heat 1 Place the transmission in the N Neutral position 2 Apply...

Page 108: ...turn ON 30 seconds before engine shutdown This indication will continue until the engine shuts down or the system is reset System Operation The Vehicle Shutdown system operates in the following manne...

Page 109: ...ng brake must be set engaged before the system will clear the previous theft deterrent code entry Theft Deterrent Code Entry Procedures Engine Start Theft Deterrent Code Entry Sequence The correct eng...

Page 110: ...ke released Warning sequence is begun an alarm will beep continuously and the red ENGINE STOP indicator will flash slowly Engine will shut down unless theft deterrent code is entered within programmed...

Page 111: ...r 1 5 second Engine runs without interruption 8 Clear switch is depressed with parking brake set No system alerts Theft deterrent code must be entered before driving vehicle Engine runs without interr...

Page 112: ...available shield eyes when near either vehicle s batteries 5 Vehicle bodies or bumpers must not be in contact 6 Connect one end of the first jumper cable to positive terminal of the dead battery or t...

Page 113: ...al dealer for information about special cold weather equipment and precautions Winter Engine Intake Operation When the WINTER position is selected the optional yellow Snow Valve warning indicator in t...

Page 114: ...ze solution to protect against damage by overheating 2 Fill fuel tank at end of daily operation to prevent condensation in tank 3 Keep external surface of engine radiator charge air cooler AC condense...

Page 115: ...any of the above are detected have the vehicle inspected and repaired at once by a qualified mechanic WARNING Do not adjust the steering column while the vehicle is moving It could suddenly or unexpec...

Page 116: ...to the locked position with your left hand Make certain the steering wheel is in the proper position and the column is locked General Start the vehicle in motion by utilizing the highest gear speed i...

Page 117: ...d or training for the specific functions provided NOTE Familiarize yourself with all of the switches that control chassis engine and body equipment and seek adequate training on the function of all fe...

Page 118: ...w engine speeds the ammeter indicator may show a negative or discharge reading When the battery is fully charged a very slight charge is indicated during normal vehicle operation Battery WARNING Keep...

Page 119: ...g Do not increase size of fuse or circuit breaker or change type of breaker supplied with your truck To do so could cause wiring to overheat and possibly burn resulting in a fire which could cause pro...

Page 120: ...on chamber The resulting cooler intake air is denser than uncooled air and will allow additional fuel to be injected for greater power while helping to reduce emissions Engine Brake Retarder Optional...

Page 121: ...e brake feature will automatically deactivate if either the accelerator or the clutch is pushed or when the engine speed falls to 1000 RPM Operational Modes The engine brake will operate in one of the...

Page 122: ...as indicated in the above warning Manually selecting 3rd gear or 2nd gear will not cause damage to the engine or transmission The manually selected gear is only for driver intent The transmission wil...

Page 123: ...g Indicators are illuminated and remain on while the ECM runs normal start up tests then goes OFF If warning indicator stays on or comes on while operating the vehicle it is an indication that the veh...

Page 124: ...if the conditions causing the shutdown are still present See Automatic Engine Shut Down and Restarting procedure Air Compressor Cycling The MaxxForce 11 and 13 Liter engines can be equipped with one...

Page 125: ...ressurized air to the air system During normal engine operation this cycle will be evident by the fluctuation of the primary air tank pressure gauge Cooling System WARNING To prevent personal injury o...

Page 126: ...ant service life details For vehicles with MaxxForce 11 and 13 engines the cooling system of your new vehicle will be filled at the factory with nitrite free Shell Rotella Ultra ELC YELLOW coolant Int...

Page 127: ...esel engines used with advanced after treatment systems Diesel Particulate Filters DPF For complete details on fuel requirements see the Engine Operation and Maintenance Manual supplied with the vehic...

Page 128: ...draw fuel tank The draw fuel tank must have fuel in it at all times otherwise the vehicle may stall and may be difficult to restart the fuel gauge reads the fuel level only from the draw fuel tank The...

Page 129: ...rviced by a technician It is important to perform a Parked Regeneration when required Failure to do so could be mission disabling and result in the vehicle being towed See the following information fo...

Page 130: ...3 Flashing An alarm will beep continuously while ignition is on Scrolls between See Visor for info and Parked Regen Required Exhaust filter is full Engine performance is LIMITED WARNING Pull vehicle...

Page 131: ...ARKD 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 conditions in s...

Page 132: ...heat generated and little or no wear However during the brief period when the clutch is picking up the load considerable heat is generated By riding or slipping the clutch the period of partial engage...

Page 133: ...hicles with Nonsynchronized Transmission Vehicle Not Moving A clutch brake is used to stop transmission input shaft rotation so that the initial first or reverse gear selection can be accomplished whe...

Page 134: ...In order to complete gear engagement it may be necessary to apply light pressure to the shift lever during initial engagement of the clutch It takes one to two seconds to match gear speeds Steady pres...

Page 135: ...ped the transmission will remain in LO gear until another gear is selected If selected while in motion the transmission will downshift when it is safe to do so To place the transmission in Neutral pre...

Page 136: ...instrument panel gauge cluster contains a Parking Brake indicator that illuminates when the ignition switch is ON the parking brake is applied and the transmission selector is in range Parking The Veh...

Page 137: ...pedal depressed before the gear selector can be moved from the P Park or PB Parking Brake position into the desired operational position Manual Parking Brake After starting the engine place foot firm...

Page 138: ...e speed is above idle when a gear is selected with the shift tower the vehicle will not move To move the vehicle the shift tower must be moved to re select a gear after the engine comes down to idle F...

Page 139: ...n into Reverse R or Drive D first place foot on brake pedal With foot on brake pedal press either R or D release the Parking Brake and then release the brake pedal When in Drive to select a lower rang...

Page 140: ...ition as indicated on LCD display and then release column shift lever Release the Parking Brake Lift foot from service brake pedal to allow the vehicle to move backward To select a forward gear while...

Page 141: ...ed in reverse gear Auto Neutral WARNING When using the AUTO NEUTRAL feature always hold the brake pedal down when releasing the parking brake since the transmission will automatically return to forwar...

Page 142: ...ill show that gear the LCD display will also indicate that gear and the AUTO NEUTRAL indicator will go off Note The Auto Neutral switch indicator will still be On indicating that the Auto Neutral func...

Page 143: ...uto Neutral mode is desired To turn off the Auto Neutral mode place the AUTO NEUTL ON switch to the off AUTO NEUTL position This will turn Off the switch indicator Power Take Off Control If your vehic...

Page 144: ...ement good traction continuously This will result in excessive tire wear and premature axle wear Never engage the PDL when the wheels are spinning The PDL should be engaged which prevents interaxle di...

Page 145: ...can be manually shifted from the vehicle cab By actuating a switch mounted on the instrument panel gauge cluster the driver can lock or unlock the rear axle differential s when the vehicle is moving...

Page 146: ...spin out are minimized CAUTION Tire sizes on both rear wheels should be the same on axles equipped with a traction equalizer If not excessive wear may occur to the traction equalizer Locking Different...

Page 147: ...fferences in tire wear or tire pressure unbalanced loading of the vehicle or operating the vehicle on a side slope may cause the locking differential to deliver power to only one side of the vehicle t...

Page 148: ...nent failure resulting in property damage personal injury or death Axle Operating Temperature Normally axle operating temperature will not exceed more than 100 F 38 C above ambient temperature However...

Page 149: ...trols either of two solenoids that cause the air actuated transfer case to operate in either the high or low gear ratio In Switch Indicator The ON FRONT AXLE switch contains an indicator that will be...

Page 150: ...Gear Ratio Shifting with Vehicle Stopped The transfer case gear ratio can be selected and the front axle can be engaged at the same time by performing the following steps NOTE Ensure that there are no...

Page 151: ...witch is in either ACC or ON position but will only fill when the ignition switch is in the ON position NOTE To lower the suspension dump operation the vehicle speed must be less than 5 mph 8 km h Whe...

Page 152: ...the DUMP position The SUSP DUMP switch indicator will blink slowly in the event of a system command fault regardless of the position of the SUSP DUMP switch Axle and Suspension Conversions WARNING Whe...

Page 153: ...death The two lift axle designs are 1 Fixed Rigid and 2 Self Steering lift axles Fixed lift axle The fixed lift axle design provides 20 000 pounds maximum load carrying capacity The design does not a...

Page 154: ...on switch must be in the ON or RUN position 2 The UP DOWN switch is used to raise and lower the lift axle one control for each lift axle installed 3 The Air Pressure Regulator is used to control the a...

Page 155: ...e controls are located and accessible from the floor mounted pedestal next to the driver s seat This system s controls consist of one AXLE ENABLE system switch an UP DOWN switch an air Pressure Regula...

Page 156: ...he AXLE ENABLE system switch an UP DOWN switch and an Air Pressure Gauge for each axle The controls on the external panel are an Air Pressure Regulator and a second Air Pressure Gauge for each lift ax...

Page 157: ...ift Axle System NOTE Before pressing the AXLE ENABLE switch ensure that all UP DOWN switches are in the UP position The ignition switch must be in the Run or On position in order to enable the lift ax...

Page 158: ...always keep that person in sight Failure to do so may result in property damage personal injury or death When the UP position of the UP DOWN switch is selected air is vented from the axle load air ba...

Page 159: ...axle and wheel equipment weighing 1200 lbs ground weight with no 0 psi air pressure Brakes WARNING Always check and maintain brakes in proper condition and adjustment Out of adjustment brakes could ca...

Page 160: ...rake system Air Brakes WARNING Stopping distance may increase under the failed condition since only one section of the brake system is operating Reduce speed and employ safe driving practices Have bra...

Page 161: ...vehicle Should the red indicator and beeper not shut off soon after startup the air pressure gauge s should also indicate at least one section of the split system has low air pressure If the red indi...

Page 162: ...ervice Manual It should be noted that upon loss of air pressure partial spring brake application will occur prior to automatic application of the control valve To release recharge system to 70 psi 483...

Page 163: ...ements refer to the Maintenance Instructions section as well as local regulations The air dryer is installed in the discharge line between the air compressor and the air system reservoirs The air drye...

Page 164: ...he operation of one valve together with the other permits the operator to select the desired functions described below Red Valve Trailer Air Supply Yellow Valve Parking Brake Function Mode Out Out Sys...

Page 165: ...are 1 The ignition switch is in the OFF position 2 The parking brake is not set 3 The driver s door any cab is opened To turn off the alarm press the service brake pedal Then after turning the ignitio...

Page 166: ...capability than the available road traction will permit If the road is slippery it will take longer to stop than on a dry road Steering maneuverability will be similarly limited Vehicle speed must be...

Page 167: ...rect steering as necessary to keep in straight lines If only your tractor has ABS Use your tractor s ABS brakes Steer clear of obstacles and watch the trailer through your mirrors to make sure it foll...

Page 168: ...n to limit wheel spin does not occur at vehicle speeds above approximately 31 mph 50 km h Therefore at speeds above 31 mph 50 km h all ATC events are controlled only by engine power limiting The Tract...

Page 169: ...eels of a vehicle ECUs optimize slip between the tire and the road surface by monitoring individual wheel turning motion during braking Advanced Stability Functions This function enhances stability by...

Page 170: ...ly on wet and slippery road surfaces It should 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 effor...

Page 171: ...t distances without suspending rear wheels or removing the axle shafts or propeller shaft In the event the chassis is equipped with tandem axle and the vehicle is to be towed from the front the forwar...

Page 172: ...alidate DIFF LOCK is FULLY engaged and axle shaft can be removed Failure to fully engage axle DIFF LOCK will allow DIFF LOCK shift collar to fall slightly and block or temporarily resist axle shaft re...

Page 173: ...ir deflector must be removed Whenever possible it is preferable to tow a disabled vehicle from the rear by raising the rear of the chassis by the rear axles When towing a vehicle with rear of the chas...

Page 174: ...DUMP position and pull the tractor away from the trailer The SUSP DUMP switch must be returned to the down SUSP position before operating with a trailer or operating in the bobtail mode Fifth Wheel Op...

Page 175: ...chase a trailer 4 Make sure brake hoses and light cords are clear of the fifth wheel 5 Back tractor squarely under trailer engaging fifth wheel jaws on trailer kingpin Always back slowly making sure t...

Page 176: ...ust be on landing gear 4 Block trailer wheels 5 Disconnect brake hoses and light cords Be sure hoses and cords are clear 6 Pull coupler release lever to disengage fifth wheel jaws 7 Release tractor pa...

Page 177: ...alent to International truck 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 co...

Page 178: ...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 the batt...

Page 179: ...e is placed in operation regular lubrication and maintenance intervals based on the type of service and road conditions should be established The loads carried speed road and weather conditions all co...

Page 180: ...ap solution and reused Be sure to wash and rinse both sides and be sure to keep the spray head at least six inches away from the filter to prevent damage Correct airflow may be restored by either repl...

Page 181: ...intake 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 mount...

Page 182: ...for optimal grease distribution within each component joint Inspect lubricate and adjust the wheel bearings at regular intervals Refer to SECTION 7 MAINTENANCE INTERVALS AND SPECIFICATIONS for the cor...

Page 183: ...cle on level ground Make sure the axle mounting U bolt nuts attaching or mounting bolts and nuts are securely tightened Loose or misaligned rear axles will affect vehicle alignment front tire wear and...

Page 184: ...respirator approved by National Institute of Occupational Studies of Health NIOSH or Mine Safety and Appliance MSA during all brake service procedures Wear the respirator from removal of the wheels t...

Page 185: ...nual adjustment must be made although this should not be a common practice a service appointment and full foundation brake ASA and other brake system component inspection must be conducted as soon as...

Page 186: ...brake system must be inspected by a trained mechanic Deteriorated components or components worn outside of specifications must be replaced Check 1 Rubber components for condition cracks tears wear mis...

Page 187: ...before the engine is started turn on the ignition and touch the air dryer housing It should be warmer than other metallic items on the vehicle If some warmth cannot be felt it may indicate that the he...

Page 188: ...ater for cleaning Damage to these parts can occur if cleaning solutions having excessive acidity or alkalinity pH are used Also the higher the solution temperature ranges the more caustic the cleaner...

Page 189: ...runs between starts low ambient operating temperatures using battery current without the engine running and vibration will reduce battery life Battery life is also affected by the condition of interr...

Page 190: ...coat of lubricant sealing grease such as Fleetrite 472141 C1 or equivalent or a spray protectant and reassemble Be sure the terminals are clamped tightly Electrical Charging and Starting System Test...

Page 191: ...cessories are connected to circuits that are both appropriate and not overloaded No modification should be made to any vehicle control system without first contacting your International dealer Fuses a...

Page 192: ...belts belt tensioners etc and inspection and adjustment of items such as valve lash etc refer to the Engine Operation and Maintenance Manual supplied with the vehicle Air Induction System WARNING To...

Page 193: ...ith the engine shutdown The gauge is mounted on the forward side of the air cleaner housing or optionally on the center dash panel wing panel Both gauges have a push type reset button The reset on the...

Page 194: ...nants from entering the engine air intake system during service of the primary element or in cases where the primary element becomes damaged Both options are serviced in a similar manner NOTE Do not c...

Page 195: ...filtered air to enter the engine Inspect to be sure that the rubber dust unloader valve at bottom of housing is in place free of debris and not cracked 4 Inspect the new air filter element for a damag...

Page 196: ...to increase air flow enough to create an initial reading Air cleaner element split open Visually inspect element Problem High Restriction Reading POSSIBLE CAUSES EXPLANATION Plugged main air filter el...

Page 197: ...nternational Type ll specifications such as the Fleetrite Premium 50 50 with SCA P N ZJJSCA5550 The Type III coolant must meet International Type IlI specifications such as the Shell Rotella ELC Exten...

Page 198: ...per sight glass remove coolant until top of coolant level can be seen in upper sight glass For vehicles equipped with an opaque deaeration tank and two sight glasses with engine HOT Assure coolant lev...

Page 199: ...make up tank as that volume will be necessary to adjust the coolant concentration freeze point later 4 After adding coolant over a period of two minutes and keeping the coolant deaeration tank full re...

Page 200: ...47 coolant mixture will achieve a 40 F 40 C freeze point The first pour should reach to the top of the reservoir fill neck 4 Because the radiator fills slowly it is important to continue to top off th...

Page 201: ...lutch Inspect for proper operation secure electrical connections and air supply as appropriate See the Service Manual for details Fuel System GOVERNMENT REGULATION Diesel fuel sold for use in 2007 and...

Page 202: ...Permanent or removable tow hooks as well as pintle hooks if present should be inspected for functionality damage or a loose mounting Removable tow hooks and or pins should be stored in such a way that...

Page 203: ...rument panel gauge cluster warning indicators See the Parked Regeneration Procedure in SECTION 5 OPERATION Cleaning If on vehicle regeneration is unsuccessful at removing soot from the DPF the DPF may...

Page 204: ...suspension height at the PM interval See the appropriate Service Manual for suspension height specifications NOTE Suspension alignment must be maintained at all times Periodically Check condition of s...

Page 205: ...ize the appropriate HOT or COLD fluid temperature specific level marks if displayed on power steering reservoir Regularly inspect steering column joint bolts and steering linkage particularly for body...

Page 206: ...Tire Warnings WARNING Due to tire manufacturers re marking tires to conform to the SI metric system tires marked with old and new loads or inflation pressures could be placed on the same vehicle For...

Page 207: ...Premature wheel failure can result in property damage personal injury or death Do not change from steel wheels or a steel inner and aluminum outer wheel combination to aluminum wheels without changin...

Page 208: ...flexing due to underinflation causes heat buildup within the tire components This leads to reduced strength breakdown of the rubber compounds and possible separation of the tire components i e ply and...

Page 209: ...1 4 inch 6 mm in diameter or 3 4 inch 19 mm in circumference should not be mounted on the same dual wheel assembly Dual Tires Mixing NOTE Never mix bias and radial tires on this vehicle It is recommen...

Page 210: ...e wheels or tires can cause vehicle vibration and bounce and shimmy Replace damaged or out of round wheels Out of round tires and wheel assemblies can be corrected by rechecking the tire relative to t...

Page 211: ...nsion components Maintain proper wheel bearing adjustment Use of Tire Chains Refer to chain manufacturer s recommendation for correct tire chain usage installation and removal Wheels Wheel and Wheel N...

Page 212: ...when necessary Failure to obtain proper clearance may result in rapid tire deflation and cause property damage personal injury or death Wheel Nut Torque Maintenance Tighten and maintain wheel and rim...

Page 213: ...tely when the wheel is contacted resulting in a wheel nut torque well below the final specified torque 8 Use a calibrated torque wrench to apply the specified torque to each wheel nut in the sequence...

Page 214: ...Maintenance Instructions 202 3879634R1...

Page 215: ...tervals provided in this manual are for normal highway and environmental service conditions These intervals may be expressed in miles kilometers hours of operation and or months of operation It is imp...

Page 216: ...6 months 20 000 miles 32 000 km 600 hours 12 months 30 000 miles 48 000 km 900 hours 18 months Lubrication and Maintenance Interval Chart Notes NOTE 1 A hand pumped grease gun should be used for opti...

Page 217: ...Type including synthetic Change Oil Severe Service and City 60 000 miles 96 000 km 6 On Highway 100 000 miles 160 000 km 12 Wheel Bearing Grease Type Repack Severe Service and City 30 000 miles 48 000...

Page 218: ...Wheel Ends inspect for leaks lube level condition and check end play with dial indicator 100 000 160 000 12 Also at brake lining service If wheel end play is found to be outside the 0 001 in to 0 005...

Page 219: ...es not spliced or taped insulation not cut cracked chafed or worn Inspect A B Power Steering Fluid Check Level A B Steering System Check Tightness A B Steering Gear Lubricate A B ATTN Install grease s...

Page 220: ...Lubricate A B Shoes Check for wear and drag A B Drums Chambers Hoses etc Check for wear damage A B Brake Chamber Rod Travel Check A B Air Dryer Desiccant Replace AD IP 1 year AD 9 2 Years Air Dryer He...

Page 221: ...al Fan Belt Auto Tensioner Inspect Refer to Engine Operation and Maintenance Manual Fuel Filter Drain Separated Water Refer to Engine Operation and Maintenance Manual Engine Fuel Filter Replace Refer...

Page 222: ...ilter Replace Refer to Transmission Operators Manual Change Oil A Initial Oil Change at 5000 miles 9000 km Transfer Case 4X4 only Meritor Synthetic Oil Change Initial Oil Change at 2 500 miles 4 000 k...

Page 223: ...s 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 the botto...

Page 224: ...iate Shaft 3 Front S Cams and Slack Adjusters 4 King Pin Bushings and Thrust Bearings 5 Tie Rod Ends 6 Steering Drag Link Ends 7 Clutch Cross Shafts and Release Bearing 8 Drive Shaft U joints and Slip...

Page 225: ...ant Deaeration Tank 3 Engine Oil Dipstick 4 Front Axle Oil Filled Hubs 5 Transfer Case if equipped 6 Drive Axle Oil Fill Level Check Plug 7 Manual Transmission Oil Fill Level Check Plug 8 Automatic Tr...

Page 226: ...5 Meritor RS 17 145 16 34 Dana Spicer 19060T 16 6 35 Dana Spicer 23082T 17 5 37 Forward Rear Axle Model No Liters Pints Liters Pints Meritor RS 21 160 RS 21 230 RS 23 160 18 5 39 Meritor RS 21 162 18...

Page 227: ...37 16 34 Dana Spicer D46 170HP R46 170H 18 5 39 17 5 37 Dana Spicer D46 170HP R46 170DH 18 5 39 17 5 37 Forward Rear Axle Model No Liters Pints Liters Pints Dana Spicer D46 170DHP R46 170DH 18 5 39 17...

Page 228: ...t concentrate is advised in order to achieve a final mixture close to 50 50 Fill the system and run the vehicle until the thermostat opens Check the coolant concentration and add additional water or c...

Page 229: ...B FRO 13210B FRO 14210B FRO 12210C FRO 13210C FRO 14210C FRO 15210C FRO 16210C 11 23 5 Fuller 10 Speed RTO F 11908L RTO F 14908LL RTO F 16908LL 13 28 Fuller 10 Speed RT 8908LL 13 28 Fuller 10 Speed RT...

Page 230: ...and fluids remain in external circuits and transmission cavities Check at operating temperature and topped off as required See Lubricant and Sealer specifications for these transmission lubes Tire and...

Page 231: ...ily Per operation Check bushings for excessive wear or movement Every 30 days Drain condensation from tank Dry climate Monthly Wet climate Daily Torque U bolts and all fasteners see lift axle Torque c...

Page 232: ...ats 450 500 610 678 NOTE Do not use lubrication on dry threads Where excessive corrosion exists a light coat of lubricant on first three threads of stud on bolt is permitted Keep lubricant away from h...

Page 233: ...400 502 542 14TBZ 23 000 lb Capacity Single Air Hendrickson PRIMAAX EX 350 400 475 542 14UNW 14UNX and 14UNY 46 000 lb Capacity Tandem Air Hendrickson PRIMAAX EX with 72 inch 55 inch and 60 inch axle...

Page 234: ...53 407 3ADE 16 000 lb Capacity Parabolic Taper Leaf 260 300 353 407 3ADG 18 000 lb Capacity Parabolic Taper Leaf 260 300 353 407 20 000 lb Capacity Parabolic Taper Leaf 260 300 353 407 3AGA 20 000 lb...

Page 235: ...e 3 Repeat steps 1 and 2 tightening all four bolts to full torque Lift Axle U Bolt Nut Torque Chart U Bolt Size UNF Grade 8 Size in inches 3 8 1 2 5 8 3 4 7 8 1 1 1 8 Min Torque lbf ft 15 40 120 200 4...

Page 236: ...ntenance Intervals And Specifications Fuse Charts The following fuse illustrations represent the fuse panel layouts The actual vehicle fuse panels will vary depending on the vehicle options 224 387963...

Page 237: ...ker Light 2548 Tail Brake Turn Light 32 3 CP 1157 Back up Light 32 CP GE1156 Ashtray Light N A N A Filter List Filter part numbers and or specifications may change during the life cycle of this vehicl...

Page 238: ...Maintenance Intervals And Specifications 226 3879634R1...

Page 239: ...local International dealer These service resources are also available via the Internet by an annual subscription to the Fleet ISIS Web site or via the iService DVD Information on the Fleet ISIS Web si...

Page 240: ...your specification your vocation International North America s leader in truck manufacturing is also North America s leader in warranty value Optional Service Contracts Custom Service Contracts and Pe...

Page 241: ...Modular Controls 152 Trailer Brake Hand Control 151 Air Cleaner Element Service 182 Air Compressor Cycling 112 A CONT Air Conditioning 82 Air Conditioning Service Checks 168 Front Access HVAC Filter 1...

Page 242: ...n of the Column Mounted Shifter 128 Parking The Vehicle 124 Power Take Off Control 131 Preparing to Drive the Vehicle 125 Torque Lock 126 Auxiliary Gauge Switch Package AGSP Optional 78 Panel Componen...

Page 243: ...g Brake Modular Controls 152 Trailer Brake Hand Control 151 Air Dryer 174 Desiccant Filter 175 B CONT Brakes cont Heater 175 Purge Valve 175 Air Reservoir Tanks Moisture Draining 175 ATC OFF ROAD or M...

Page 244: ...ibration Procedure 55 Component Code Numbers 2 Line Set Ticket 2 C CONT Components Requiring Fluid Check and Fill 213 Components Requiring Lubrication 212 Connecting Disconnecting a Trailer to a Vehic...

Page 245: ...ote Keyless Entry Operation Optional 84 Door Opening Unlock 85 D CONT Double Clutch Procedures Nonsynchronized 121 Downhill Operation 147 Drive Shafts 192 Driver Reward 87 Driver Controlled Differenti...

Page 246: ...ssions Special Driver Instructions 109 Operational Modes 109 Engine fluids and contaminated material 180 E CONT Engine Idle Shutdown Timer Optional 96 System Operation 96 Engine Idling 101 Engine Nois...

Page 247: ...uel Requirements 115 Unacceptable Fuel Blends 115 Fuel and Lubricant Additives 116 Fuel System 189 Fuel Tank Draining and Cleaning 189 Fuel Tank Draining and Cleaning 189 F CONT Fueling Precautions 11...

Page 248: ...ification Number VIN 12 Irregular Wear 199 L Left Engine Compartment 18 Left Front of Vehicle 19 Left Rear of Vehicle 31 Left Side Cab Area 17 Lift Axle Control Identification 144 Lift Axle Controls 1...

Page 249: ...auges 43 Instrument Panel Gauge Cluster 39 Instrument Panel Gauge Cluster Alarms 45 Integral Digital Display 47 Integral Digital Display Detailed Information 56 M CONT Main Instrument Control Panel co...

Page 250: ...Normal Maintenance 170 O Operating Instructions 103 Automatic Transmissions 123 Air Parking Brake or Power Parking Brake 125 Allison Generation IV T Bar Gearshift Control 126 Allison Transmission with...

Page 251: ...Fuel 115 Additional Unsafe Practices 115 O CONT Operating Instructions cont Fuel and Lubricant Additives 116 Fueling Precautions 116 Fueling Procedures 116 Hazards of Diesel Fuel Gasoline Blends 115...

Page 252: ...l Engine Protection System 3 Way 08WPP 112 Optional Instrument panel gauge cluster Compass Calibration Procedure 52 Compass Declination Zone Set Procedure 52 Compass Directional Calibration Procedure...

Page 253: ...tion 197 Rotation Is Advisable 197 Tire Replacement 198 Rotation Is Advisable 197 S Safety Recalls and Authorized Field Changes 5 Scheduled Maintenance 180 Seat Belts 91 Care of Seat Belts 93 Operatio...

Page 254: ...ontrol 12VXT 71 Throttle 70 Storage Duration One Month or Less 2 Storage Duration Over One Month 3 Storage Facilities 4 Supporting Your Vehicle for Service 167 Suspension Air and Steel Springs 192 S C...

Page 255: ...Removing Axle Shafts Before Towing 160 Towing Vehicle with Front Wheels Suspended 159 Towing Vehicle with Rear Wheels Suspended 161 Towing Vehicles with Driver Controlled Differential Lock 160 Install...

Page 256: ...ssion 217 Unlocking the Door 86 Upholstery Care 176 Use of Tire Chains 199 V Vehicle Identification 12 V CONT Vehicle Identification cont Engine Serial Number 12 Feature Codes 12 Line Set Ticket 12 Ve...

Page 257: ...el Nut Torque Maintenance 200 Wheels 199 Wheel and Wheel Nut Maintenance and Installation 199 Hub Piloted Wheel Installation Procedures 200 Wheel Nut Torque Maintenance 200 W CONT Window Lockout Funct...

Page 258: ...Index 246 3879634R1...

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