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International Pro Star Operator`s Manual

1. eeeeeeeee eee es 137 Fuel and Lubricant Additives cccceee eee eee eens 137 Fuel Syste ehnisa andes fe vedanta teers av eeel ey eects 195 Fuel Tank Draining and Cleaning eeeeeee eee 195 Fuel Tank Draining and Cleaning eeeee eee ees 195 Fueling Precautions 00 cece cece cence tence eee eaeeees 138 Fueling Procedures 0ccceeeeeeeee eee e ence eee e eee ees 137 Fuse Chaliske nienn iidie tear ee desea ted aeaiia aA 228 Pilte MliStsiitin uses Pest r E e E aes 232 ProStare Series Light Information eeeee eee 231 Typical Interior Fuse Panel Layout 2 2 0005 229 Typical Luggage Compartment Fuse Panel Layout 230 Fuses and RelayS ccceeceeeeeee eee eeeeeeeeeeeeeneees 186 G Gags ne de Seeds danaa e aE idee eder ace 50 82 General Text and Warning Messages cccccecceecceecee 56 H Hazards of Diesel Fuel Gasoline Blends 006 137 HeadlightSwutosteeeededeeteed sete teed ae 75 Heater aina eare aa aeDA AAAA a ds 181 High Restriction Reading Table ssnesneerneerrrnrrnn 191 Ho di oneness there de tise a e Aa a a a a a 18 Lowering the Hood ssssssssrssrssrenrrsrrrrresrerrrsrena 19 Raising the HOOd ceceeeee eee e eee siduri Anuna nera RA 18 3878859R2 Index H CONT HOOK UP edtetenetdeenersey cre diauieneneeempeeneseenneett EPEE 167 Horizontal Refrigerat
2. cee cece cece eee eee eens 182 Exposed Rubber and Unpainted Plastic Parts 182 Upholstery Care cece eee eee eee e ARAIA 182 Washing and WaXiNng 0seeeee eee e eee e eee e eens 182 Cab Controls A Era cecil cei nea ine Geddes EE 118 Cab Doors and LOCKS ee cece nee e eee VANE RRINE 90 Cab Entry and EXit 0 0 ccc eeeee eee ee eee ARRERA ees 18 Cab Interior Inspection 0 ceeeeeeee eee eee 41 GADES saret EEEE ENEE EEEE my dulled 110 Airline Cabinets assasssrssrssrnnranranrnnrrnrnrrrnrenn 114 3878859R2 C CONT Cabinets cont Dresser Cabinets sre rrn enner AE eee e eset seen ee tenes 1 Horizontal Refrigerator 0 c cece cece cece eee eee eens 1 Rear Wardrobe Cabinet cceeeeeee eee eee 1 Refrigerator Cabinet cc cece ee eee e eee e eee ete e nes 1 Tower Wardrobe Cabinet cece ee eee cece nena anes 1 Cabinets Storage cceeeeee cece teen teen nena 1 Canadian Registered VehiclesS ccccceeeeeeeeeeeeeees Care of Seat Belts cece eee eee eee eee eneeeeeees 1 Care of Vehicle 0 cece cceee eee eee ee eee tent Aaa LEATA 1 Bright Metal Care ccccccece cece eect eee e eee e teens 1 Exposed Rubber and Unpainted Plastic Parts 1 Upholstery Carey i ckiscesetere el birni E SAna deat g 1 Washing and WaxXing e cece cece eee e
3. 00eeeee ee 206 Wheel Nut Torque Maintenance 2 eeeeeee eee ee 206 WheelSiss osoia ere teak chin ete ash ee eee Sees tee 205 3878859R2 Index W CONT Wheels cont TTANSMISSION 0 c ccc eect e cece a eee e een eeeeeeeeees 208 Wheel and Wheel Nut Maintenance and Installation 205 Hub Piloted Wheel Installation Procedures 206 Wheel Nut Torque Maintenance 2 eeeeee 206 Window Lockout Function 0ccce cee ee cee eeetaeeeeees 92 WINKOWS sess steele datede wededtloniieag nd a Gens uebelieyakeean 102 Winter Front Usage 0ccccceee ee ee eee eeeeeeeeeeeeeeees 127 249 Index 250 3878859R2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm
4. 2 cceeee cece eeeeee esses eeeee eee eees 115 237 Index C CONT Convenience Features cont Sleeper Curtain rrr rrr rrr rarr eee eee AT 115 Sleeper FAN vs sseeesseeerseg sees AASA ATEAN E EERE 115 Speako lS naaran E EAA E AEAEE ETEA RKA 115 Television Mount 000eee cece ee eeeeeee ee eee eeeeneees 115 Coolant and Optional Coolant Filter 4 194 Coolant Concentration Freeze Point c cece ees 194 Coolant Level Check 02 cceeeeeeeee cece ee eeeeeeeees 192 Cooling SySteM cece cece eee eee eee teen eee aaaeeeeees 192 ANG OZ son hd ae eaa E a enue eay AA AA Renee AE ouwhe 194 Coolant and Optional Coolant Filter 08 194 Coolant Concentration Freeze Point 5 194 Coolant Level Check 22 ccceeee cece cece ee eeeeeaeee 192 Fan Clutei iiss Siesta tiered a a tection ae 194 Filling InStructiOnS 0 0 cece eee ence eee eee eens 192 Cooling System Refill Capacities eee eee 220 Courtesy Lights is s he lt ssesesedeececcccancasssaaaganaooesooseees 76 Crankcase and Oil Filters cc cece eee 220 Crankcase Ventilation Filter 2 cceeee eee eeeee ees 195 Cruise Control aerer oo Sre AEREE EERE cis ENANSA iia 78 Customer Security Guide for International Trucks 6 D Dash Components e ri ia eects eee DDN Es 44 Daytime Running Lights DRL sscse
5. 00ceeeeeee eee e eee 20 Lubricant and Sealer Specifications ceeeeeee ees 223 Lubrication and Fluids Charts 00 ccceeeeeee eee rete ees 217 Components Requiring Fluid Check and Fill 219 Components Requiring Lubrication 0e 218 Lubrication and Maintenance Interval Recommended Synchronized Intervals Table cee ee cece eee eee ees 211 Lubrication and Maintenance Interval Chart Notes 210 Lubrication and Maintenance Interval Chart Symbols Key 210 Lubrication and Maintenance Intervals 04 209 Maintenance Intervals 0 c cece eeeeeee eee e eee e teers 209 Lubrication Points 0 cece eee een eee ASERI 199 Luggage Box ACCESS 0ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeees 21 Driver and Passenger Side eeeee eee eee e eee eeeee 21 3878859R2 M Main tPF atures sez isudede tania Redtne hed ogudadeue beaseebens 95 Maintenance Guidelines ccc cece cece cece ee eeeeenes 171 Maintenance Intervals cccccee cece cee eeeeeneeeenees 209 Lubrication and Maintenance Interval Recommended Synchronized Intervals Table 0 cc eeeeeeee eee ees 211 Lubrication and Maintenance Interval Chart Notes 210 Lubrication and Maintenance Interval Chart Symbols KO E A A bevee aoa ee E AT 210 Maintenance Record Noise Control 00ccceeeeeeeees 5 Manual Climate Contro
6. i Luggage Door External Hook Ups for Telephone and TV External Electrical Hook Up Shore Power Removable Skirt Option Battery Access Chassis Skirt Aero Fuel Cap NO a A YO ND External Hook Up for Block Heater 3878859R2 10 11 12 13 Model Description Side Marker Turn Light Fog Light Tilt Away Bumper Headlight VORAD optional Sunshade 15 Model Description 3878859R2 Model Description Work Lights 5 In Transit Heat optional 2 Luggage Door 6 Gladhand Storage Bracket 3 Fuel Cap 7 Grab Handle 4 VORAD optional 3878859R2 17 Model Description Cab Entry and Exit 18 A WARNING Do not step or climb upon any vehicle surface unless it is slip resistant and a handhold is provided Failure to follow this warning could cause you to slip or fall and could result in personal injury or death A three point stance should be used three out of four extremities should be in contact with the vehicle climbing system at all times Face inward towards the cab when entering and exiting Always keep steps and handholds in continuous good repair Make sure all attaching bolts and hardware are tight thus eliminating any movement of steps and handholds Keep steps grab handles and shoes free of grease mud dirt fuel ice and snow Use extra care during inclement weather Failure to follow this warning could cause you to slip or fall and could result in
7. Install new filter into air intake housing 4 Close and secure filter access door by turning screws clockwise one quarter turn 3878859R2 Maintenance Instructions Recirculation Filters The recirculation filters are mounted on the left and right sides of the HVAC unit which is located in cab under the left side dash 2 8487421 1 Recirculation Filter 2 HVAC Unit Cab HVAC Filter Replacement 1 Remove by gently pulling filter away from HVAC unit 2 Install new filter onto HVAC unit 175 Maintenance Instructions Sleeper HVAC Filter 8487423 1 Air Intake 2 Filter 3 Lower Bunk Platform Sleeper HVAC Filter Replacement 1 Raise lower bunk platform 2 To avoid damaging the filter carefully grasp the end of the filter and pull it up and out 3 Slide a new or cleaned filter fully into the slot by pressing down on the outer two edges of the filter s top surface 4 Close lower bunk platform Axles Front Axle Inspection and Lubrication Check to make sure that the front axle mounting U bolts attaching or mounting bolts and nuts are securely tightened Loose or misaligned front axles will affect vehicle alignment front tire wear and handling Re torque the U bolt 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 e Kingpin wear insp
8. Reading Lights The bunk reading light is positioned on the side panel left side to provide illumination for easy reading If the sleeper compartment is equipped with the upper bunk option a second reading light is provided at the head of the upper bunk Depressing the switch on the housing will turn the reading light on and off 3878859R2 Sleeper Features Floor Lights There are two red floor lights located under the lower bunk included with all sleeper cabs These floor lights are controlled by the same two switch arrangement as the sleeper dome light Accent Lights Convenient accent lights are located on the sleeper compartment headliner and provide an additional level of illumination within the sleeper compartment There are four accent lights in the long sleeper and two accent lights in the short sleeper Two switches are located on the sleeper control panel for controlling the accent lights e Accent Light Dimmer Switch Used for adjusting the brightness of the sleeper compartments accent lights e Accent Light Switch Used for turning the accent lights on and off 97 Sleeper Features Sleeper Control Panel The sleeper control panel comes with several optional features but the main components are the switch pack sleeper climate General Information controls and inverter control panel Sleeper Control Panel ee ee 1 Switch Pack The sleeper control panel is equipped with locations for up to six switches 2 C
9. The Differential Lock feature locks together the axles left and right axle shafts for improved traction on reduced traction surfaces ae Some vehicles are equipped with this optional driver controlled differential lock feature DIFF LOCK The air actuated traction device can be manually shifted from the vehicle cab By actuating a switch mounted on the instrument panel the driver can lock or unlock the rear axle differential s when the vehicle is moving or stopped 8487182 Other vehicles with tandem rear axles 6X4 are equipped with two optional driver controlled differential lock features DIFF FR AXLE LOCK and DIFF RR AXLE LOCK The air actuated traction devices can be ssns 8487181 manually 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 vehicle is moving or stopped When the differential is fully locked the vehicle will have a slight under steer condition This will increase the turning radius of the vehicle On vehicles with multiple drive axles the differential lock can be used in conjunction with the Power Divider Lock PDL to achieve maximum available traction in adverse road surface conditions To limit stress on the axle and tires during vehicle turning maneuvers and improve stability the use of the differential lock 150 must be limited to low vehi
10. ccceeeee cece eee e eee ee anes 5 Reserve FUlar esatean AARE ENRE beard eats 138 Reservoir Moisture Draining eeeee cece ee eeee eens 153 Restraint Webbing System cece cece eee eee ee ees 103 Right Engine Compartment ccc ceeeee eee eee e eee e teens 32 Right Front of Tractor cc cece eens 30 Right Rear of Tractor cece ce eeeeee eee eee teen KE ENARTAR 35 Right Side of Cab ccceeeceeee eee e eee e eee EEE e eee e tenes 33 Right Side Under Vehicle 0 0 cece cece eee eeeeeee eee 34 ROtatION ses EE ich conan EE ANETE 203 Rotation Is Advisable cece cece cece eens 203 Tire Replacement cece cece eee e eee eeeeeeeeeeeees 204 Rotation Is Advisable 00 ccceeeeeee eee eee eeenaaaeeees 203 S Safety Recalls and Authorized Field Changes 5 Scheduled Maintenance cc ceeeeeeeeeeeeeeeeeeeeeeeees 187 Seat BOIS sce ss sc eres secccedeseeeeeeeeeeeeee doe AOOO 118 Care of Seat Belts cc ccceeeeeee eee eee es 120 Ope ratlOn eer ceren soe Errar ATAN 119 SOAS viceaye nese E E ers Ye E tise sageeeRineht opens 121 Self Diagnostics so 6 3464 ves dene dee aes deans eee enamine 134 Service Information cece eee c eee eee ee eee eenaeeees 233 Side Access HVAC Filter 0 cece eeeee eee e eee ee eee e ees 174 Sleeper Control Panel ccc eeeeeeee
11. 00 cceeeeeee eee eee ee eaaees 1 Exhaust Diesel Particulate Filter Regeneration 1 Parked Regeneration Procedure 2 s0eeeeeeees 1 Regeneration Inhibit Switch 0 cceeeeee eee eee 1 Three Position Regeneration Inhibit Switch 1 Two Position Regeneration Inhibit Switch 1 EXhauStSySte nies emai cece Gach N 1 Exiting The Upper Bunk 2 c cc eeeee eee eee eee eae 1 Exposed Rubber and Unpainted Plastic Parts 1 Extended Chassis SkirtS ceeeeee cece eee e ee eee eee Exterior Components 6 cece cece e eee e eee eee e ete ee eee ees Exterior Lights Check cece eee eee e eee eeee eee e eens 240 E CONT Exterior Noise Emissions 2 00ceeeeee cece cece eeeeeee 4 F Fan Glutehwse aano eei es esas ei een end Sa Se 194 Feature CodeS pregara batted nae e asa x eanagaciiaasiiieiedd 12 Fifth Wheel and Coupling Area cc cece eeeeee eee eee e ees 40 Fifth Wheel Jaw Monitoring 0 ceeeeee eee ee eee enna nes 169 Fifth Wheel Jaw Unlock Control cece cece e eee ees 168 Fifth Wheel Operation 0 cceeeeee eee ee ee ee eee eaaaes 166 Fifth Wheel Jaw Monitoring cceeeeeee eee eee 169 Fifth Wheel Jaw Unlock Control 00 e cece eee eee 168 Fifth Wheel Slide Switch Optional eee 167 HOOK U a PEAR E EATE ETTET
12. 0eeeeeee 233 Introduction Electrical System ccceee eee eee KTERE 43 Main Features cc rhcccceetendddddak lee ess Veins 95 Irregular Wear dide reire A ence eee ee eee eee eeenneeaeeees 205 L Left Engine Compartment cece cece ee eeeee eee eters 26 Left Front of Tractor sretan a Er er aE E N E 27 Lett Reat of Tractor sisi ee eed e eee ARAE eee eee 38 Left Side Cab Area cece E emeen ESR KEE EKARA 25 LIGHTING tase aioe ete ies ores ae bes Air eho E 97 242 L CONT Lighting cont Accent LightS 2 ccceeeee cece cece eee e eee e ee eee tees 97 Dome Hight vs se ec av eaaa Enar A VASER EKER 97 Floor Liga ereere r TREERE DREN E E EEA 97 Reading Light a 4060s2e0ccccnesete pied t anas a Aa 97 Lights On With Wipers 00 irrien tirer eaaa Eea 75 kine Set TICKS armea eaaa ree eaea Ea eE 2 13 LOANS EE AE NE E E 203 Lock Unlock From Interior cece cece eee e ence eee ees 91 Locking the DOOL aisi rir inttr arsar Er EEEE EEEE 91 Unlocking the DOor 0 c cc eeeeeeee eee eee eee KEES 91 Locking Differential 0 0 ccc cece cece eee eee eee ERAR ETA 178 Locking or Limited Slip Differentials 0 148 Locking the DOO ere deeb d cinerea Sd bore TEER EAEAN 91 Lower BUNK assine ei hie e nook Gale e oa asthe ae y 105 Lowering the HOOd 0 ccceeeeee eee ee eee e teen eeaaeeeeees 19 Lowering the Tilt Away Bumpel
13. 220 Crankcase and Oil Filters For specific engine crankcase capacities refer to separate Engine Operation and Maintenance Manual provided with vehicle Hydraulic Clutch System bescrpton o NOTE Use only approved DOT 3 or DOT 4 brake fluid Power Steering Systems Power Steering Fluid Volume pints liters TRW PCF60 Steering Gear 8 4 3 9 Sheppard HD94 Steering Gear 8 4 3 9 3878859R2 Maintenance Intervals and Specifications Transmission Eaton Fuller 9 Speed synthetic transmission oil 13GPL Eaton Fuller 10 Speed standard transmission oil 13GKZ Eaton Fuller 13 Speed standard transmission oil Eaton Fuller 18 Speed standard transmission oil Eaton Fuller 18 Speed standard transmission oil A variety of transmissions are available for the International ProStars Series truck Refer to the Transmission Manual for required capacities and transmission oils Eaton Fuller 10 Speed standard transmission oil Manual 13GAH 13GHJ 13GHK 13GHL 13GHN 13GHP 13GHR 13GHS 13GNB Approximate refill quantity less than initial fill as fluids remain in external circuits and transmission cavities Check at operating temperature and top off as required 3878859R2 221 Maintenance Intervals and Specifications Rear Axle Unit Refill Capacities 6X4 TANDEM AXLE Forward Rear 4X2 SINGLE AXLE Description Code Pints Liters Pints Liters gt RT 4
14. Door Lock UNnIOCK 00 ccc cece e cence eee e eect eeeneeaneeas 90 Automatic Door Lock Function 0ccccceeeeeeeees 91 Cab Doors and LOcKS ccc ccc cee cece cence eeeeneeeeaes 90 Lock Unlock From Interior ccc ccc cee ee ceeeeeeaees 91 Locking the DoOkitccctseesiiecetagaiea stews boeddlceiaiaeee 91 Unlocking the DOOr cc ccceceee cece eee e eee eeeeeeees 91 Remote Keyless Entry Operation Optional 90 Double Clutch Procedures cc cece cece ccneeeeeeeaeees 145 Downhill ODETI EAEE AEE EE EETRI ERRETA 152 Dresser Cabinet 221 cbiee cde hieededdennaneennnarhhaatneaes ade 111 Drive Shaft ca caduiancuwngennseeiasensew anise s aai 197 Driver and Passenger Sid cceeeeeeee eee eee e eens 21 Driver Controlled Differential Lock cccceeeeeees 150 Driver ROWAN i ecciccutd ceded A e AEE CAE EESE vated 93 Driver Passenger WiNdOWS cece eee eee ee eee tees 91 Manual Operation 00 91 3878859R2 D CONT Driver Passenger Windows cont Mirror Controls 0 cece eee eee eee eee eee teeter ened 92 Power Operation orosei vates terkira NAVIERA AERE YESA iR 92 Vent INMAN aien OREITIA RE ERA EAA 92 Window Lockout Function ceeeeeee cece cette ees 92 Dual Tires Matching ceeeee cece cece cece ee eeeaeeees 203 Dual Tires Mixing KEERT EERE EKRAR eee eee eee eee tees 20
15. SD AGSP TPMS Exhaust Module Telematics AGSP 2 SIC 2 AGSP 3 SIC 1 PAM Hybrid Service Tool Global ECM TCM Shift Selector ABS Retarder Driveline EGC Compass Module ESC VSM SD AGSP TPMS Exhaust Module Telematics AGSP 2 SIC 2 AGSP 3 SIC 1 PAM Hybrid Service Tool Global Retarder Temp Gen Rtrd FIt Description Flash Yes No Warning Indicator Association Message is displayed when a module other than the engine requests the red stop warning indicator Message is displayed when a module other than the engine requests the Yellow warning indicator Message is displayed when instrument panel gauge cluster receives signal from the Retarder Driveline requesting the Yellow warning indicator Message is displayed when instrument panel gauge cluster receives signal from the Retarder Driveline requesting the Red warning MIL or PROTECT indicator or the Yellow warning indicator without the conditions to display Retarder Temp Red warning indicator Yellow warning indicator Yellow warning indicator Yes see description DRV Reward Expected TN PORVRewardGood J ooo e e OE DPV Reward Excellent oo e e O JORVRewardPenaty o oo de e Ek 72 3878859R2 Controls Features Messages Association Dav Rewardinereasng SCS SSCS S ORV RewardDeceasng OOOO e e A S vs Owsewpring OOOO e Blank screen available only when engine rpm less than No or equal to 325 RPM
16. Set the parking brake and chock the wheels Use support stands not a jack whenever you must be under a raised vehicle Do not smoke Wear safety glasses for eye protection Operate engine only in a well ventilated area Do not work on brakes or clutch unless proper precautions are taken to avoid inhaling friction material dust Do not wear loose clothing hanging jewelry watches or rings Tie up long hair and avoid rotating machinery Avoid contact with hot metal parts allow hot components to cool before working on them 3878859R2 10 Correct any problems that were revealed during inspection prior to operating the vehicle Supporting Your Vehicle for Service Always use floor stands to support the vehicle before working under it Using only a jack could allow the vehicle to fall resulting in property damage personal injury or death When performing service repairs on a vehicle first 1 Park vehicle on level concrete floor 2 Set parking brake and or block wheels to prevent vehicle from moving 3 Select jack with a rated capacity sufficient to lift the vehicle 4 Raise vehicle with jack applied to axle Do not use bumper as a lifting point 5 Support vehicle with floor stands under axle s If axle or Suspension components are to be serviced support vehicle with floor stands under frame side members preferably between the axles 3878859R2 Maintenance Instructions Chassis Lubrication New v
17. Side Turn Lamp Incandescent 3156 Filter List Filter part numbers and or specifications may change during the life cycle of this vehicle Current information on the appropriate chassis and engine filters for your vehicle can be obtained by contacting your local International dealer Parts department If you need assistance finding a local International dealer use the Dealer Locator icon at internationaltrucks com 232 3878859R2 Customer Assistance SECTION 9 CUSTOMER ASSISTANCE Service Information The continued premium performance of this International chassis can best be assured through proper servicing This can be accomplished in several ways International Truck Dealers Your local International Truck dealer provides an excellent resource through his knowledgeable experienced and well equipped service staff to handle all your maintenance repair and replacement work Service Publications Those persons who are properly trained technicians with the facilities equipment tools safety instructions and know how to properly and safely service a bus medium duty and or heavy duty chassis can purchase the appropriate service manual sections applicable to specific vehicle components or areas of this International vehicle Engine diagnostic manuals and engine service manuals for all current International diesel engines are also available to these trained persons for purchase Information on the purchas
18. This feature gives the operator the capability of reading maximum restriction with 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 It is recommended that the operator not reset the gauge until it has been determined if air cleaner service is required FILTER MINDER H20 VACUUM 25 Q Aaa dE RE 10 lt lt iL cbs A 4 7 SHTORESET J 8487190 188 The initial restriction with a new air filter element will vary with air cleaner design and installation After servicing the filter element reset the yellow indicator by pushing the reset button and releasing it The yellow indicator will drop to near or below the window so the air restriction gauge can be reused NOTE After starting engine indicator may be seen in lower part of window This is normal and should not be mistaken as a signal for element service 3878859R2 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 for applications in excessively dusty environments that may require more frequent service intervals The secondary element is inside the primary element and prevents contaminants from entering the engine air intake system during service of the primary element or in cases where the primary element becomes
19. To prevent property damage personal injury or death take care when performing any maintenance or making any check or repair Some of the materials in this vehicle may also be hazardous if used serviced or handled improperly If you have any questions pertaining to the service have the work done by a skilled technician WARNING To prevent property damage personal injury or death when servicing the vehicle park on a flat level surface set the parking brake turn off the engine and chock the wheels Always disconnect the ground battery terminal first then the positive cable When reconnecting the battery cables connect the positive cables first and then reconnect the negative cables Failure to follow this warning may result in a direct battery short which is a fire or explosion hazard which could result in property damage personal injury or death 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 batteries to the vehicle Be sure the detached connectors are not touching the vehicle If welding close to an electronic component temporarily remove that component Attach the welder ground cable as close as possible to the part being welded When servicing your vehicle always 1 w E OM Turn off the ignition switch unless the procedure calls for a running engine
20. battery cables connections engine startability starter etc To maximize battery life it is important to keep electrical components battery boxes and the engine in top condition and to minimize or eliminate electrical loads when the engine is not running Battery life can be extended by keeping the batteries fully charged at all times Periodically charging the batteries with a battery charger may be able to charge the batteries more completely than the vehicle s alternator in certain severe applications Use a battery charger float charger that automatically reduces amperage or shuts off when the batteries are fully 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 batteries resist charging Battery performance can be improved by regularly or even periodically storing vehicles and charging batteries with an automatic float charger for 8 to 24 hours in a warm garage during the cold winter months 3878859R2 Allowing batteries to become heavily discharged and exposed to subfreezing weather will cause them to freeze and become damaged Your vehicle utilizes maintenance free batteries which will not require the periodic addition of water Wipe the tops of the batteries clean to avoid a slow current flow through the dirt resulting in a loss of charge Be sure the terminals are clamp
21. cause excessive pressure in the axle and create leaks 217 Maintenance Intervals and Specifications Components Requiring Lubrication 8 1 f CI l i 10 5 8487221 1 Steering Gear 6 Steering Drag Link Ends 2 Steering Intermediate Shaft 7 Clutch Cross Shafts and Release Bearing 3 Front S Cams and Slack Adjusters 8 Drive Shaft U joints and Slip Joint 4 King Pin Bushings and Thrust Bearings 9 Rear S Cams and Slack Adjusters 5 Tie Rod Ends 10 Fifth Wheel Pivot Points and Top Plate 218 3878859R2 Components Requiring Fluid Check and Fill Maintenance Intervals and Specifications an ey pil UNZ Engine Oil Dipstick Power Steering Fluid Reservoir Engine Oil Fill Tube Coolant Surge Tank PF N 387885
22. or death 4 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 3878859R2 27 Inspection Guide 28 Shock Absorber Check for cracks leaks and missing or broken mounting bolts or bushings Air Suspension if equipped Check for air leaks loose components and damage to air bag Inspect stabilizer bar for worn loose or damaged components 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 for cracked worn or frayed hoses and for secure couplings 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 between push rod and adjuster arm should be approximately 90 degrees when brakes are applied 10 11 12 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 6mm or contaminated by lubricant Wheel and Lug Nuts Check for damaged or bent wheel Check to see that all lug nuts are present and not loose look for rust trails around nuts Ensure that no cracks or damage are present at wheel mount holes Tire Check tread depth tire inflation and note if tread is evenly worn Minimum tread depth is
23. or off 3878859R2 Sleeper Features Engine Control Switch Never start the engine unless you re sure the transmission selector is in neutral and the brake is applied otherwise accidental movement of the vehicle can occur which could result in property damage personal injury or death DO NOT crank the engine for more than 30 seconds at a time wait two minutes after each try to allow the starter to cool Failure to follow these instructions could cause starter damage The ENGINE CNTL switch allows the operator to start the vehicle from the sleeper compartment NOTE The ENGINE CNTL switch will only operate under the following conditions e Dash mounted SLPR ENGINE CNTL switch is ON e Transmission is in neutral 8487144 e Parking brake is set e Hood is closed e Ignition switch in the ON position with the engine not running 99 Sleeper Features To start the engine from the sleeper press and hold the top of the ENGINE CNTL switch There will be a 15 second delay during which an audible engine start alarm will sound then the engine will begin cranking Release the switch as soon as the engine starts To stop the engine press the ENGINE CNTL switch again Manual Climate Controls NOTE If sleeper air conditioning is desired and the main cab blower is not enabled the air conditioner will not function and the message Activate Front Blower will appear on the instrument panel gauge cluster The manual climate con
24. or vehicle speed less than 2 mph 3 km h No No Calibrate Compass Message is displayed when vehicle speed is less than 2 mph 3 km h and the operator has not requested Calibrate Compass in the current ignition cycle End Calibration 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 Calibration 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 Declination Zone Message is displayed only when vehicle speed is less than No No 2 mph 3 km h If this message is displayed drain water from fuel water separator 3878859R2 73 Controls Features Warning Messages In addition to the Diagnostic Trouble Codes DTC the digital display will display a warning message whenever an Engine indicator is illuminated This warning message will be toggled with the normal DTC as follows Yellow Warning indicator WARN ENGINE message Red Stop indicator Stop Engine message The following chart provides the warning messages that are displayed along with corresponding instrument panel gauge cluster indicators MaxxForce Engine Warning Indicator Warning Message Red Stop Stop Engine Quadrant 3 Display Messages Outside Temperature and Compass Displays Optional The optional Outside Temperature and Compass He
25. 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 cleaner housing 189 Maintenance Instructions 190 With the air cleaner cover latch at the 1 o clock position align cover tabs with corresponding slots Push the cover into the slots Rotate the cover clockwise in direction of lock on cover until the locking tab snaps into its locked position When servicing is completed reset air restriction gauge by pushing and holding the reset button and releasing it The yellow indicator will drop below the window The air restriction gauge is now ready for the next operating cycle 8487170 NOTE After starting engine the indicator may be seen in the lower part of the window This is normal and should not be mistaken as a signal for element service 3878859R2 Maintenance Instructions Troubleshooting No Restriction Reading POSSIBLE CAUSES HOW TO CHECK Plugged fitting or vacuum line Remove the gauge and apply a vacuum until it is locked up at the red zone Re insert the gauge and hold in the reset button Indicator will fully return unless line or fitting is plugged A slow return is normal due to safety filter in fitting Leak in vacuum line Apply vacuum to gauge until locked up at red zone Re connect gauge and close end of line airtight Hold in reset button Indicator will drop slightly a
26. the shade when possible If your vehicle has been parked in the sun with 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 Failure to follow recommended service procedures and maintain adequate air flow through air exchange devices may result in component failure Cleaning should be performed by a qualified technician Keep radiator area free of bugs leaves etc Do not cover the condenser with a wire screen At least once or twice a month turn on the air conditioner for a few minutes while the engine is running This periodic operation keeps all the mechanical parts of your air conditioner in good operating condition 88 It is normal for small amounts of water to drain out of the air conditioner module This water is condensed moisture removed from the air inside the vehicle Correct airflow may be restored by either replacing the filter s which can be done without tools or by cleaning the filters The filter s may be cleaned by using a power washer with a soap solution Keep the spray head at least six inches away from the filter to avoid damage Rinse thoroughly NOTE If your air conditioning performance seems lower than expected check the front of the A C condenser for an accumulation of dirt or insects Clean with a gentle water spray from behind the radiator and through the condenser as required Check for dirt and de
27. 0 0 cece cece cece eee e teeter E 9 AXIGS EITE TEAT EEEE AT L A EATE 176 235 Index A CONT Axles cont Fron Axles e a aE aae A sane pains sees E EAN 176 AHONEN eseas osese Nee NSSE ARAARA Asaa ia 177 Inspection and Lubrication eee eee eee 176 Normal Maintenance 0c cece eee cece eee eeae ees 177 Locking Differential 0c cee eee seen eee e eee e eee eee 178 Rear Axle Anei k a t Weert a aE aE RE 177 Inspection and Lubrication cece eee eee 177 B Base DISplay ss eerce evi penneres Me bead E fie eerste bourne i 89 Batte hese E E th naw ntens vans T 184 Batteryiss etcanceuegetede tell ddania ld be oe netade ENE E AERA 130 Battery Cables 2 ddat tr PARERE ED EE EEEE i E E a 185 BATTERY ON Indicator ccceeeeeeeeeeeeeeeeeeeeeeeees 131 Bobtail Proportioning System 2 cece eee eee eee 157 BOG shit deck dU haaddada AEAT eer 196 Brake Application cceeee eee e cece e teen ee eenaaeeeeees 154 Brak Sde pman s ca aae A AAAA SEEN 151 178 ABS Connections and Sensors ecssececeeeeereene 182 Ait BIAKGSiwccianeadsd aan e a iad AAE PAAA NAA 152 179 Air Gauge Low Air Pressure Beeper and Warning ARESE e EET E PAE T A TEA 153 Brake Application 20 ccceeeee ir aa aki 154 Inspection and Adjustment ccceeeeeeeee eect ees 179 Reservoir Moisture Draining eeeeee eee eee 153 AIR DIVER E ced
28. 101 Remote Power Inverter Panel eeeee eee eee 101 WINKOWS E EE EEE race aes dat oee sae terian feed ace totes 102 General Information cc cece cece ee eee eens 102 Bunk Restraint System ce eee eeeee eee eee eee eaaes 103 General Information ccceee cece eee ee eee eenee 103 Adjustable Belts cce cece cece eee eeeeeeeeeee ees 103 Restraint Webbing System cscs cece eee eee ees 103 Lower BUNK aiei titre titi arabian euee E AE ESER 105 General Information ccc eee eeeeeeeee eens 105 Upper BUNK oresar daa ccs aaa eae ennpnons 106 General Information 0cceeeeeeeeeeee eens 106 Entering The Upper Bunk ee cece eee e ees 107 Exiting The Upper Bunk eeee eee cece eee 108 Cabinets Storage cceeeee R SAA EEEN ENEE EEROR 109 General Information cc ceeee eee e ee ee eens 109 Cabinets esse feat ties eh i a a A 110 Refrigerator Cabinet cceeee cece cece ee eeeeeeees 110 3878859R2 Table of Contents Horizontal Refrigerator cc cceeeeeeeeeeeeeeeeeeeeees 111 Dresser Cabineti sses biarr nunta ae a 111 Tower Wardrobe Cabinet cccc cece cece eeeeeees 112 Rear Wardrobe Cabinet ccc cece eee e eee eeeees 113 Airline Cabinets ccc cece cece ence cent eeeteneneus 114 Convenience Features c cece cence cece e
29. 24 Other Models 125 000 miles 200 000 km 12 coon Conentaton inspeciowagusment Ae SS C S T ran sade swo Check baragetConact i CS Coolant Additive See Engine Operation and Maintenance Manual Exended ite Coolant Replace See Engine Operation and Maintenance Manua_ Cooling Package External Cleaning NOTE 3 Engine Engine Oil Level Check OAB o eee Engine Engine Belts and Belt Tensioner Inspect Replace if AB Op ration and significantly deteriorated Maintenance ee eee Coolant Filter if equipped Replace Manual for Air Induction System Check for Looseness Leaks complete Engine Oil and Oil Filter s Replace See Engine Operation and Maintenance Manual See Engine Operation and Maintenance Manual maintenance Engine Fuel Fil guide On Engine Fuel Filter ir Fi As required by restriction gauge reading 1 year Engine Air Filter Replace NOTE 3 214 3878859R2 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Recommended Synchronized Intervals cont Fuel System Fuel Sender Hose Connections Check for Loose AB Connectors Non Davco Fuel Water Separator Filter Replace See Engine Operation and Maintenance Manual Davco Fuel Water Separator Filter Replace Fo See Engine Operation and Maintenance Manual Fuel Tank s Drain and flush NOTE 3 Eo o o 100 000 miles 160 000 km 12 Exhaust Pipes Muffler Inspect for Leakage Looseness Dama
30. 4 32 inch on steering tires Look for cuts or other damage to the tread or sidewalls Check for missing broken or damaged valve cap and stem Hub Check for obvious leaks on outside or inside of wheel Verify correct oil level in hub 3878859R2 Front of Tractor 8487004 1 Lighting System Lower hood and inspect parking clearance identification lights turn signals fog lights and reflectors on hood bumper and cab They should be clean operational and the proper color 3878859R2 Inspection Guide Headlights Lenses should be clean If equipped check daytime running lights Eaton VORAD Front Sensor if equipped Check for damage and proper mounting Ensure sensor s view is clear of mud dirt ice or any material or objects Bumper Inspect for damage and security Grille Inspect for damage and security Check bug screen for damage and cleanliness Hood and Fenders Check hood panels and fenders for signs of breaks or damage Ensure hood opens and closes properly 29 Inspection Guide Right Front of Tractor 30 UA 8487006 A WARNING If wheels or tires must be changed obtain expert tire service help Mounting and demounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment otherwise the result could be property damage personal injury or death Do not operate vehicle if any of the following conditions are
31. BRAKE valve knob yellow should be pushed in first after sufficient air pressure is built up apply foot brake to prevent vehicle from rolling The TRAILER AIR SUPPLY valve knob may then be pushed in The TRAILER AIR SUPPLY valve knob red and PARKING BRAKE valve knob will automatically pop out if the system pressure both front and rear circuits drops to 20 to 40 psi 138 to 276 kPa The tractor protection valve will then close 156 the tractor spring brakes will apply and the trailer emergency system will be activated On vehicles equipped with the standard two valve system the operation of one valve together with the other permits the operator to select the desired functions described below Red Valve Yellow Valve Function Mode Trailer Air Supply Parking Brake System Park Trailer Charge 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 simultaneously causes the trailer supply valve to pop out thus applying both tractor and trailer parking brakes The trailer brakes may be independently released by pushing only the TRAILER AIR SUPPLY valve red control in The TRAILER AIR SUPPLY valve red valve delivers air to the trailer supply and will automatically pop out shutting off the trailer supply if pressure is decreased to approximately 35 psi 241 kPa For exact air pressure set po
32. C Solutions that are more acidic or more alkaline will attack the metallic coating If you are having difficulty with your washing compound contact your local supplier for the acidity alkalinity QH specification A nonabrasive chrome cleaner may be used sparingly to clean the bright metal Do not use steel wool Use of automobile wax or polish on bright metal usually will restore the original brightness Upholstery Care Use a whisk broom and vacuum cleaner 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 used follow instructions supplied with cleaner Exposed Rubber and Unpainted Plastic Parts To better protect plastic surfaces from fading use Meguiar s 40 vinyl and rubber cleaner conditioner Spread evenly with sponge or towel and allow to penetrate Buff off excess product with clean cloth 3878859R2 Clutch Pedal Free Travel All International ProStar Series vehicles are equipped with pull type clutches If a non self adjusting clutch clutches other than the Eaton Solo series was selected free pedal must be checked each time the vehicle chassis is lubricated If free pedal is less than 1 2 inch 13 mm the clutch must be adjusted Contact your International Truck dealer for proper clutch adjustment procedures After proper clutch adjustment clutch free pedal
33. Making modifications to various parts components and systems of your vehicle such as brake suspension and steering systems can adversely affect the quality and reliability of your vehicle Such modifications must be avoided Cautions and Warnings Throughout this manual you will find Cautions and Warnings Warnings advise you of hazards the consequences and what to do to prevent them not only to prevent damage to your vehicle or property but to help prevent situations and occurrences which could result in personal injury or death Cautions will advise you of the proper care to be taken to prevent damage to your vehicle or property 3878859R2 Study this manual carefully Do not operate your vehicle until you are completely familiar with the contents of this manual Always retain this manual in your vehicle for reference If you sell the vehicle make sure the manual goes with it Assistance Guide When parts are required always provide the unit code number vehicle model and vehicle serial number Request the salesperson to assist you in obtaining this information upon delivery For information not given in this manual or if you require services of trained service personnel we urge you to contact a nearby International dealer or phone 1 800 44 TRUCK 87825 for assistance Every customer is entitled to the best service both from the product itself and from the firm that sells and services that product If f
34. ROAD or MUD SNOW switch off when you return to a firm surface The function of this switch is to allow greater engine power and more wheel spin When operating on soft road surfaces place the OFF ROAD or MUD SNOW switch in the ENABLE position The switch indicator will flash slowly to indicate that this function has 720 been selected and will flash rapidly whenever ATC is operating to control excessive wheel spin Stability Control Systems Bendix RSP WABCO RSC Bendix ESP A WARNING Vehicles equipped with Stability Control have reduced effectiveness when pulling double or triple trailers Failure in understanding this warning could result in property damage personal injury or death 3878859R2 Stability Control systems are designed to enhance overall 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 additional driving risks Failure to follow this warning could result in property damage personal injury or death The optional stability control system provides the core ABS function as well as Automatic Traction Control ATC and Roll Stability functions Core ABS Functions The core ABS system reduces wheel lock up to help drivers maintain steering control while braking Antilock Braking Systems ABS use wheel speed sensors ABS pressure modulator valves and an Electronic Con
35. To avoid needless delay and expense allow only competent and experienced mechanics to perform these operations 145 Operation Eaton AutoShift Transmissions Optional To prevent unexpected vehicle movement hold the brake pedal down while you move the gearshift from position to position Hold down both brake and clutch pedal while pushing the R and D button If you do not hold the brake pedal down your vehicle may move unexpectedly and cause property damage personal injury or death The optional Eaton AutoShift transmission is a_ partially automatic transmission that automatically selects and engages the proper transmission gears Vehicles are equipped with a clutch pedal that must be used when starting and stopping the vehicle 146 8487193 To shift the Eaton transmission into Reverse R or Drive D first place foot on the brake and clutch pedal When in Drive D the transmission selects the starting gear and automatically selects the proper gears for operating loads If low L is selected while the vehicle is stopped the transmission will remain in low 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 press the N button Manual mode should be used whenever the driver wants to select the shifts instead of letting AutoShift transmission select them automatically
36. To open depress the knob the knob will extend from the work table then pull the work table open To close the work table depress the tab along the forward side of the work table and slide the work table shut Once the work table is closed the knob needs to be pressed in to a flush position with the work table this prevents the knob from getting hung on your clothing and other items as you move around in the sleeper compartment Lift Release Handle The drawer is equipped with a lift release handle To open the drawer lift the handle from the bottom and slide the drawer open To close push the drawer shut until the lift release handle locks the drawer shut 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 lock to the right Door The optional 1 7 cubic ft refrigerator is equipped with an adjustable thermostat internal light shelf and small freezer for making ice The door provides an attractive look to the refrigerator cabinet and hides the refrigerator Magazine Pocket Provides a storage area for books magazines and maps Refrigerator Cabinet The refrigerator cabinet is available on select International ProStare Series long sleeper models and is located behind the passenger s seat 3878859R2 8 Drawer A small drawer is provided at the top of the refrigerator cabinet for storage 9 Work Table Pull out work
37. When disconnecting the trailer lower the landing gear disconnect the brake hoses and rear light connectors from the trailer and pull the release lever on the fifth wheel Slowly pull the tractor forward just far enough to release the king pin from the fifth wheel and stop Switch the SUSP DUMP switch to the 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 Operation Always follow the fifth wheel manufacturer s instructions for hooking and unhooking as well as sliding the fifth wheel Failure to follow this warning could result in property damage personal injury or death 3878859R2 When using an assistant to reposition a sliding fifth wheel the driver must be ready to stop as soon as the fifth wheel moves to the desired position The assistant must keep feet hands and body clear of the vehicle s tires and other moving parts to prevent personal injury or death The driver must not begin to move the vehicle until the assistant is clear and signals the driver to move the vehicle Fifth Wheel Slide Switch Optional An optional Fifth Wheel Slide switch may be present This switch allows the operator to electronically unlock the fifth wheel to allow it to be moved forward or backward and re lock it once the desired position is attained STH WHEEL 8487109 To unlock the fi
38. 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 angle sensor provides a greater stability margin than a vehicle that is not equipped with this sensor Brake Demand Sensors The stability control system RSP and ESP was designed to supplement the drivers actions By directly measuring driver brake demand the system can transition seamlessly between driver intended and system intended braking pressure For example if in a certain maneuver the system calculates 40 psi 276 kPa is needed and the driver is only applying 20 psi 138 kPa the system compensates automatically to deliver the needed 40 psi 276 kPa If however during the same maneuver the driver steps on the brake pedal quickly to apply a higher above 40 psi 276 kPa braking level the driver s braking input overrides the temporary change made by the system ABS Stability System Interaction With the ABS based stability control system the ABS system is given priority at the 161 Operation wheel ends to manage wheel slip for optimal braking The ABS system functions similarly whether the stability system or the driver applies the brakes Towing Instructions This vehicle may be equipped with optional dual tow hooks for recovery purposes only Always use both tow hooks to prevent possible overloading and breaking of individual hooks Fail
39. all dirt and debris from grease fittings before applying grease If the fitting is not cleaned dirt can be pushed into the component with the grease Always fill grease to the point where old grease and contaminants are forced out from the part and only new grease comes out Ifa fitting does not accept lubrication due to damage or internal stoppage replace with a new fitting Remove excess grease from fittings and other surfaces after applying grease Some vehicles may have optional remote mounted grease zerks for the clutch 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 the bottom of the transmission bell housing 3878859R2 Manual for engine oil specifications Wait five minutes after shutting off the engine before checking the oil level This gives the oil time to drain back to the oil pan Clean all caps and fill plugs prior to removal to prevent dirt and debris from entering system Filling the power steering fluid above the MAX COLD mark when cold will result in fluid overflow when hot If engine is cold and coolant is above the MIN ADD line no additional coolant is needed Excessive filling when cold can cause tank to overflow when hot When checking the axle hub fluid level maintain fluid level to fill line on hubcap Check the rear axle s vent for blockage Blockage can
40. and engage the two hooks 3 Rotate the locking handle 90 upward to lock the chassis skirt in position 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 install the same as the rear driver side chassis skirt Extended Chassis Skirts Optional extended chassis skirts are available for the ProStar Series trucks with sleeper and full aero package While the passenger s side extended chassis skirt is stationary the driver s side opens to allow access to the deck ladder To open pull out on the upper right hand corner of the extended chassis skirt and open to its full extension To close grab the upper right hand corner of the extended chassis skirt and guide it to its fully closed position 3878859R2 Inspection Guide SECTION 3 INSPECTION GUIDE Introduction General Information WARNING To prevent property damage personal injury or death when servicing the vehicle park on a flat level service set the parking brakes turn the engine off and chock the wheels Exercise care when working on vehicles with running engines that are equipped with an automatic fan clutch The fan engages when engine coolant reaches a_ predetermined temperature or the refrigerant pressure if equipped with air conditioning reaches a predetermined setting The fan will start with
41. axle air suspension height at engine oil change intervals See the appropriate Service Manual 3878859R2 Maintenance Instructions NOTE Suspension alignment must be maintained at all times NOTE Refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS for proper U bolt torque values Periodically e Check condition of spring leaves for evidence of fatigue bending or breakage e Check condition of suspension mounting brackets and bushings e Check that suspension mounts brackets bushings fasteners etc are tight e Check that torque rod mounting fasteners are tight e Check U bolts as follows 1 After the chassis has been operating 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 torque interval may be lowered to 25 000 miles 46 000 km to synchronize with oil change interval Front Suspension The front suspension should be regularly inspected for loose worn or broken components Front suspensions axles should be checked periodically for proper alignment to promote maximum tire life 197 Maintenance Instructions On vehicles equipped with the optional front air suspension the air suspension components including air bags height control valves ail lines and fittings should be inspected for wear damage and audible air leaks Rear Suspension The
42. axle positions e Front Steering Axle Replace tires at front wheels when tread is worn to 4 32 inch 3 mm or less e Rear Axles Tires must be removed when the tread is worn to 2 32 inch 2 mm or less Tires identified with the word regroovable molded on the sidewall can be regrooved A minimum of 3 32 2 38 mm of undertread must be left at the bottom of the grooves 204 Wheel and Tire Balancing Out of round or out of balance 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 the wheel The tire and wheel assembly should thereafter be dynamically balanced and reinspected while spinning for an out of round 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 been called rolling wear channel or river wear Erosion wear is found more often at free rolling tires This is an indication that the tire is being used in a slow wearing operation What happens is that the belt plies are held very rigid and the tread is not allowed to distort as it passes through the contact area Wear will only occur at the edge of the tread No corrective action required If erosion gets to be 1 16 inch 2 mm or more the tire may be rotated to a drive a
43. clutch linings should follow the same precautions as outlined for handling brake linings Hydraulic Clutch Your vehicle is equipped with a hydraulic clutch actuation system The reservoir is located just below the cowl left of center on the firewall To prevent vehicle and or engine component damage use only approved hydraulic clutch fluid DOT 3 or DOT 4 brake fluid in the clutch hydraulic system Do not mix different types of brake fluid The wrong fluid will damage the rubber parts of the system causing loss of clutch function 183 Maintenance Instructions To prevent vehicle and or engine component damage do not allow the fluid level in the reservoir to go below the MIN line If too much air enters the hydraulic system will not operate correctly and the clutch could be damaged Ao eae Max MN O 8487228 1 Reservoir 2 Cap If the fluid level is below the MIN line remove cap and fill the reservoir with DOT 3 or DOT 4 brake fluid until the level reaches the MAX line 184 Electrical Batteries Battery life and performance varies greatly depending on duty cycle Conditions such as short 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 interrelated components such as alternators
44. connecting and disconnecting trailer Inspect fifth wheel jaws to be sure they have closed on trailer king pin and the trailer plate is resting securely on the fifth wheel Be sure the coupler release lever is in the locked position 167 Operation 9 Charge trailer brake system Set trailer brakes either with the hand valve or tractor protection valve Pull against trailer for an additional check of hook up Do not pull hard enough to damage or strain the equipment 10 Set tractor parking brakes and fully raise trailer landing gear Refer to Brakes segment of this section for Operation of Parking Brakes and Trailer Brakes 11 Check operation of all trailer lights and correct faulty lights Un Hook 1 Try to keep tractor and trailer in straight line Apply tractor and trailer parking brakes Lower trailer landing gear making sure it is on solid level ground The weight of trailer must 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 Release tractor parking brakes Pull out from trailer slowly allowing landing gear to take load gradually 168 Fifth Wheel Jaw Unlock Control Your vehicle may be equipped with an optional Fifth Wheel Jaw Unlock feature A guarded switch mounted in the cab allows the operator to unlock the fifth wheel jaw from inside the vehicle There are t
45. diesel engine near flammable vapors in the air may cause the engine speed to increase uncontrollably and overspeed If this situation occurs mechanical damage fire explosion personal injury or death could result Turning off the ignition switch will not slow or stop the engine due to uncontrollable fueling of the engine through flammable vapors being drawn into the engine air inlet Operation of components such as starter alternator electric motors etc and static electricity could also ignite flammable vapors Do not operate the truck in the possible presence of flammable vapors unless both a complete hazard analysis is performed and necessary additional safety processes and or equipment such as vapor testing air intake shutoff devices ventilation etc are 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 conditions and hazards that may be encountered 3878859R2 WARNING Do not exceed the truck s gross axle weight gross vehicle weight and gross combination weight ratings Exceeding these ratings by overloading can cause component failure resulting in property damage personal injury or death WARNING Always use occupant restraint system when vehicle is moving Any location in the vehicle not equipped with a seat belt should not be occupied when the vehicle is being o
46. down all electrical loads except for lights Allowable idle times may vary from state to state and with owner operator preferences Idle times may also be dependent on vehicle conditions such as Parking Brake status PTO if equipped status transmission status and others The vehicle owner or operator is responsible for compliance with all state and local regulations If the vehicle has this system enabled the yellow IDLE IDLE SHUT DOWN indicator in the instrument panel SHUT gauge cluster will turn on 30 seconds before engine DOWN shutdown This indication will continue until the 8487074 engine shuts down or the system is reset Winter Front Usage Unless extremely cold 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 3878859R2 which are equipped with engine charge air coolers Cooling air flow restriction affects emissions and can cause high exhaust temperatures power loss excessive fan usage and a reduction in fuel economy If you insist on using a winter front the device should have a permanent opening above or directly in line with the fan hub The opening s minimum dimension must be at least 120 in 774 cm Hot Weather Operation 1 Keep cooling system filled with clean permanent antifreeze solution to protect against damage by overheating 2 Fill fuel tank at end of daily operation to
47. eae ves 183 Pedal Free Travel ccceeeeeeeeeeeee eee eeeeeeeeeeee 183 Clutch Brake cece cece eee c eee e eect eee eeeeeneeeeeeee 148 Clutch Precautions ccc cece cece nett teen eee e eee 145 Cold Weathelr 0c c cece cece cee cece ee eee eeeeee ee ee ened 125 Cold Weather Operation 00seeeeeee eee e eee e eens 126 Cold Weather Starting cece eee cece cent eeee eens 125 Engine Idle Shutdown Timer Optional 127 Engine dling seu sees se daa veen eee dite vie dea eee 126 Winter Front Usage 0 cece cece cece e eee eee e ees 127 Cold Weather Operation 0c cece cece eee 126 Cold Weather Starting cee eeeee eee eens 125 Compass Declination Zone Set Procedure 57 Compass Directional Calibration Procedure 60 Component Code Numbers cccceeeee cece eee eeeeeees 2 Line Set Ticket ai soy os see ee eee week a ce eee eee ere 2 Components Requiring Fluid Check and Fill 219 Components Requiring Lubrication eee eee 218 Connecting Disconnecting a Trailer to a Vehicle with Air SUSPENSION ci eE ALEE EENAA NAAL Haden teen de ehanmnee 166 Convenience Features ccceeeee eee e eee e eee e eee 115 Foor COVO aises a ee eee ANa 115 Power Inverter 22 cceee eee ceeeee eee eee nent ee eeeeeeee 115 Power Sockets
48. eee eee 177 Rear Axle Unit Refill Capacities 0 0 cece cece e eee 222 Rear AKES hontre aE Ea Sates PAE AEU RIEAN A ETARE ETAT 148 Driver Controlled Differential Lock 2 eeeeee 150 Locking or Limited Slip Differentials 148 Tandem Axle Power Divider Lock PDL Control 149 FREAK Of Tacto oan eet a e ete eawe te then te Aas aa tatee es 37 Rear SuSpension cece cece eee eee eee eee eee eee 150 198 Air Suspension System Faults eeeee cece eee ees 151 Rear Air Ride Suspension cece eeeeeeeeee 150 Rear Air Suspension Air DUMp eeee eee teens 150 Rear Wardrobe Cabinet c cece eee ee eeeeeeeeeeeees 113 Recirculation Filters cece eee eee eee eee eee ees 175 Refrigerator Cabinet 2 ccc cceeeee eee teen eeeeeeeeeee ees 110 Regenerator rerien sa seve AEAEE NEKEEN cored 196 Regeneration Inhibit SWitch 0 cece cece eee eee eee eee 141 Remote Keyless Entry Operation Optional 90 Remote Power Inverter Panel eeeeeee eee ee eee 101 Removal errre esos ck acd ARER AERAR deans oa 21 Removing Axle Shafts Before Towing eeeee eee 164 3878859R2 Index R CONT Reporting Safety Defects ceeceeeeeee eee eects 5 Canadian Registered VehicleS 00eceeeeeeeeee eee 5 U S Registered Vehicles 0
49. eee eee e teens 21 Driver and Passenger Side eee eee eee eeee ees 21 CHASSIS SKINS eane titanio EEE NIA EAA we ete 21 Removal aasre aan a e eaen ESEE th O ENS 21 Installation neea ARERR RERE EEAS 22 Extended Chassis SkirtS 0c seeeeeeeee eee eee eee es 22 Section 3 Inspection Guide IntrOGUCTION fie ee SEEE ie et vs pir OE ERITAR 23 General Information 0 ccceeeeeeee eee e eee eee 23 Tractor INSPECtION s cctetegseseeeeeeeeeees th bhe EERE 24 Preparatlonics 2222425 4itin Mossi AANE ERRERREEE REEERE 24 Exterior Lights Check 0 24 Left Side Cab Area 2 0 cc ccceee eee eee eee eee eeeeeeeees 25 Left Engine Compartment 00 cece eeeeeeeee eee 26 Left Front of Tractor cc cece cece cece eee eee e tees 27 Front Of Tractor sees eeeucucuddveceeeeeeesueeeeeeeobaaaaaaa 29 Right Front of Tractors o errire errit Ee ERA e ee eee eee ees 30 Right Engine Compartment cece eee eee ees 32 Right Side of Cab 0c cece cece ee eee eens 33 Right Side Under Vehicle 0 cece eeeeeee eee 34 Right Rear of Tractor ceeeee eee eee cece eee eeeaeeeees 35 Rearof Wactor c cacrsecced dees neee E NEEE EEEE 37 Left Rear of Tractor cece eee eeeee eee idae adare 38 Fifth Wheel and Coupling Area eee 40 Table of Contents Cab Interior InSpection 00 c cece cece eee eee ee
50. eee intial dices dias Peete 155 180 Desiccant Filter orreri erised irn rara eee eeeeeeees 181 Heater e aee erT se uh bol DEAETE ERRER RE 181 Purge ValVe ccceee eee eee ARANT O EONA TE EEES 181 Air Reservoir Tanks Moisture Draining 181 236 B CONT Brakes cont Antilock Brake System ABS 158 ABS Operation en arkara eN KAAR AEA AEK ONERA 158 ABS Self Check reriseerrer renren eimino eee e eee EREA 159 Antilock Driving TipS cece eee eee eee ee ees 159 Bobtail Proportioning System eee cece eeeee eee 157 Downhill Operation 20 cc eeeee eee eee teen ee eee ees 152 Parking Bra RE oeiee ree Ee Aeaee AA A SS 154 Parking Brake Alarm 0000 cece eee eeeeeeeeeeeeees 155 Parking Brake ReSet cc ccccceeeeeeeeeeeeeeeeeeeees 155 Parking Brake Indicator cece cece eee eeeeeenee 157 Trailer Air Supply and Parking Brake Modular Controls 156 Trailer Brake Hand Control e cece cece eee eeenees 155 Bright Metal Care ccc ceeeeee ee ee ee eee eee RASSA 182 Bunk Restraint System 2 ccc ceeeeee eee ee ee eee eaeee ees 103 Adjustable Belts 00 0 ccceeee eee s rrenek A PEREKI IREA 103 Restraint Webbing System ccceeeeee eee eee eee 103 Cc CAD ees saya A Fe aR Shea Raney BE eee TE 182 Care of Vehicle 0 ccc cece AA EEES EEEE RI 182 Bright Metal Care
51. equipped with A C moving the mode knob to the MAX A C position will close the fresh air door eliminating outside air from entering the vehicle Turning off the fan speed control also turns off the A C compressor 37 Temperature Control Use this control to regulate the temperature of the air discharged from the vents The blue area of the control indicates cooler temperatures while the red area indicates warmer temperatures 38 Mode Control NOTE The dot between the mode control icons is an additional mix position between the two modes Use this control to direct the flow of air as follows 86 3878859R2 MAX lt NORM 8487119 wD 8487146 m O 8487147 4 ye 8487148 3878859R2 Controls Features MAX Air Conditioning Mode In this mode all airflow is directed to the panel air outlets and the air is recirculated inside the vehicle Use this mode to block out any outside odors smoke or dust and to cool the interior rapidly upon initial start up in very hot or humid weather NOTE Continuous use of the recirculate mode may make the inside air stuffy Use of this mode for longer than fifteen minutes is not recommended The A C compressor turns on and off automatically as needed when in this mode NORM Air Conditioning Mode 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 off automatically as needed w
52. in property damage personal injury or death DO NOT crank the engine for more than 30 seconds at a time wait two minutes after each try to allow the starter to cool Failure to follow these instructions could cause starter damage General Information NOTE Before starting the engine e Read and understand the Controls Features section of this manual e Perform the left and right engine compartment inspections outlined in the Inspection Guide section of this manual e f 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 neutral and vehicles with a clutch pedal require the clutch pedal to be depressed before the starter will engage 3878859R2 Operation Engine Starting oa fF oO N 2 The ignition switch has four key 3 positions as follows 1 ACC Accessory E 2 OFF 3 ON 8487026 4 START Apply the parking brake and place the transmission in the neutral position If equipped with a clutch pedal the clutch pedal must be depressed Turn OFF the headlights and all accessories Turn the key clockwise to the ON position Turn the key to the START position When the engine starts release the key The key will return to the ON position and the engine will continue to run To stop the engine rotate the key counterclockwise to the OFF position To plac
53. indicator and beeper not shut off soon after start up the air pressure gauge gauges should also indicate at least one section of the split system has low air pressure If the red indicator beeper and gauge indicate a loss of pressure while driving the vehicle still has a portion of the braking capability because one half of the split system braking capability is retained However the distance required to stop the vehicle will be increased Reservoir Moisture Draining The Bendix AD IS air dryer automatically drains the wet tank Daily draining is not required Moisture taken in with the air through the compressor inlet valves collects in the reservoirs and necessitates draining each reservoir periodically This is done by opening the drain cocks located at the end of all tanks optional pull cable operated drain valves may be present If the drain cock is opened in the end of the tank there must be some air pressure in the system to assure proper drainage Be sure to close the drain cocks after all moisture has been expelled On vehicles so equipped the reservoir automatic drain valve ejects moisture and contaminants from the reservoir in which it is connected It operates automatically 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 153 Operation Brake Application Rapid s
54. lubricate the tilt or telescoping steering mechanism 3878859R2 Adjustable Steering Column 8487029 1 Steering Wheel 2 Release Handle If equipped with the optional tilting and telescoping steering column the steering wheel can be adjusted as follows e Grasp the steering wheel with your right hand and unlock the release handle with your left hand by pushing forward on the release handle 3878859R2 Operation Using both hands grab the sides of the steering wheel and adjust the telescoping feature to the desired position and then the steering wheel tilt to the desired position Hold the steering wheel in the newly acquired position with your right hand and pull THE RELEASE HANDLE backward towards you to the locked 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 in the transmission that will enable the engine to easily pull the load without slipping the clutch Accelerate smoothly and evenly to engine rated speed Rapid acceleration will result in high fuel consumption When approaching a hill depress accelerator smoothly to start the upgrade at full power then shift down as needed to maintain vehicle speed Prevent over speeding of the engine when going down long and steep grades The governor has no control over engine speed when it is being pushed by
55. need any adjustment 3878859R2 Operation Operation 8487102 1 Three Point Seat Belt Retractor Buckle Tongue Clip OY Re 00s NS 119 Operation To operate the seat belt follow these steps 120 1 Slowly pull the three point seat belt out of the retractor and slowly pull it across your lap far enough to engage the buckle If the retractor locks too soon allow the seat belt to retract slightly then slowly pull it out again To fasten the seat belt insert the tongue into the buckle until it latches Give the seat belt a firm tug to ensure that the buckle is securely fastened The 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 for body movement The seat belt will return to the retractor as the body returns to its original position The retractor will retain moderate tension across the body in its operation mode The seat belt is equipped with a clip to eliminate the moderate belt tension across the body It can be adjusted by pressing the button and sliding the clip along the seat belt To release the seat belt push the button release latch on the buckle and give the seat belt a tug to assist the seat belt into the retractor Care of Seat Belts Do not bleach or re dye seat belt webbing Bleaching or re dying may cause a weakening of the webbing
56. not be equipped with all the features listed in this section Duct Work Vents Rear Wardrobe Cabinet i 8 8487429 Airline Cabinets Speakers Control Panel Cup Holders and Storage Trays Lower Bunk OO N OR ON if O92 O Under Bunk Storage Area 3878859R2 95 Sleeper Features Common features on the International ProStar Series 73 inch 185 cm long sleeper model with lower bunk 96 oa F oO DN Fay 8487413 Duct Work Vents Rear Wardrobe Cabinet Airline Cabinets Speakers Control Panel Tower Cabinet Common features on the International ProStar Series 73 inch 185 cm long sleeper model with lower and upper bunks 8487415 7 Lower Bunk 8 Under Bunk Storage Area 9 Refrigerator Cabinet or Dresser Cabinet 10 Upper Bunk NOTE Although not illustrated the long sleeper models are equipped with the same cup holders and storage trays both ends of lower bunk as illustrated for the short sleeper model 3878859R2 Lighting Dome Light The sleeper dome light is a large fluorescent light located on the headliner of the sleeper compartment The sleeper dome light can be controlled by switches located on the sleeper control panel and on the dash instrument panel This two switch arrangement permits the driver to turn the sleeper dome light on or off before entering the sleeper area and turn the sleeper dome light on or off without having to go back to the cab area
57. of interest SmartWave Display 84873338 The optional SmartWave tire alerts and warnings display has three automated tire alerts to instantly warn the driver of an underinflated tire before it becomes dangerous pressure 89 Controls Features deviation alert critical low pressure alert and high temperature alert Refer to http Awww smartire com support manuals for complete owner s manual Door and Window Controls Door Lock Unlock Cab Doors and Locks The cab door and sleeper luggage doors can be unlocked with the same key used for the ignition lock There is also a keyless remote entry available NOTE The vehicle is delivered with two identical keys If more keys are needed order them through your authorized International Truck Dealer Record the key code and keep it in a secure place A new key can be made if the keys are lost With mechanical locks only one door can be locked unlocked at a time Electrical locks can lock unlock both doors by operating either the key keyless entry fob or the inner door lock handle on either side 90 Remote Keyless Entry Operation Optional NOTE This device complies with Part 15 of the FCC Rules and with RSS 210 of Industry Canada Operation is subject to the following two conditions 1 This device may not cause harmful interference 2 This device must accept any interference received including interference that may cause undesired operation Changes or
58. open Electrical Load Control and Shedding CONTINUOUS TONE The Instrument panel gauge cluster will display the ELCS Alarm Optional message Load Shedding in the LCD display and emit a continuous tone for 5 seconds that coincides with the start of the visual alert 3878859R2 53 Controls Features Direct Drive Warning Indicators The direct drive warning indicators give information to the operator of various conditions of the vehicle Eight spaces are available for the direct drive warning indicators Blank cover plates will be used in spaces that do not have direct drive warning indicator installed at those locations eral is Forward rear axle differential is locked Yellow Rear axle differential is locked C en i otsed Yellow ICON system is activated o m Rete E Ca an O o E Luggage door is ajar Engine brake capability is activated Integral Digital Display The Integral Digital Display is located below the speedometer and the tachometer It is arranged in four quadrants that display vehicle information The four quadrants can be individually selected by using the display control button Display Control The Display control is used to scroll to a quadrant and to select the various modes within a quadrant To navigate between quadrants turn and release the control either clockwise or counterclockwise To select the screens within a quadrant press and release the control Pressing and holding
59. or parasitic electrical loads from discharging the battery Storage Duration Over One Month Units in storage longer than one month should be driven until the engine reaches operating temperature 1 Insure all tires are inflated properly remove vertical exhaust stack covers and reconnect batteries Check all vehicle fluid levels and fill as required 3 Startand run the vehicle at fast idle until it reaches operating temperature To remove surface charge from the battery built up from previous start ups and short idle periods operate the heater and or air conditioner headlights and other accessories for several minutes 4 Turn off heater and or air conditioner and any other accessories shut off the headlights Park the vehicle and shut off the engine 5 Perform the procedure for Storage Duration One Month or Less if returning the vehicle to storage NOTE After every 30 additional days of storage perform Items 1 through 5 Foreword Storage Facilities A Whenever possible store vehicles indoors protected from sunlight in a dry well ventilated area If indoor storage is not available select storage lots to eliminate conditions that cause deterioration B Park away from transformers and or electrical motors because when the protective wax in tire compound cracks ozone in the air attacks the exposed areas C Park away from trees high weeds and or grass to prevent damage from tree or weed sap and to
60. performed due to a vehicle interlock or an engine fault Air Filter Restriction Message displayed indicates restricted air flow to the Yes No engine Exterior Lamp Check Active Message displayed indicates Exterior Lamp Check is in Yes No progress HVAC Temp Setting Bar graph displayed show temperature setting in low to high increments Activate HVAC Front Blower Bar graph displayed show blower speed setting in Off and low to high increments 68 3878859R2 Controls Features Quadrant 2 Display Description Flash Yes No Warning Indicator Messages Association HVAC Sleeper Blower Speed Bar graph displayed show blower speed setting in Off and No No low to high increments weena OOOO O S eme nates athe Cruse Conor Syse is umodon no fe esn O e eS exero es eS engine Conor Smudown ies iS oneck aerate fies dS Parkd Regen Required Indicates parked regeneration is necessary No sti S Parkd Regen Inhibited Eng Tmp Message is displayed when engine coolant temperature is No No below 170 F 76 6 C Regen Inhibit Switch Active Message is displayed when Regen Inhibt Switch is On and regeneration Is disabled Parkd Regen Available Pana Reven Waive A S Low Coolant Level Message is displayed when coolant level is less than or Yes No equal to 80 Stop Engine Message is displayed when Red Stop indicator is Yes Red warning indicator illuminated 3878859R2 69 Controls Features Quadrant 2 Display Descr
61. pressure may result in sudden tire destruction improper vehicle handling and may cause rapid and irregular tire wear Therefore inflation 3878859R2 Maintenance Instructions pressures should be checked daily and always before long distance trips Follow the tire manufacturers recommended cold inflation pressure for the tire size type load range ply rating and axle loading typical for your operation Each steer axle tire load will equal 1 2 steer axle loading each drive tire load will be 1 4 the axle loading if fitted with four tires Checking Inflation Always check inflation pressure when tires are cold Never bleed air from hot tires to relieve normal pressure buildup Normal increases in pressure during operation will be 10 to 15 psi 69 to 103 kPa which is allowable in truck tires Tires on the same axle should have the same air pressure as the corresponding other tire s on that axle Steer tires should be within a 3 psi 21 kPa pressure range All drive tires should be within a 5 psi 34 kPa pressure range Tag or pusher axle tires on the same axle should be within a 5 psi 34 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 use of shop air dryers is strongly recommended to avoid moisture in the high pressure air used for tire inflation Underinflation Tires s
62. prevent condensation in tank 3 Keep external surface of engine radiator charge air cooler AC condenser and accessories clean to avoid dirt build up Excessive coolant temperature could be experienced while driving in too high of transmission gear ratio which would lug the engine To correct the problem engine speed should be increased by down shifting into the next lower gear to increase engine RPM s which will increase coolant flow through the radiator and increase fan speed 127 Operation Operating Instructions General Information 128 WARNING All vehicles have blind spots Make sure your way is clear in all directions before moving your vehicle Failure to follow these procedures could result in property damage personal injury or death WARNING Operating an engine beyond the maximum governed speed could result in engine failure and cause vehicle damage personal injury or death Steering 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 above are detected have the vehicle inspected and repaired at once by a qualified mechanic Do not adjust the steering column while the vehicle is moving It could suddenly or unexpectedly move causing the driver to lose control of vehicle which could result in property damage personal injury or death Do not
63. r aa nea pee enekd dias eaves TEO 89 Premium Display 0ceeeeeeeeeeeeeeeeeeeeeeeeeeaaaea 89 Emergency Starting 0 ccc eseeeeeeeeeeeeeeeeeeeeeeeeeees 124 Emission Control Systems 0 0 cceeeee cece eee e eee renee 5 Engaging the Clutch 0 eaea eee ee PEREAT 143 ENGINE vt gag teehee Pe ALA a 132 186 Air Cleaner Element Service c cece cece eee eee 189 Air Compressor Cycling cc cceeeeeeeeeeeeeeeeeeeeeees 135 Air Induction System errereen reier ceeeee eee eee eee E 187 Air Restriction Gauge 0 ccceeeee eee e ee eee eeeaeeees 188 Certified Clean Idle ccc ccccecce cece eee e teen eens 134 Charge Air Cooler 0 ccc cceeeeee eee eee e eee eenaaeeees 132 Charge Air Cooler And Radiator Core Inspection And ClO AM IN Gros ere tans aes teeet nd andes ead owe ena bes 192 Inspection and Cleaning seee ee eeeeeeee eee es 192 Cooling SySteM ccc cece eee e teen ees 192 ANTICO CLS cs cress cisssteitie cissciece sis cid iaisisisis EEEE 194 Coolant and Optional Coolant Filter 000 194 Coolant Concentration Freeze Point 25 194 Coolant Level Check cceeeee cece cece eens 192 Fan Clutch 1034 CO A ERTER ET AO ETES 194 Filling Instructions 0c nenn nE EE EENS 192 Crankcase Ventilation Filter 195 Electronic Engine Controller l a 133 Engine Brake rcsrerrs s
64. rear by raising the rear of the chassis by the rear axles When towing a vehicle with rear of the chassis suspended the front wheels must be locked in the straight ahead position Tractor Trailer Connections Whenever possible make trailer connections while standing on the ground Provide adequate lighting of working areas Inclement weather and accumulated road contamination deposits on handholds and stepping surfaces require extra care to prevent slips and falls which could cause personal injury or death Do not climb on the back of a tractor unless it has been provided with a deck plate and handholds Use a three point stance when climbing up and down from a deck plate Do not jump from vehicle Connecting Disconnecting a Trailer to a Vehicle with Air Suspension The Air Suspension has a dump valve system option Code 14899 that permits exhausting air from the suspension system thus lowering the frame when connecting disconnecting or 166 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 located on the instrument panel to the DUMP position and air will exhaust from the suspension system lowering the tractor This will permit backing under the trailer without undue loading of suspension system After making the connection to the trailer return the switch to the SUSP position then raise landing gear
65. section in Vehicle Operations 3878859R2 55 Controls Features er Quadrant Number and Message Function Message Description Quadrant 3 Compass Heading Outside Optional Displays compass heading when vehicle is equipped with a compass Temperature module Displays outside temperature reading is obtained from the temperature sensor Le Display Control Toggles the information display from one screen to the next when pressed and released General Text and Warning Messages Temperature Graphic The operator of the vehicle can make z eeel o H adjustments to the sleeper temperature and or sleeper blower speeds by using the SLPR TEMP and or SLPR FAN dash EZ Blower Speed switches that are located on the center dash s7 8487088 Graphic panel wing panel When the operator makes a change with either of these two switches the appropriate graphic for the sleeper temperature or sleeper blower speeds will be displayed in the general text and warning message area of the instrument panel gauge cluster 2 LPR SLPR 8487216 AN m m i D 8487217 56 3878859R2 Optional Instrument panel gauge cluster Compass Calibration Procedure All new vehicles with an optional compass must have an initial compass calibration performed A compass calibration may or may not have been completed at the vehicle assembly plant If the compass headings are noticeably incorrect or become noticeably incorrect or
66. teen TA ESTIRAR 198 SWITCHES ssc cere duia anea a n an eparnnn bedad tamed aig GOs 75 82 Courtesy HoMe areen aaa aas toads 76 Daytime Running Lights DRL cee eee e eee eee 75 Dome LIQhtinG iis sooecc veauis haha aaiedadddd saavavaaadeoeeed crererererertee 76 POACIQIIS Hsien scan seeadsenepaphihd acne y deacon gues AE PEDANE 75 Lights On With Wipers cece eee cece ee 75 Panel Lightingeycssyevertaecesscnes give E sav ees eeu es eee 75 Park Lights seictinstenecues peatenreauen eer AIKA tase Eee 75 System Description 0 cece cece eee eeeeeeeeeeeeeeeeeees 93 T Tampering with Noise Control System Prohibited 4 Tandem Axle Power Divider Lock PDL Control 149 Television MOunt eeee cece cece eee sees teen nent eet enes 115 Terminal Inspection Cleaning Corrosion Protection 185 Three Position Regeneration Inhibit Switch 142 Tightening Steering Intermediate Shaft Joint Bolts 198 Tilt Away BUMPEl 00 cece eee eee eee nena 19 Lowering the Tilt Away Bumpetl eeeeeeeeeeee ee 20 3878859R2 T CONT Tilt Away Bumper cont Raising the Tilt Away Bumper 0ceeeee eee eee eee 20 Tire Maintenance 0 cece Kiiski a riuk airna wenei diddi iaa 201 Checking Mialo sersan rora eee E Ena NA 201 Underniatonm cer aa AREE ERRESU EEES 201 Tire Replacement 0 iEn eSEE Aan
67. the NO CAL message is displayed the Declination Zone may need to be reset to agree with the current geographic location or the Compass Directional Calibration will need to be recalibrated The compass direction is displayed in the lower left quadrant of the instrument panel gauge cluster display just below the outdoor temperature reading Text messages necessary to calibrate the compass can be found in the instrument panel gauge cluster display in the lower right quadrant quadrant 2 of the display Twist the instrument panel gauge cluster display knob until the cursor is flashing in the lower right quadrant Press the instrument panel gauge cluster display knob until the desired text message is displayed Compass Calibration related text messages include Calibrate 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 thereafter the Compass Directional Calibration procedure can be performed Both procedures are listed on the following pages and must be followed exactly to ensure proper calibration of the compass 3878859R2 Controls Features Compass Declination Zone Set Procedure The Declination Zone number is used to account for the errors between magnetic North and true North in the vehicle s geographic operating area and must be set correctly for the compass to dis
68. the selected speed in memory aries To return to the predetermined speed press the AUTO MAN Optional Allows RESUMEMACCEL SWIER driver to select higher or lower gear of e When you press the OFF position of the ON OFF switch automatic transmission or if the vehicle is shut off the selected speed setting is canceled and removed from memory Steering Column and Switches Cruise Control Do not use the cruise control system when unpredictable driving conditions are present Such conditions include heavy traffic roads that are winding icy snow covered slippery or with a loose surface These conditions may cause wheel slippage and loss of vehicle control resulting in property damage personal injury or death a Press the ON position of the ON OFF steering wheel control b Bring the vehicle to the desired operating speed above eee 35 MPH and push the SET COAST position of the steering wheel control c Once in the cruise mode the RESUME ACCEL switch The steering column contains switches and levers to aid in the can be used to increase or decrease vehicle speed by comfort of the operator and to assist the operator while driving pressing and holding the RESUME ACCEL to increase the vehicle the speed or by pressing and holding the SET COAST to decrease vehicle speed 78 3878859R2 1 Tilting and Telescoping Adjustment Lever Allows the steering wheel placement to be adjusted for driver comfort Push do
69. the upper portion of the rocker switch To dim the instrument panel gauge cluster lighting continually press the lower portion of the rocker switch 75 Controls Features Dome Lighting The overhead dome light is used for reading and for illumination when entering and exiting the vehicle The dome light on off is also controlled by pushing on the lamp lens When either entrance door is closed the courtesy light will remain ON for approximately 20 seconds or until the ignition switch is turned ON At that time the lights will dim gradually until the light is off The Optional keyless entry key fob also turns on the light for a time period when the Unlock button is pressed and turns off the light dims gradually to off when the Lock button 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 Pee eee a Enables Auto Headlights in vehicles equipped with this feature Used to turn work lights on and off 76 Headlight Park Lamp Switch Activates the headlight or parking lights and illuminates the instrument panel gauge cluster This switch functions even when ignition switch is turned off a warning will sound when this switch is ON and the ignition switch if OFF Panel Dimmer Adjusts the panel lights brightness Used to turn cab dome light on and off and make it possible to activate deactivate the dome l
70. to correct excessive push rod stroke Excessive stroke indicates that a problem exists with the foundation brake ASA brake actuator other brake system components or their installation or adjustment In the event that a manual 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 possible to ensure the integrity of the overall brake system prior to returning the vehicle to service Failure to follow this warning may result in property damage personal injury or death A regular schedule for periodic cleaning lubrication adjustment and inspection should be established based on the type of vehicle operation It is difficult to predetermine an exact maintenance interval time or mileage since vehicles will be used in a wide variety of applications and conditions 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 braking Push rod travel should be checked every service interval to determine if adjustment is necessary 179 Maintenance Instructions Brake chamber push rods on original equipment chambers now incorporate an overstroke indicator an orange paint marker near the base of the push rod to aid adjustment checks If the push rod is clean a
71. to movement is felt The turn signal lever will return to the off position when released 3878859R2 Controls Features 5 Windshield Wiper The electric wiper has two speeds hi low which can be operated by rotating the WASHER WIPER knob The optional intermittent control provides five wiper on off cycle intervals varying from 2 to 14 seconds This is done by rotating the wiper control from the wiper OFF position to the any of the five intermittent wiper interval positions Automatic Intermittent Interval Control Optional This feature automatically changes the wiper speed from HIGH or LOW to the slowest intermittent speed when the parking brake has been set and the wipers have been on for a predetermined length of time When the parking brake is released the wipers return to their previous speed A WARNING Do not use the washers in freezing weather without first warming the windshield with the defrosters otherwise the washer solution may freeze on the windshield and obscure your vision and cause an accident which could result in property damage personal injury or death Do not use radiator coolant or antifreeze in the windshield washer reservoir Radiator coolant in the washer reservoir can severely reduce visibility when sprayed on the windshield Keep the fluid reservoir filled with Fleetrite Windshield Washer Solvent or equivalent 6 Low High Beam When the turn signal stalk is pulled past the click po
72. to the 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 not yet be apparent during normal daily operations Terminal Inspection Cleaning Corrosion Protection Periodically inspect electrical connectors on the engine battery and frame for corrosion and tightness Inspect exposed cables for fraying or signs of abrasion Exposed terminals such as cranking motor alternator and feed through studs should be cleaned and recoated with a dielectric grease such as Fleetrite 472141 C1 or equivalent paste or spray protectant The inspection cleaning corrosion protection should include feed through connections power and ground cable connections for batteries engines and the starter stud 185 Maintenance Instructions Connectors that are more subject to corrosion may be disassembled and sprayed internally with a light coating of dielectric grease Use grease sparingly as too much grease will not allow air to escape from the connection and this compressed air will push out the seals in the electrical connectors Accessory Feed Connections Electrical circuits are designed with a particular wire gauge to meet the fuse and circuit breaker current rating 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 a
73. use an occupant restraint system could result in personal injury or death General Information Two types of sleeper bunk occupant restraint systems are available with sleeper bunks supplied by Navistar Inc If the sleeper berth is not provided with one of these two types of restraint systems that bunk is not intended to be occupied when the vehicle is in motion and must not be used when the vehicle is being operated The description and recommended usage of the two available restraint systems for sleeper berth areas are as follows 3878859R2 Sleeper Features Adjustable Belts This two belt system is standard with the sleeper lower bunk To use the adjustable belt system the bunk occupant should place one belt across the lower body positioned above the occupants knees but below the hips and the other belt should be positioned across the upper body above the hips but below the shoulders Slack must be removed from belts after connecting the buckle by pulling the loose end of each belt to fit the connected belt snugly across the occupant s body Restraint Webbing System The optional restraint webbing system is secured around the bunk with seven buckles The only restraint system provided with the optional upper bunk is the restraint webbing system To use the restraint webbing system follow these steps 103 Sleeper Features 104 l O Oi Od Op Pe 89s IN 8487138 Bunk Restraint Webbing System Re
74. while PTO function A or B is engaged Display Format 100 000 0 PTO HOURS A PTO HOURS B 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 This display will provide a record of the Engine PTO hours sent from engine Display Format 100 000 0 ENG PTO HOURS 63 Controls Features Quadrant 1 Display Messages Engine PTO Trip Hours Instantaneous Fuel Economy Trip Average Fuel Economy 64 This display will provide a record of the Engine PTO Trip hours sent from engine Display Format 100 000 0 ENG PTO TRP HOURS This display provides a record of the instantaneous fuel economy sent 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 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 gallon or liters per 100 kilometers corresponding to the units selected while in the odometer mode Display Format 30 0 TRIP MPG TRIP L 100KM 3878859R2 Controls Features Machine PTO Fuel Used A and B The display value shall be the calculated Machine PTO Fuel Used Display Format 100 000 0 PTO GAL A PTO GAL B PTO LA PTOLB Machine PTO Tri
75. 0 ccc ce cece cece e eee eee ened 117 Cab Controls cc cece cece eeetennes 118 Optional Diamond Logic Electronic Application Solutions 8 Optional Instrument panel gauge cluster Compass Calibration PFOCECUICseiiaceeesecdddedhdegeddeiddd Maddadieceseadisbitessede 57 Compass Declination Zone Set Procedure 57 Compass Directional Calibration Procedure 60 244 O CONT Outside Temperature and Compass Displays Optional 74 Outside Temperature Reading eee eee e eee eee eens 74 Overhead Console eceeee eee eee eee e ee eenaaeeeeeees 45 P Panel IGN aiaa ra AAKRE EEEE EEEE AA AAEE AAT 75 Park LINS eeaeee aeren An EA OERE RREA VIKARA ER RESENA 75 Parked Regeneration Procedure 00seeeeeeee ee es 141 Parking Braka scccevest citi EA ERES de ANARO TIEA 154 Parking Brake Alarm ceeee eee eennee eee e teen eens 155 Parking Brake Reset cceeeeceeeeee eee e eee teens 155 Parking Brake Alarm ee eeeeeee cece eee e eee e eee ees 155 Parking Brake Indicator cccceeeeeeeeeeeeeeeeeeeteeees 157 Parking Brake Reset cece cece cece eee ee eee tees 155 Pedal Free Travel vscs iss sevivey gees KAKKA ee RERAN SO REKENEN ENA 183 Power Inverter cece cece cece cette eee t eee e eee e tees 115 Power Operation cccccceee eects eee eee eeteeeeenes 92 Power Receptacle rosoe e ee
76. 0 145 30 2 14 3 25 8 12 2 RS 23 160 14051 14ARB RT 40 145A S23 190 14AHE 31 14 7 28 DS405P RS405 DS404 RS404 DS404P RS404 13 2 DST41 RST41 14GUD DST40 RST40 14GJE MT 40 143 MA N MT 40 144 MA N D46 170HP R46 170H D46 170P R46 170 D46 170P R46 170D D46 170 R46 170 RT 46 160 RT 46 160P 187 222 3878859R2 Maintenance Intervals and Specifications Lubricant and Sealer Specifications Component Vendor Lubrication Type Applicable Temperatures Non driving Front Axle Front axle Mineral Oil 75W 40 F to 15 F 40 C to 26 C wheel bearing oil 75W 80 40 F to 80 F 40 C to 27 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 F and above 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and above 26 C and above 85W 140 10 F and above 12 C and above Synthetic Emgard 2979 Synthetic Lubricant All Temperatures NOTE Do not mix conventional mineral based lubricants with synthetic lubricants Front Axle Tie Eaton Dana axle Hendrickson Steertek Rod Ends Drag International Multi Link axle and Meritor axle Link King Pins Fleetrite NLGI 2 Lithium Complex Based Moly and Bushings grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease NOTE Eaton Dana and Meritor Easy Steer axles With chassis load on axle force grease through thrust bearings then with axle lifted clear of floor for
77. 00 353 407 14SAU 20 000 Ib 9072 kg Capacity RR Springs Multileaf with Single Torque Rod 258 295 350 400 14SAW 23 000 Ib 10 433 kg Capacity RR Springs Multileaf with Single Torque Rod 260 300 353 407 14TBJ 20 000 Ib 9072 kg Capacity International Air Suspension IROS for axles 260 300 353 407 14ADN 14ADP 14AJC 14AJE 14ATP and 14ATR 20 000 Ilb 9072 kg Capacity International Air Suspension IROS for all other 370 400 502 542 axles 14UNL 14UNM 14UNN 40 000 Ib 18 144 kg Capacity International Air Suspension IROS 370 400 502 542 14UNS 14UNT and 14UNU NOTE For all other vendor supplied suspensions refer to vendor s website for proper torque specifications Torque Feature Code Front Suspension Capacity and Type 12 000 Ib 5443 kg Capacity Monoleaf Hendrickson Softek 353 407 12 350 Ib 5602 kg Capacity Monoleaf Hendrickson Softek 353 407 3878859R2 227 Maintenance Intervals and Specifications Feature Code Front Suspension Capacity and Type Tt Nem O BAHN 12 350 Ib 5602 kg Capacity Parabolic Taper Leaf 260 300 353 407 NOTE For all other vendor supplied suspensions refer to vendor s website for proper torque specifications DISC WHEEL NUT TORQUE CHART Fuse Charts The following fuse illustrations represent typical fuse panel Lug Nut Lug Nut e fono ing fuse ills present yp p Si z Moten Nem layouts The actual vehicle fuse panels will vary depending on ype the vehicle o
78. 167 Uni HOOK fetiaercetrnawinarestaiedddeeddecaniaieeserseeeeiecses 168 Fifth Wheel Slide Switch Optional cceeeee ees 167 Filling INStrUCTIONS cece cee eee eee e tet e tt eeeeeeees 192 Filtet List mes sac bau edie becee aha enedoneh dd de aaaeecuashed aves eas 232 Foor COVErING ites cow ee E eae eesti es 115 Foor EOM lt 4 4 23500 c00soeeneend TIERA SARAS ADE DERT AEAEE EEE 97 FIAMe irni a tecasenk canine i AAA KEER N OA E 195 Front Access HVAC Filter 2 2 ccc eeeceeeeeeeeee neers 175 FrOntAxle rs a aa a hh cop tils setts tetas bi Gates A eas 176 AlIGNMO MM cc eniset te ctatas be ceee es NAIARA AKTEKKE RARESA 177 Inspection and Lubrication eeeeee eee eee 176 Normal Maintenance 022 ccccceeee cece eeeee eee ees 177 Front Of Mactopia le ki eee CTE EA Aa ech 29 Front SUSPENSION 0 cece e cece eee eee EE 197 FUG S22 E E E EEA see oath sonny ee eines maces eas aie eee E 137 Additional Unsafe Practices 0c cceeeee eee eee eens 137 Fuel and Lubricant Additives ce cece eee eee ee 137 Fueling Precautions 2 cc cceeeeeeeeeeeeeeeeeeenee 138 3878859R2 F CONT Fuel cont Fueling Procedures 02 scceeeeeeeeeeeeeeeeeeeeeeees 137 Hazards of Diesel Fuel Gasoline Blends 137 Reserve Fuel resu a i naei hodne aa eNi 138 Ultra Low Sulfur Diesel Fuel Requirements 137 Unacceptable Fuel Blends
79. 3 E Eaton AutoShift Transmissions Optional 146 Eaton UltraShift Transmissions Optional 148 Eaton VORAD Collision Warning System Optional 93 Diiver ROW iicsaccmtinthaamiads im eeeven ee bed leeds beebteeen ne 93 System Description cc cece cece cece eee eeee eens 93 EleCtriGals oceeteer se ecser rece e ey dieses E E 130 184 Accessory Feed Connections cceeeeee cece eee es 186 ALSTON eos fala tole eee E S 130 Batteries ee bens i6000006 5a eee 184 Battery re reee ooo IIe A eee aetna Es 130 Battery Cables erri a AAAA AAA E eee eee reo 185 BATTERY ON Indicator sas cc eee e seen eee e eee 131 Circuit Breakers Fuses and Fusible Links 131 Electrical Charging and Starting System Test 185 Electrical Load Control and Shedding ELCS 132 Fuses and RelayS cceeeeeeeeeeeeeeeeeeeeee eee EDD 186 Terminal Inspection Cleaning Corrosion Protection 185 Electrical Charging and Starting System Test 185 Electrical Load Control and Shedding ELCS 132 Electrical Systemi a dance es ouotu trai RANET AAE ENA 43 Electronic Climate Controller 0 0 cece eeeeeeeeeeeees 100 Electronic Engine Controller 00 cece eee cece enna ees 133 3878859R2 Index E CONT Electronic Vehicle Monitoring ceeeeee eee eee 89 Base Display eraai
80. 487187 Controls Features SUSP DUMP This switch allows the operator to release the air from the air bags ina rear air Suspension system when the vehicle s speed is less than 5 mph PTO OFF ON Used when vehicle has single PTO option PTO A OFF ON Used when vehicle has dual PTO option PTO B OFF ON Used when vehicle has dual PTO option 5TH WHEEL SLIDE This momentary switch when held on releases the sliding 5th wheel when ignition switch is in ON and vehicle speed is less than 2 mph 83 Controls Features 84 8487209 JAW LOCK a 8487226 JAW UNLOCK I 8487227 LOCK DIFF eI 8487182 8487180 FIFTH WHEEL JAW UNLOCK Press and hold this momentary switch to unlock the fifth wheel jaw Vehicle must be stationary parking brake set and ignition switch in the RUN position 5TH WHEEL JAW MONITORING LOCK UNLOCK These switches activate an electronic jaw lock indicator system showing fifth wheel jaw status to the operator DIFF LOCK Used when 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 differentials for improved traction on poor surfaces at low speeds TRLR 8487113 DIFF RR AXLE LOCK Locks rear drive axle differential when vehicle has 6x4 independent locking differentials for improve
81. 5 engines is filled at the factory with Nitrite free Shell Rotella Ultra ELC Yellow coolant International Truck recommends using only the approved coolant with the 2010 cooling packages and will not warrant these cooling systems that have not utilized the recommended coolant The label on the deaeration tank provides additional coolant antifreeze information Consult the Engine Operation and Maintenance Manual for coolant service life details Some engines are ordered with an optional coolant filter that should be replaced periodically For Ultra ELC equipped vehicles use only water filters without Supplemental Coolant Additives SCA s as SCA s are not necessary with Ultra ELC Any time a silicone gasket seal exposed to the coolant is replaced while using Ultra ELC a fresh charge of silicates must be added to the coolant to protect the new gasket seal International truck recommends Ultra ELC due to its ease of maintenance and lower long term cost of operation Any system using or contaminated with more than 10 conventional coolant must be maintained like conventional coolant and receive regular tests for Supplemental Coolant Additive SCA levels Coolant Concentration Freeze Point Cooling systems should be checked twice a year to assure proper coolant water concentrations A 53 47 coolant water mixture from the factory provides freeze protection down to 194 minus 40 F 40 C as well as excellent corrosion prot
82. 92 Window Lockout Function ceceee eee eee 92 Mirror GontrolS ssecescdcscecceensaebeddeiacea eed AEA ASA hides 92 Vent WiINdOW 0 cece eee EEEE AEE AAA SE Tiaa 92 Eaton VORAD Collision Warning System Optional 93 System Description ccc cece cece eee eeeeeeeeeeeee 93 Driver Reward ssrin eenen eee eee teens 93 Section 5 Sleeper Features INtPOCUCTION i srh sa cocnmas secon s Maddddecsnese E EE Aaa 95 General Information 0 ccc cece ccc e cece eee e eee eee 95 Main Features 0 c ccc cece cece cence eee e nena eee 95 3878859R2 Brala g s AE ca heh aaa eee neg Mee NE 97 Dome LIQKt oiccnisee senna be ANEA AAN EEREN FA 97 Reading Lights ssceeeeee eee e cent eee EARRA eee ees 97 Foor LoM Seer EEE EEEEEEEEEEEEEEERERE EER eres 97 ACCONBLIGNIS aE ARER EE AAA 97 Sleeper Control Panel cccceeeeeeeeeeeeeeeeeeeeeeeeeees 98 General Information asssssssrrserrrrrenrrrrrenrrreren 98 Accent Light Dimmer Switch eee 99 Accent Light SWIC inerents rra EErEE VARATA 99 Sleeper Dome Floor Light Switch ee eee eee 99 Engine Control Switch cccceeeeeee eset teen ees 99 Manual Climate Controls cece eee cece nena ees 100 Electronic Climate Controller a se 100 Power Receptacle cceeee cece cece cece eee e eens 101 Radio Remote Control ccceeee essen eee eee eee
83. 9R2 W N gi 201 CH 8487222 Windshield Washer Fluid Bottle Front Axle Oil Filled Hubs Transmission Oil Fill Level Check Plug Drive Axle Oil Fill Level Check Plug 219 Maintenance Intervals and Specifications Unit Refill Capacities Cooling System Refill Capacities Cooling system refill capacities vary considerably due to differences in engine models and optional equipment including sleeper heater circuit in addition to the amount of coolant remaining in the system after draining Total capacity may range from 12 to 15 gallons 45 to 57 Liters If system has been drained fill with a 50 50 mixture of Nitrite free Shell Rotella Ultra Extended Life Coolant ELC yellow concentrate and demineralized or distilled water or Nitrite free Shell Rotella Ultra ELC 50 50 Premix yellow If the system has been flushed with water or cleaner a significant amount of the rinse water will remain in the system In this case refilling with a mixture with a higher percentage 60 to 66 of coolant concentrate is advised in order to achieve a final mixture closer to 50 50 Fill the system and run the vehicle until the thermostat opens Before adding any fluid check the coolant concentration and add additional water or concentrated undiluted coolant to adjust the concentration Run the vehicle and retest for coolant volume level set to MAX line and concentration level
84. A W CUSTOMER ACCESSORY 2 9 REMOTE START STOP 2 RELAY h TOA W ICON OR NO IDLE HEAT VALVE 1B RELAY 2 STD W SLEEPER N A W DAY CAB 5 RELAY MERITOR FREEDOMLINE XMSN W ICON 8 REMOTE START STOP RELEAY 1 3 W EATON AUTOSHIFT ULTRASHIFT XMSN amp MERITOR 6 25A W TRAILER AUX SOCKET OR NO IDLE HEAT VALVE 1A RELAY LO FREEDOMLINE XMSN TOA W TRAILER SOCKET SWITCHED CONTROLLED CENTER PIN 7 3878859R2 229 Maintenance Intervals and Specifications Typical Luggage Compartment Fuse Panel Layout 10A SLPR DOME LUGGAGE READING LIGHTS 10A ACCENT LIGHTS HaIOOMENS Ld vol 15A TV POWER ADYNOS HAMOd 10A OPT REFRIGERATOR 5A OPT UPPER BUNK WARDROBE LIGHTS AW144 LHS o zee mim fr gt O U lt o m IJ AE ta AHOSSJ09Y J9Y99N1 1dO A 1gJ4 IHVLS SLOWSY 1dO A134 dOLS SLOWSY 1dO AVISH COOH IWHLNAN 8487191 230 3878859R2 Maintenance Intervals and Specifications ProStar Series Light Information Lamp Description Bulb P N Sleeper Dome Lamp F15T8 CW Cab Dome Lamp 577 Accent Lamps 577 Under Bunk Lamp 577 Cab Floor Lamp W5W Sleeper Floor Lamp W5W Wardrobe Cabinet Lamp 7575 Door Lamps W5W Stop Turn Tail Lamp LED International ProStars Series Truck Lite Super 40 Truck Lite Super 44 Optional Back Up Lamp LED Truck Lite Super 40 Work Light 4411 3878859R2 231 Maintenance Intervals and Specifications Parking Turn 3357AK Side Turn and Marker Lamp assembly 01 5242
85. AA AAA ORIRE EA 220 Cooling System Refill Capacities 05 220 Crankcase and Oil Filters 2 0cceeee neces 220 Hydraulic Clutch System 2 cece eeeeeeee eee eee 220 Power Steering SystemS 22 eee e cee eeeee eee ees 220 TRANSMISSION ech ansacncee tec hisesanacaaeaanusasan 221 Rear Axle Unit Refill Capacities cc cece e eee 222 Lubricant and Sealer Specifications 0e 223 Torque Specifications ccc cee cece eee eeeee ence ee eee 227 U Bolt Nut Torque Chart 0c eee eee eee ee 227 Disc Wheel Nut Torque Chart c cece 228 Fuse Ghartsis ee e eevee bens ena tees ean eh ad ee es Beall 228 Typical Interior Fuse Panel Layout 22555 229 Typical Luggage Compartment Fuse Panel Layout 230 ProStar Series Light Information 065 231 Filter Lista e a a iden A a aE EE EEDAN 232 Section 9 Customer Assistance Service Information cece eee n eect eee ee eee NKEA Ea 233 International Truck Warranty Program 00eeeeees 233 vii Table of Contents Section 10 Index viii 3878859R2 Foreword SECTION 1 FOREWORD Preface Your vehicle has been engineered and manufactured so that it can provide economical and trouble free service However it is the owner s responsibility to see that the vehicle receives proper care and maintenance
86. BRAKE ON OFF 8457154 All of the optional braking features are controlled by the driver using the ENGINE BRAKE ON OFF switch on the steering wheel and the ENGINE BRAKE 1 2 3 power level selector switch located in the Center Control Switch Panel 3878859R2 Operation To activate the engine brake press the push button ENG BRAKE ON OFF switch on the steering wheel pressing this switch again will deactivate the system Baj The ENGINE BRAKE SELECTOR 1 2 3 switch is then asmo used to adjust the amount of braking applied Using engine braking features can extend brake lining life The features also allow the driver to slow the vehicle down or maintain a constant speed on steep road grades that would otherwise result in prolonged use of the service brake that could cause brake fade Refer to the Engine Operation and Maintenance Manual for detailed information on the engine braking system MaxxForce 11 13 and 15 Engine Brake With Eaton AutoShift UltraShift Transmissions Special Driver Instructions Low or manual transmission mode can be used to maximize engine brake performance e Keep engine speed as close to 2250 rpm as possible e Maintain brake pedal application until any desired downshifts are completed Failure to do so may cause missed shifts e The gear display on the shift selector will stop blinking when the downshift is completed and the driver will notice resumption of engine braking as an indication that the sh
87. Compressor Cycling The MaxxForce 11 13 and 15 liter engines can be equipped with one of two different types of air compressor and may have one or two cylinders Head Unloaded Air Compressor This single cylinder constantly engaged air compressor works in conjunction with the air governor and air dryer to pump compressed air to the air dryer and air tanks When additional compressed air is not needed air is shut off from the air compressor discharge line and confined to the air compressor cylinder and its head Clutched Air Compressor This high capacity two cylinder air compressor is periodically engaged by using an on off clutch It works in conjunction with air governor and air dryer to pump air to the air dryer and air tanks When additional compressed air is not needed the clutch is disengaged compressor speed goes to zero and all air pumping ceases This system provides relatively low cylinder temperatures and sound verses other compressors during the unloaded cycle It is used to promote maximum fuel economy by eliminating pumping energy loss during 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 When the air pressure reaches approximately 110 psi 758 kPa the governor signals the air compressor to resume pumping pressurized air to the air system During normal 3878859
88. EN switch to cancel Parked Regeneration Regeneration Inhibit Switch The optional Regeneration Inhibit switch is used to prevent the normal regeneration or parked regeneration processes NOTE There are two versions of the regeneration sr inhibit switch the two position and the three position switch Therefore its necessary to verify which version is installed in this vehicle Both versions have the same switch labels 141 Operation Two Position Regeneration Inhibit Switch With the optional two position switch pressing the ON position of the ON INHIBT REGEN switch will inhibit both normal and parked regeneration Regeneration will be inhibited latched when in this position and the switch indicator is turned on Three Position Regeneration Inhibit Switch The optional three position switch is a center stable momentary switch Pressing the ON position inhibits normal regeneration while the engine is running and is reset when the ignition switch is turned off The Inhibit function is cancelled when the lower position is pressed or parked regeneration is initiated PARKD REGEN switch is turned to the ON position The switch indicator will be turned on whenever regeneration inhibit is enabled Transmission Manual Transmissions Vehicles with a manual or AutoShift transmissions have a clutch pedal that is used to engage or disengage the clutch connecting or disconnecting the engine from the transmission and rear wh
89. For operating instructions refer to the Transmission Manual The current gear selection and other information is also displayed on the instrument panel gauge cluster display 3878859R2 Operation Automated Manual Transmission Controls UPSHIFT The UPSHIFT mode is used in the MANUAL mode to select upshifts 8487195 DOWNSHIFT The DOWNSHIFT mode is used in the MANUAL mode to select downshifts 8487196 MANUAL Allows the driver to hold current gear and manually select the appropriate gear for road conditions using the upshift downshift buttons Manual mode should be used whenever the 8487197 driver wants to select the shifts instead of letting Autoshift select them automatically GEAR DISPLAY The GEAR DISPLAY shows the current gear position of the transmission The GEAR DISPLAY will flash the target gear position of the transmission when in neutral during a shift 8487198 REVERSE Selects Reverse gear once vehicle speed is less than 2 mph 3 km h 8487199 NEUTRAL Places the transmission in neutral 8487200 DRIVE Selects the default starting gear and automatically selects gears between the starting gear and top gear 8487201 LOW When Low mode is selected the transmission downshifts at the earliest opportunity for maximum engine braking 8487202 3878859R2 147 Operation Eaton UltraShift Transmissions Optional The optional Eaton UltraShift transmission is an automatic transmission that can automatically select and engag
90. NOTICE Be advised that this motor vehicle may be equipped with computer recording devices Their function is to allow an authorized individual to download data or information relating to the operation or performance of this vehicle The stored data or information may be neither downloaded nor retrieved except by the vehicle s registered owner or in the alternative by another individual or entity authorized by the registered owner such as an International Dealer who may need this data or information to properly service or diagnose this vehicle for repair or following an accident Any access to this information without the owner s consent may be in violation of law and may subject that person or entity to criminal penalties CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Important The information specifications and illustrations contained in this manual are based on data that was current at the time of publication International reserves the right to make changes and or improvements at any time without notification or liability or without applying those changes or improvements to vehicles pre
91. PT DESCRIPTION LOCATION AMP STO OPT DESCRIPTION LOCATION AMP STO OPT DESCRIPTION Fi a 5 acc STD BODY CONTROLLER F4 c 10 16N OPT TRANSMISSION SEE NOTE 3 F5 J 10 10N OPT SATELLITE COMMUNICATION Fe p 30 etry sto TRAILER ABS ECU F1 B 5 BTRY STD CAB HVAC CONTROL F4 D 10 IGN STD ENGINE ECU N ICON F5 K 15 16N smD AIR DRYER F8 E 15 etRY opt skIRT LIGHTIING Fi c 5 etRY NOTE FLOOR LIGHT F4 E 10 ACC OPT VEHICLE SENSOR MODULE Fs 16N fopen Fe F 30 ptRY OPT TRANSMISSION SEE NOTE 3 F1 0 5 BTRY OPT SECONDARY GAUGE CLUSTER F4 F 10 ACC STD CB RADIO ENTERTAINMENT RADIO FS M 10 IGN STD BACK UP LIGHTS F8 G OPEN F2 A 15 BTRY sTo TRAILER LEFT TURN F4 6 10 IGN NOTE 1 OPTIONAL WARNING LIGHTS Fe A 30 BTRY STD CAB HVAC BLOWER MOTOR Fe H 30 etry sto ENGINE ecu F2 8 15 etRY sTo CIGAR LIGHTER F4 H 10 16N OPT REMOTE START STOP Fe 8 gt OPEN F9 A 30 etRY OPT POWER WINDOW DOOR DRIVER F2 C 15 BTRY STD TRAILER RIGHT TURN F4 10 ACC OPT SECONDARY DISPLAY TIRE PRESSURE F6 C 10 BTRY OPT FUEL TRANSFER PUMP F9 B 7 5 IGN OPT ICON PED 10 BTRY STD CAB DOME MAP LIGHTS F4 K 10 ACC STD SWITCH PACK F6 0 20 BTRY OPT FUEL HEATER F9 C OPEN F2 E 10 BTRY STD ENTERTAINMENT RADIO MEMORY F4 L 10 IGN STD CLUSTER CAB HVAC CONTROLLER N ICON F7 A 30 BTRY NOTE 2 SLEEPER FUSE PANEL FEED F D 20 etry oPT INTERNATIONAL ENGINE ECM RELAY F2 F 10 BTRY OP
92. R2 engine operation this cycle will be evident by the fluctuation of the primary air tank pressure gauge To prevent personal injury or death from hot coolant or steam use only the following procedure to remove the pressure cap from the radiator or expansion tank Allow the engine to cool first Wrap a thick heavy cloth around the cap Unscrew the cap slowly to allow pressure to release from under the cap After the pressure has been released the pressure cap may be removed A WARNING Exercise great care when working on vehicles with running engines that are equipped with an automatic fan clutch The fan engages when engine coolant reaches a predetermined temperature or the refrigerant pressure if equipped with air conditioning reaches a predetermined setting The fan will start with no advance warning Failure to observe these precautions could result in vehicle damage personal injury or death Cooling System 135 Operation If the coolant should get extremely low and the engine very hot let the engine cool for approximately 15 minutes before adding coolant then with the engine running add coolant slowly Adding cold coolant to a hot engine may crack the cylinder head or crankcase Never use water alone The cooling system in vehicles with MaxxForce 11 13 and 15 engines is filled at the factory with Nitrite free Shell Rotella Ultra ELC Yellow coolant International Truck recommends using only the approv
93. RBER VAKER dares ieee eds 103 Adjustable Steering ColUmn cceeeeeee eee eee eens 129 After the Engine Starts ccc cc ceeeeee eee eee ened 124 Ait Braks nrto a A wales kah lesa 152 179 Air Gauge Low Air Pressure Beeper and Warning geier irel PEEP EE EE E ITS 153 Brake Applicator raa EUC cece e eee eee eee eee 154 Inspection and Adjustment 0 ccceeeeee eee ee eens 179 Reservoir Moisture Draining cece eee eee eee 153 Air Cleaner Element Service ccceeeeeeee eee e eens 189 Air Compressor Cycling ceeeeceeeeeeee eee eee ened 135 Air Conditioning a arere ee eee ee alleles eer ee 88 Air Conditioning Service CheckS 00 cceeeee eee eee 174 Front Access HVAC Filter 0 e eee eee eee eee eee 175 HVAC FilterStvccsatephs lo reer EEE AAEE ADEE EE KERNERNE ys 174 Recirculation Filters 0 0 cece cece eee e eee teeter eee 175 Side Access HVAC Filter 0 0 cc cceeeeeeee eee teers 174 Sleeper HVAC Filter 02 e cece eee ee eee ee eee eee 176 Air Drygt en etess shia We saa deemmewe dees a Medes 155 180 Desiccant Filter 0 erR rE eee e TATTERI 181 Fear sc siy rece E EAr te oe AER AANE reeset eg nt 181 3878859R2 A CONT Air Dryer cont Purge Valve i aee aa A deads oie Ueber ema eked 181 Air Gauge Low Air Pressure Beeper and Warning INDICATION aadewe ves eecbokbon hen sanded A EE AA
94. T SATELLITE COMMUNICATION F4 m 10 IGN STD BODY CONTROLLER CAB HVAC LPM F7 B NOTE 6 BTRY OPT TRLR SOC AUX OR SWITCHED CENTER PIN Fo c 30 etRy OPT POWER WINDOW DOOR PASSENGER F2 6 15 BTRY STD INSTRUMENT CLUSTER FS A 10 IGN OPT COLLISION AVOIDANCE F7 C Fr 2s ee OPEN F9 F oe OPEN F2 H 10 etry opt sPoT LIGHT F5 B 10 Ion oPT PTO F7 0 30 etrY STO TRAILER STOP F9 20 pTRY OPT INTERNATIONAL ENGINE F3 A 10 BTRY STD KEY SWITCH F5 C 10 IGN STD WINDSHIELD WASHER PUMP F7 E 30 BTRY NOTE 2 SLEEPER HVAC BLOWER F9 H zz i a OPEN F3 8 20 etRY sto TRAILER TAIL LIGHT F5 p 10 16N OPT SECONDARY GAUGE CLUSTER F7 F 15 etRY OPT WORK LIGHTS CUSTOMER SUPPLIED Fio a OPEN F3 C 15 BTRY OPT AUX POWER SOURCES F5 E 10 IGN STD CLUSTER CAB HVAC CONTROLLER W ICON F7 G aie e ee OPEN F10 8 30 BTRY OPT CUSTOMER ACCESSORY 1 F3 D 20 eTRY STO TRAILER MARKER LIGHT Fs F 10 16N OPT DRIVER DISPLAY F7 H 30 BTRY NOTE 2 SLEEPER FUSE PANEL FEED Flo c z OPEN F4a a acc JOPEN Fs 6 1cN OPEN Fe A 10 eTRY OPT VEHICLE SENSOR MODULE ree hee pai er el lene eee ea es F4 B 10 ACC OPT POWER MIRROR F5 H 10 IGN OPT COMPASS MODULE F8 8 30 BTRY STD TRACTOR ABS ECU 5 BTRY OPT DRIVER DISPLAY SEt Y DISPLAY Li ea iaaa a Gaa RN 5 BTRY OPT ICON OR NO IDLE HEAT 5 IGN sto TRACTOR ABS ECU Pires OPT W DAY CAB STD W SLEEPER 4 RELAY EATON ULTRASHIFT XMSN IGN OR FREEDOMLINE XMSN BACK UP 7 30
95. T deren 153 Air Induction System cece ee eects 187 Air Intake SysteMm 00 cceeeeee eee eee eee e eee e teens 196 Air Reservoir Tanks Moisture Draining 000eeeeeee 181 Air Restriction Gauge 0 e eee eee eee eee eee 188 Air Suspension System Faults 151 Airline Cabinets 0 cceee cece eee eeeeeeeeeeee eee e ee tees 114 AGNO eea en 255 aktad dee EAA deeded AOR eee eee eb 177 Alternator enen eben ee glenn ie daa ern 130 A L 6 ZC ie wes cite Soild e ire E dense heninah E 194 Antilock Brake System ABS 00 seeeeeeeeeee eee e eee 158 ABS Operation 00 cece cece cence eee eeeeeeeeeeeeeeeees 158 ABS Self Chokri Soe benny eee aetna 159 Antilock Driving TipS ceee eee e eee e eee e eens 159 Antilock Driving TipS 2 ce eeeeeee cece eee e ened 159 Assistance Guide 2 ccc ccc eeeeee eee etter teen ee ennaeeees 1 ATC OFF ROAD or MUD SNOW Switch 50 160 ATC System Check 0 cece cece eee eee eeeeeee eee e ees 160 Automatic Door Lock Function 0scceeeeee eee eee eee 91 Automatic Traction Control ATC System eee ee 159 ATC OFF ROAD or MUD SNOW Switch 160 ATC System Check 0 cece cece e sence eeeeeeeeeeeeees 160 Stability Control Systems Bendix RSP WABCO RSC Bendix ESP 0 c cece cece eee e eee eee e ees 160 Available Models 0
96. TETEE 204 Tire WarningS reeeo Var eNA eeeeeeeee eee eee e eee ennnes 199 TIVGS E E ne citete eas E E ena detente 199 Dual Tires Matching 000ceeeee nent eee e eee e eens 203 Dual Tires Mixing 00ccceeeeeeeeeeeeeeeeeeeeneeees 203 INSPOCHON Avena ee yeren wenden oes eeaaasey Seeder sedan eaters bes 202 OAS ais oSeik T EAT eee iia padres tas 203 Rotationin t2ii2 ei raa ae das caer 203 Rotation Is Advisable 0c cece eee eee eee 203 Tire Replacement 02 cece cece eee eee eee 204 SmartWave Tire Pressure Monitoring System TPMS 202 Tire Maintenance neea ireren haenu eer e cece eeeeeeenes 201 Checking Inflation 0 0 eee 201 Underinflation 0 c ccc ceeeee eee eee IEEE Eaa iE 201 Tire WarningS cece cece cece e cece eeeeeeeeeeeenes 199 Use of Tire Chains 00 cccceeeee cece eee eee NEAN 205 E E E A OA endear A E Boao ey 204 Irregular Weal 2 cecceee cece eee eects tees eeeeenes 205 Wheel and Tire Balancing ccceeeeeee eee enna aes 204 Torque Specifications 0 cece eee eee r seen eee e eee e ened 227 Disc Wheel Nut Torque Chart e cece eee ee 228 U Bolt Nut Torque Chart cece eee ee eee 227 TOW HOOKS amp cadsve via cet sact AIREAN renee Seek EEEE 163 Tower Wardrobe Cabinet cceeeeeeeeeeeeeeeeenee 112 Towing INStructiONS 00 cece cece eee e eee ete eens 162
97. TOW HOOKS esi dniys aTa eine AAEE dees ia oceder als 163 3878859R2 Index T CONT Towing Instructions cont Towing Vehicle With Front Wheels Suspended 164 Towing Vehicle With Rear Wheels Suspended 165 Towing Vehicles With Driver Controlled Differential Lock 164 Installing Axle Shafts 0 cc cece cece eee eee ees 165 Removing Axle Shafts Before Towing 164 Towing Vehicle With Front Wheels Suspended 164 Towing Vehicle With Rear Wheels Suspended 165 Towing Vehicles With Driver Controlled Differential Lock 164 Installing Axle Shafts 165 Removing Axle Shafts Before Towing 2 0 164 Tractor IMS pecto sssri vances ITANA EEEO abe 24 Cab Interior INSpection 0 0 cece eee eee nent eens 41 Exterior Lights Check 0 0 e cece cece eee eee eee eee 24 Fifth Wheel and Coupling Area ceeeeee eee eee 40 Front Of MACON aaee es vung ARA AEAEE RRRA dante 29 Left Engine Compartment cece cece eee eee 26 Lett From of Tract laera ev Eee ORERE REE EEEE ER S 27 Left Rear of Tractor cece cece eee eeeeee teeter EREA Ta 38 Left Side Cab Area occ cc cccceeeeee eee eee e eee eee eeneeenee 25 Preparation sasanti dd eeeencendbdeceyes eanousaleeengaes ONERE 24 Rear Of TARON ranen ERENER TE 37 Right Engine Compartment cece eee eee 32 Right Front of Trac
98. USP DUMP switch is in the DUMP position e The SUSP DUMP switch indicator will blink slowly in the event of an ESC command fault regardless of the position of the SUSP DUMP switch Brakes General Information Always check and maintain brakes in proper condition and adjustment Out of adjustment brakes could cause reduced braking ability and result in property damage personal injury or death 151 Operation Downhill Operation 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 into a lower gear and could result in possible vehicle runaway resulting in property damage personal injury or death Always descend hills with extreme care relying primarily on the engine braking effect to control vehicle speed Heed warning signs posted for any grade Stop and check brakes for condition and adjustment at available pull off areas before starting a descent Observe the following precautions e Never coast downhill Service brakes alone should not be used to control speed on major downgrades Brakes will fade from overuse e Downhill speed is controlled by removing one s foot from the accelerator pedal engine running with closed throttle and putting the transmission rear axle in reduced gear If the transmission rear axle is in a gear that results in more than the appropriate speed a proper downshift should be made to avoid overuse of the brak
99. ached to the rear wall 3878859R2 Lower Bunk General Information 8487135 Upper and lower bunks are available in the International ProStar Series sleeper compartment The lower bunk is standard while the upper bunk is an option The lower bunk is hinged for access to the features under the bunk Gas shocks aid in opening and closing of the lower bunk and hold the bunk in the raised position for access 3878859R2 Sleeper Features ee 1 Release To open press upward on the latch mechanism Latch and lift the front edge of the bunk platform To close lower the bunk until the latch mechanism is locked in place 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 bunk is raised and turn off when the bunk is lowered These lights also operate when the exterior luggage doors are opened 4 Storage A removable storage tray is located under the Tray center of the bunk and can easily be removed from its location once the bunk is opened 5 Lock Boxes Two lock boxes are provided under the bunk storage tray for securing valuables out of site Power The optional power inverter is stored under the Inverter bunk in the center compartment Sleeper The sleeper heating ventilation and air HVAC conditioning HVAC components are stored Components under the bunk Luggage Acce
100. ading 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 the relative direction of the vehicle within a particular geographical zone 74 Vehicle must be moving to acquire an accurate temperature Quadrant 3 Description Display Messages Outside Display Format Temperature and Compass Heading 8590030 Outside Temperature Reading The Outside Temperature is displayed on the first line of Quadrant 3 above the Compass Heading The temperature sensor is located near the front bumper Due to its location the sensor readings can be affected by road or engine heat during idling or prevailing driving conditions extended slow movement The display will be in F or C depending on the units selected while in the odometer mode 3878859R2 Quadrant 4 Transmission Gear Displays Quadrant 4 Transmission Gear Indications Allison P R N D L gear display PRii i4 1 8487430 Eaton Transmission display TN2 8590031 Switches Six switches are located on the lower left and right side of the instrument panel gauge cluster Configurations are optional Blank cover plates will be used in spaces that do not have switches installed at those locations Headlights The headlights will be at 100 brightness with the headlight switch activated The p
101. age personal injury or death Always wear eye protection when working around batteries Do not attempt to jump start a vehicle with a frozen battery because the battery may rupture or explode If a frozen battery is suspected thaw out battery and recharge 130 3878859R2 DO NOT Check Battery Condition By Shorting Flashing Across Terminals Failure to follow Operation of the instrument panel gauge cluster The green BATTERY ON indicator will illuminate any time the battery disconnect switch is in the ON position batteries connected regardless of the key state This indicator can easily be viewed with the driver door open and without entering the vehicle this warning could result in property damage personal injury or death When working around the terminals and battery use extra care to avoid shorting A good practice is to use insulated pliers and screwdrivers BATTERY ON Indicator 1 8487392 1 Left Side of Dash 2 BATTERY ON Indicator If the vehicle is equipped with a battery disconnect switch an optional BATTERY ON indicator may be located on the left side 3878859R2 Circuit Breakers Fuses and Fusible Links Electrical circuits are designed with a particular wire gauge to meet the fuse and circuit breaker current rating 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 fir
102. am above Refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS for proper torque values 3878859R2 10 Maintenance Instructions 8487336 1 Flange Nut Mount 8 Stud 2 Flange Nut Mount 10 Stud All wheels undergo a process called joint settling when placed in service after a wheel installation has been performed This process results in a reduction in the torque on the wheel nuts To correct this condition operate the vehicle normally for approximately 50 miles 80 km then use a Calibrated torque wrench to retorque the wheel nuts to specification using the appropriate pattern shown in the wheel nuts torque sequence diagram As part of a daily pretrip inspection look for loose or missing wheel nuts Also look for rust streaks extending outward from the wheel nuts this can be an indicator that one or more wheel nuts are loose even if they cannot be turned by hand Normal periodic maintenance should also include checking the wheel nut torque with a torque wrench 207 Maintenance Instructions Transmission Check lubricant level With the vehicle on level ground verify that transmission lubricant level is even with the bottom of the inspection plug in the side of the transmission Check shifter for proper operation e Check operation of transmission neutral safety switch Try to start the vehicle in all shift selector positions other than neutral The starter should ONLY operate when the shift select
103. and Maintenance Manual Service intervals are based on average operating conditions In certain environments and locations more frequent servicing will be required The required maintenance operations may be performed at a service establishment Any replacement parts used for required maintenance services or repairs should be genuine OEM service parts Use of inferior replacement parts hinders operation of engine and emission controls and can reduce engine life and or jeopardize the warranty 3878859R2 Receipts covering the performance of regular maintenance should be retained in the event questions arise concerning maintenance The receipts should be transferred to each subsequent owner of the engine vehicle Engine fluids and contaminated material PN HUT GOVERNMENT REGULATION Engine fluids oil fuel and coolant may be a hazard to human health and the environment Handle all fluids and other contaminated materials e g filters rags in accordance with applicable regulations Recycle or dispose of engine fluids filters and other contaminated materials according to applicable regulations Scheduled Maintenance For information regarding routine scheduled maintenance such as replacement of oil filters coolant 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 3878859R2 Maintenance Inst
104. ar Latches Rear Buckles Font Latches Front Buckles Side Latch Plates Side Buckles Restraint Strap To install the restraint webbing system onto the sleeper bunk 1 Enter the bunk and lay the restraint webbing system out on top of your body Insert two rear latches on the rear wall into two mating buckles 4 that are sewn to the restraint webbing system making sure that both buckles are fully latched Insert three front latches that are sewn to the front of the restraint webbing system into the front buckles mounted at the front of the bunk making sure that all three front buckles are fully latched 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 plates that are sewn to the restraint webbing system into the side mating buckles located on the sleeper compartment side walls To adjust the restraint webbing system pull the short straps at the side latch plates on each side of the restraint webbing system to tighten Loosen the restraint webbing system by raising the side latch plates away from the restraint strap to allow the restraint strap to loosen through the latch plates Removal of the restraint webbing system is done by loosening both side latch plates unlatching the side latch plates unlatching the three buckles at the front of the bunk and unlatching the two buckles att
105. are a morra omea ei c EE a AF 8487400 3878859R2 47 Controls Features Warning Indicators The instrument panel gauge cluster contains 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 instrument panel gauge cluster At ignition the warning indicators will illuminate for 8 to 10 seconds as part of the vehicle power up sequence S Illuminates Yellow when the intake 00 heaters and glow plugs are in operation and special starting procedures are required Refer to the Starting Switch paragraph in the Vehicle Operation section for more information 2 IDLE Illuminates Yellow to alert driver that SHUT vehicle idle shutdown timer will turn 3813045 DOWN engine off in 30 seconds 8487074 3 Illuminates Yellow Used in conjunction with other Warning Indicators or General 8487080 Text and Warning Messages and may be accompanied by an audible alarm to indicate an Alert condition to the operator 48 IIluminates Yellow Used in conjunction with other Warning Indicators or General Text and Warning Messages to indicate an Alert condition to the operator Iluminates Red Used in conjunction with other Warning Indicators or General Text and Warning Messages to indicate a red STOP alert a llluminates Red when the parking brake PARK is applied If the brake warning
106. ark lights tail lights markers and clearance lights will be on as well An alarm will sound if the headlight switch is on and the ignition switch is off Your vehicle may be equipped with an optional headlight warning alarm that sounds immediately after ignition switch is turned to OFF position when headlight switch is on and the driver s door 3878859R2 Controls Features is closed It also sounds when headlight switch is on ignition switch is in OFF position 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 whenever the Parking Brake is released and the ignition switch is in the ON position The lights will stay on until the Parking Brake is engaged Lights On With Wipers This feature allows the headlights low beam to be automatically turned on when the windshield wipers are in steady or intermittent mode not washer The low beams will remain on until the ignition switch is turned to the OFF position or the headlights are cycled on and then off Park Lights The park lights tail lights markers and clearance lights will turn on when the headlight switch is in the park or headlight position Panel Lighting The panel lighting brightness is controlled by the PANEL rocker switch To increase the brightness of the instrument panel gauge cluster lighting continually press
107. ase from under the cap After the pressure has been released the pressure cap may be removed 192 Do not exceed the pressure rating on the de aeration tank cap Ensure that the pressure rating of the de aeration tank cap matches that listed on the side of the tank or the tank may burst causing property damage personal injury or death If the coolant should get extremely low and the engine very hot let the engine cool for approximately 15 minutes before adding coolant then with the engine running add coolant slowly Adding cold coolant to a hot engine may crack the cylinder head or crankcase Never use water alone Filling Instructions NOTE If system has been drained fill with fresh 50 50 diluted concentrate coolant or 50 50 pre mixed coolant If the system has been flushed with water a significant amount of the freshwater flush will remain in the system In this case refilling with a mixture with a higher percentage 75 of coolant concentrate is advised in order to achieve a final mixture close to 50 50 3878859R2 8487436 1 Deaeration Tank 2 Vented Fill Cap 3 COLD MIN and COLD MAX Lines NOTE Vented fill cap may differ slightly in location on tank between engine sizes 3878859R2 Maintenance Instructions To function properly the coolant system must be completely filled with coolant and all air must be expelled To accomplish this the following procedures should be carefully completed 1 Tu
108. avistar Inc Cherry Tree Corporate Center 535 Route 38 East Suite 300 Cherry Hill New Jersey 08002 856 486 2300 SOUTHEAST Navistar Inc 2400 Commerce Avenue Building 1100 Suite 100 Duluth Georgia 30096 678 584 2700 SOUTHWEST Navistar Inc 2595 Dallas Parkway Suite 203 Frisco Texas 75034 972 377 1200 WEST Navistar Inc 3017 Douglas Boulevard Suite 300 Roseville California 95661 916 774 7526 CANADA Navistar Canada Inc 5500 North Service Road 4th Floor Box 5337 Burlington Ontario L7L 5H7 905 332 3323 MEXICO Navistar Mexico SA DE CV Ej rcito Nacional 904 8 Piso Col Palmas Polanco 11510 Mexico D F 525 262 6666 BRAZIL International Caminh es do Brasil Av Carlos Gomes 466 conj 1002 Bairro Auxiliadora CEP 90480 000 Porto Alegre RS 55 51 4009 5800 CUSTOMER ASSISTANCE CENTER 1 800 448 7825 1 800 44 TRUCK Navistar International the International Diamond logo with and without endorsement ProStar and MaxxForce are registered trademarks of Navistar Inc or its subsidiaries in the United States and other countries All other trademarks are the property of their respective owners 3878859R2 Operator s Manual ProStar Series Service Publications Operator s Manual ProStar Series An Operators Manual is shipped with this vehicle for customer use Information on the purchase of other available Operator s Manual service publications for this vehic
109. ble d Accelerator foot brake and clutch if present pedals must not be depressed e Engine temperature must be at a sufficient level to allow regeneration With some engines this may be as high as 76 6 C 170 F NOTE The engine coolant temperature must be above 76 6 C 170 F before the parked regeneration procedure can be performed If the engine coolant temperature is too low the parked regeneration procedure will not activate 3 Press the ON position of the ON PARKD REGEN switch to initiate the regeneration cycle The engine speed will automatically ramp up to a preset RPM PARKD REGEN ACTIVE will be displayed in the 3878859R2 Operation 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 step 2 have been met Once started the regeneration cycle will last approximately 30 minutes NOTE If any of the above conditions are altered during the Parked Regeneration process regeneration will be halted and must be restarted 4 When the regeneration cycle is complete the switch indicator will go off the engine rpm will return to normal idle and all exhaust filter warning indicators will be off The vehicle may now be driven normally 487175 NOTE In the event of an emergency situation where the vehicle must be moved after beginning Parked Regeneration press PARKD REGEN position of the ON PARKD REG
110. bris in both the cab and sleeper HVAC intake filters that may reduce airflow 3878859R2 Controls Features Dehumidification The heater defroster systems can be operated simultaneously with the air conditioner during mild weather and high humidity conditions to dehumidify the cab air Turn the mode button to one of the A C positions and position the temperature knob at a comfortable temperature location The air conditioner will remove the humidity while the heater keeps the cab comfortable Electronic Vehicle Monitoring Base Display Ss A Engine Oil Leve 1 i Navigation Messages 76 0 pert fi Into 7hone 8487337 The optional Electronic Vehicle Monitoring Driver Information Display provides trouble code reporting trip status vehicle 3878859R2 and engine usage fuel economy information video inputs for external cameras and a USB port for loading MP3 audio files that can be played through the radio This unit also provides an interface for the optional SmartWave tire pressure management system and a port that is compatible with the optional Qualcomm Omnivision system Refer to the Driver Information Display operator reference card or visit http www lectronix biz support html for additional information Premium Display The optional Premium display is the same as the Base unit but with an additional navigation feature This feature provides mapping features turn by turn directions and truck points
111. button on the unlock symbol in the door control panel located by the vent window Pressing the lock unlock button once on the unlock symbol unlocks the driver door Pressing it twice unlocks both doors Automatic Door Lock Function The automatic lock function automatically locks the doors at a predetermined speed Driver Passenger Windows Manual Operation To lower door glass driver door turn window regulator handle clockwise To raise glass turn handle counterclockwise Reverse this procedure for the passenger door 91 Controls Features Power Operation Trucks may have optional electrically operated 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 passenger To lower or raise driver window press and hold either Up or Down direction on the driver side AUTO window control To lower or raise passenger window press and hold 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 full down position automatically Window Lockout Function The driver also has the ability to prevent passenger window up down operation by pressing the WINDOW LOCK control 92 Mirror Controls 8487166 1 Mirror Sele
112. ccurs in one system the remaining system continues to provide braking action When a failure is detected the air dryer is provided with a limp home feature to allow the vehicle to be driven to a service center If vehicle has been parked for an extended period in cold weather always check to be sure all wheels are rolling free brakes are not frozen when starting out Always clean accumulated ice and snow from brake linkage Air Gauge Low Air Pressure Beeper and Warning Indicator To prevent loss of vehicle braking or control resulting in property damage personal injury or death never operate the vehicle when insufficient air pressure less than 60 psi 414 kPa is indicated for either the primary or secondary air system The volume of air required to stop the vehicle may be greater than that available Have the brake system checked and repaired before returning the vehicle to service Should air pressure in either section of the split air brake system be reduced to 60 to 76 psi 414 to 524 kPa the warning beeper will sound and the red BRAKE PRESSURE warning indicator on the instrument panel will glow Also the air gauge gauges will indicate low air pressure in at least one of the independent systems The warning beeper and red indicator will automatically shut off when the air pressure in both systems 3878859R2 Operation is sufficient approximately 55 to 76 psi 379 to 524 kPa to operate the vehicle Should the red
113. ce Contracts 233 Customer Assistance Custom Service Contracts the most flexible aspect of the International Truck Warranty Program can provide extended protection that is specifically tailored to meet each customer s specific requirements Finally through Performance PM Service customers can obtain a comprehensive preventative maintenance program designed to ensure consistency in pricing and the level of service received ADVANTAGES of International Truck Warranties 234 Extends warranty protection to specified component coverage to suit individual needs length and Honored at over 1 000 International Truck Dealer locations in North America Stabilized and predictable maintenance costs Increased owner confidence and peace of mind Improved resale value on your vehicle International Truck Warranties may be transferable for a nominal fee Contact the Service Contract Center 1 800 346 4429 option 1 for transferability Most coverage is 100 labor with NO DEDUCTIBLES parts and Customized warranty programs are offered to suit your needs 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 Performance PM Service designed to assure the lowest possible cost of ownership are also available Optional Service Contracts have been pre packaged to fit m
114. ce eee e eee eeee 125 Engine Idle Shutdown Timer Optional 127 Engine Idling 00 ccceeeee eee eee teen eee TOETSE 126 Winter Front USage sees eee eee e teen eee e eee 127 Emergency Starting i tirit Iar EERE REEERE RRS 124 Engine ShutdwNi eirs reete enerne anaa ER 124 Engine Starling s eeraa cceeeee eee AEE EINA ARERIA TEESE 123 Hot Weather Operation e cece eeeeeeee eee teens 127 Steering aes sands fhe eta AE deeds ceetest teens 128 198 Adjustable Steering ColUMn ceeeeee eee eee e tees 129 Lubrication Points 2 cece cece cence eee eee tenes 199 Power Steering c cece eceeeeeeeeee eee eee e teen nenes 199 246 S CONT Steering cont Tightening Steering Intermediate Shaft Joint Bolts 198 Steering Column and Switches cece nese eee 78 Steering Wheel Controls cc cece eee eee eee tees 77 Cruise Control 2 cccceceee cece eee eee e eee eeeeee ees 78 Storage Duration One Month or Le SS 2 6200eee eee 2 Storage Duration Over One Month ee cence es 3 Storage FacilitioS 0 cccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 4 Supporting Your Vehicle for Service cece eee es 173 Suspension Air and Steel Springs ee eee eee ees 197 Front SUSPENSION cece eee 197 Rear SUSpensiOn 2 EaR IE eee
115. ce grease between king pin and bushing surfaces 3878859R2 223 Maintenance Intervals and Specifications Component Vendor Lubrication Type Applicable Temperatures Engine See Engine Operation and Maintenance Manual Lubricating Oil Power Steering Engine Oil 15W 40 Engine Oil In extreme cold conditions 20 F or below replace the 15W 40 and use power steering fluid Fleetrite P N CH990625C2 or equivalent Steering Gear Fleetrite NLGI 2 Lithium Complex Based Moly Lubricant grease P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease Steering Fleetrite NLGI 2 Lithium Complex Based Moly Intermediate grease P N 991044C2 or equivalent GC LB NLGI Shaft 2 Multi purpose Lithium Complex grease U Joints Slip Joint Lubricant U Joint Fleetrite Lithium Complex Based Moly grease Lubricant P N 991044C2 or equivalent GC LB NLGI 2 Multi purpose Lithium Complex grease 224 3878859R2 Maintenance Intervals and Specifications Component Vendor Lubrication Type Applicable Temperatures Clutch Release Fleetrite Lithium Complex Based Moly grease Bearing P N 991044C2 or equivalent GC LB NLGI 2 Shafts Fork Multi purpose Lithium Complex grease Lubricant Cooling System Extended Life Shell Rotella Ultra Extended Life Coolant See Engine Operation Coolant ELC Type Ill and Maintenance Manual Heavy Duty Type Il Purple Fleetrite P N ZJJSCA5550 See Engine Operati
116. cece eee eee enna 157 Bobtail Proportioning System cceeee eee eee es 157 Antilock Brake System ABS eeeeeeeeee eee 158 General Information cc cee eee eee e eee ee eens 158 ABS Operate osondo veel vsnned anaE EEIE O 158 ABS Seli CNeCK or irate ieee enue aed TETERE TVETER 159 Antilock Driving TipS ceeee cece eee e eee e eee ee ees 159 Automatic Traction Control ATC System 805 159 General Information 0c ceeeeeeeeeeee eens 159 ATC System Check 0 0 2 cece cece cece cece ne eee eee eeeeees 160 ATC OFF ROAD or MUD SNOW Switch 160 Stability Control Systems Bendix RSP WABCO RSG Bendix ESP eviin aaa aAA AAAA ARAA 160 Towing INStructiONS eea aiee eaaa ETE RETER EEEE TORE 162 TOW sHOOKS eai e raae E EAA AEREE ENN 163 3878859R2 Table of Contents Towing Vehicle With Front Wheels Suspended 164 Towing Vehicles With Driver Controlled Differential HOCK PEREL E E T EE eee 164 Removing Axle Shafts Before Towing 164 Installing Axle Shafts cc ccceeeeee eee eee e eee eee ees 165 Towing Vehicle With Rear Wheels Suspended 165 Tractor Trailer Connections ccc cceeeeee eee e eee e eee ees 166 Connecting Disconnecting a Trailer to a Vehicle with Air SUSPONSION 0cceee EE AANA ATAA EEA 166 Fifth Wheel Operation 0 0 cece cece eee ee eee ees 166 Fifth Wheel S
117. cedures Before towing be sure to fully release the parking brake The spring actuated type parking brake can be released by recharging the air system with at least 64 psi 441 kPa of air If brake system will not retain air pressure then the spring brakes must be held in the released position caged manually See Parking Brakes Tow Hooks Two removable front tow hooks are optional on International ProStar Series models The tow hooks 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 the vehicle in emergency situations 3878859R2 Operation Cai OGM as SSK 9p 8487104 1 Front Bumper 2 Tow Hooks 3 Receiver Portion of Front Suspension Bracket NOTE The optional tow hooks are stored in a bracket attached to the rear side of the seat bases on day cab models and in a plastic case under the bunk on sleeper models NOTE Do not leave tow hooks in receivers when not in use Insert the tow hooks through the front bumper and into the receivers tow hooks must have the point of hooks vertical while inserting into receiver Push on each tow hook and rotate outward 90 to secure the hooks in the locked position The point of each tow hook is pointed outboard on the truck to prevent damage to the bumper during towing 163 Operation Towing Vehicl
118. cific equipment in question before operating Failure to observe this warning may cause property damage personal injury or death 3878859R2 NOTE This vehicle may be equipped with electronic application specific options not described in this Operators Manual Many of these features are supplied with rocker switches that have custom labels applied The presence of these options as factory installed can be verified from the Line Set Ticket included with the vehicle A truck equipment manufacturer TEM however may have installed some of these options after production In that case they will not appear on the Line Set Ticket If installed by a TEM you should receive an operating guide and or training for the specific functions provided Familiarize yourself with all of the switches that control chassis engine and body equipment and seek adequate training on the function of all features before operating this vehicle Electrical System The Electrical System provides a means to distribute the electrical power and provide the driver with controls and indications of vehicle performance Unlike previous electrical systems this system uses multiplexing for connecting to major functional areas of the truck with much less wiring The system is controlled by the Body Controller which provides interfaces to a majority of vehicle switches and sensors The Body Controller also communicates with the standard and optional system controllers and modu
119. cle speeds under 25 mph 40 km h Also to maintain vehicle stability the differential must not be locked when the vehicle is traveling down steep grades and traction is minimal DIFF LOCK will automatically disengage when vehicle speeds exceed approximately 25 mph 40 km h Do not engage the locking differential when the tires are spinning The vehicle may need to be decelerated or turned once or twice for the differential lock to fully disengage Rear Suspension Rear Air Ride Suspension The vehicle must not be operated on the road without air in the suspension air bags Failure to observe this will result in ride degradation and suspension damage Rear Air Ride Suspensions automatically adjust to different loads to maintain constant frame height The system maintains vehicle ride quality and driver comfort Rear Air Suspension Air Dump This feature also allows the rear of the vehicle to lower several inches for trailer attachment detachment 3878859R2 The system is controlled by the two position SUSP DUMP switch with an indicator light in the fd DUMP position This switch controls solenoids which sie direct air to the suspension dump and height valve When the SUSP DUMP switch is in the DUMP position and the vehicle speed is below 5 mph 8 km h air supplied to the rear air suspension is released lowering the frame for loading 8487108 Placing the switch in the SUSP position causes air to fill or remain in
120. csecceceeceeeee 75 D h midificalio Nrs a EVENE ee 89 Desiccant Filter 2 c cece cece cece ai aaa 181 Diesel Particulate Filter DPF ccc eee cece eee eee 196 COTS AMAIA Go sz cezces cc ce ccsnse con cnemanansn ttt geananonct th Rot ton tutes cod totontonununen gtatee eee 197 Regeneration 02 cece ee eeeeeeeeee eee e eee eeee 196 Direct Drive Warning Indicators cc cece seen eee ees 54 238 D CONT Disc Wheel Nut Torque Chart eeeeeee eee eee ee 228 Dome Light ccccecccec cece e teen eee eeeeeeeeennes 97 Dome LoM essensen aee ERRERA acess veg eeeeea deena ti EVENE 76 Door and Window Conttrols ccccceeeeceeeeeeeeeeeaes 90 Door Lock UNIOCK meane ea lit ccc cece cence ene e ee eneeeaneeeanes 90 Automatic Door Lock Function ccccce eee aes 91 Cab Doors and LOcks cece ceee cece eee eeeneeeees 90 Lock Unlock From Interior cceeeeeeeeeeeee eens 91 Remote Keyless Entry Operation Optional 90 Driver Passenger WiNdOWG eccceeeeee eee e eee ee ee 91 Manual Operation 0 cc cceeeeee eee ee eee eeeaeeeees 91 Mirror Controls cc cece cece cece cece eee a AAE Eaa i 92 Power Operation cece eee eee eeeeeeeeeeeeeeeees 92 Vent WINdOW 0 0 ccc cece cee cence neces eneeeneeaneeeas 92 Window Lockout Function ccceeceeeeeeneeeaes 92
121. ct Switch 2 Mirror Direction Control Switch These controls provides the driver with the ability to operate both driver and passenger side flat mirrors Use the mirror select switch to select which mirror is to be adjusted and adjust the mirror using the mirror direction control switch Vent Window Vehicles are equipped with either a fixed or opening vent window The opening vent window can be opened and closed to allow additional air flow into the cab 3878859R2 Controls Features Eaton VORAD Collision Warning System Optional WARNING Before using this feature read and thoroughly understand the Eaton VORAD Collision Warning Systems Driver Instructions manual and obtain proper training on the system Improper use of this system could result in property damage personal injury or death The Eaton VORAD Collision Warning System is intended solely as an aid for an alert and conscientious professional driver It is not to be used or relied upon to operate a vehicle The system should be used in conjunction with rear view mirrors and other instrumentation to maintain safe operation A vehicle equipped with the Vorad Collision Warning System should be operated in the same safe manner as if the Vorad Collision Warning System were not installed The system is not a substitute for normal safe driving procedures It will not compensate for any driver impairment such as drugs alcohol or fatigue Failure to heed this warning may
122. d Scrolls between See Visor for info Exhaust filter is full Pull vehicle safely off roadway and start Parked and Parked Regen Regeneration to prevent loss of engine power Required An alarm will beep See oe Exhaust filter is full A WARNING iv whil See Visor for info Enoi f continuously while ad Parked Regen ngine periormance Is Pull vehicle safely off roadway and ignition is on LIMITED Required start Parked Regeneration to prevent Flashing engine stopping 3813052 E Exhaust System Temperature is HOT adto TEMP A warnnG Exhaust components are operating under normal conditions and exhaust gases are at extremely high temperatures When stationary keep away from people and flammable materials vapors or structures or STOP ENGINE A serious problem has occurred Engine may SHUTDOWN soon Pull vehicle safely of roadway turn on flashers set parking brake place warning devices and STOP ENGINE Seek service immediately 8487086 140 3878859R2 Parked Regeneration Procedure Perform the following steps to initiate Parked Regeneration cleaning of the exhaust filter 1 Park the vehicle safely off the roadway and away from flammable materials 2 Before initiating parked regeneration using the ON PARKD REGEN switch the following conditions must be in place a Parking brake must be set b DPF indicator illuminated Solid or Flashing c Transmission must be in Neutral N or Park P if availa
123. d Shut off engine and TURN KEY BACK ON Without brake pedal applied note air pressure drop for one minute It should be less than 2 psi 14 kPa Depress and hold brake pedal and make sure there is no more than a 3 psi 21 kPa per minute pressure drop For combination vehicles there should be no more than 4 psi 28 kPa per minute pressure drop Step on and off brake pedal and check that warning indicator and alarm come on at about 60 or 76 psi 414 or 524 kPa Step on and off brake pedal and check to make sure the parking brake knobs pop out between 20 and 45 psi 138 and 310 kPa 3878859R2 Controls Features SECTION 4 CONTROLS FEATURES Introduction General Information The controls features enable the driver to monitor and manage the operation of the majority of the vehicle s functions This section describes and identifies various components within the Overhead Console Instrument Panel Gauge Cluster Center Dash Panel Wing Panel Steering Column and Switches Steering Wheel Controls Door and Window Controls Eaton VORAD Collision Warning System and Vehicle Information Display Electrical This vehicle may be equipped from the factory with electrical switches intended to operate equipment that was installed by a truck equipment manufacturer TEM Instructions Cautions and Warnings for this additional equipment will NOT be found in this manual Read and understand the appropriate manual for the spe
124. d ave rA An A bees 132 Air Compressor Cycling 0eeeeeeee eee e eee e eens 135 Certified Clean Idle cece c ce eeeee eee eee 134 Charge Air Cooler eceeeeee eee eee eee eens 132 Electronic Engine Controller a se 133 Engine Brake ccceeeeee cece eee eee e eee e eee eeeeees 133 Engine Oils ecsehiyucitecdecnsdteswebdeegeed eebbl id tea 136 Engine Performance Problems 555 136 MaxxForce 11 13 and 15 Engine Brake With Eaton AutoShift UltraShift Transmissions Special Driver INSTPUCTIONS 3 eses anak peat deemed taaaamadaacn 133 MaxxForce Engine Features cece ee eee 134 Self Diagnostics 0 eect eee enna 134 Exhaust Diesel Particulate Filter Regeneration 139 Parked Regeneration Procedure 002 005 141 Regeneration Inhibit Switch ccceeee eee eee ees 141 Three Position Regeneration Inhibit Switch 142 Two Position Regeneration Inhibit Switch 142 Fuels ihr dsnedadapenieemenemdddacsebinyenelieueenn need ees 137 Additional Unsafe Practices cceeeeee eee e teense 137 Fuel and Lubricant Additives ccc ceeeeee eee es 137 Fueling Precautions ccc eee eee eee eeeaee eens 138 Fueling Procedures ccceceee cece cece eee eeeeeees 137 Hazards of Diesel Fuel Gasoline Blends 137 Reserve Fuel 0 cece eee e
125. d clean if dirty Battery Box Inspect for damage and secure mounting of battery box Remove battery box cover 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 must be clean and free from foreign material Replace battery box cover Fuel Tank s Check to see that the fuel tank s and cap s are secured and make sure there is no damage or leaks at the tank s or fuel lines 25 Inspection Guide Left Engine Compartment 26 Air Cleaner Check air cleaner element housing and hoses for loose connections or damage Check air filter restriction gauge for restriction reading For element replacement see Air Cleaner Element Service in the Maintenance Instructions section Oil Level Use dipstick to verify that the oil level is between the full and add marks 3 Fuel Water Separator Check sight globe if Davco equipped inform maintenance personnel if fuel level is at 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 Power Steering Fluid Verify that the fluid level is between the Cold or Hot as applicable MIN and MAX marks 5 Radiator and Charge Air Cooler Check for loose mounting and damage Inspect condition of all hoses for damage cracks and leaks Inspect for fore
126. d traction on poor surfaces at low speeds PARKD REGEN ON DPF regeneration activation when parked switch is used for engine after treatment Manually initiates DPF regeneration INHIBT REGEN ON The Regeneration Inhibit switch is used to prevent the Normal Regeneration or Parked Regeneration processes SLPR ENGINE CNTL Sleeper engine control switch is used when the vehicle has remote start Allows the remote engine start stop via a switch on the sleeper control panel TRLR AUX ON Auxiliary trailer socket center pin control 3878859R2 QUAL com 8487115 8487434 SPARE ON Spare switch provided for customer usage of additional options QUAL COM PANIC Sends distress signal Used in conjunction with the optional Qualcomm satellite communication system see Qualcomm System Owners Manual ENAB DATA LOG When enabled allows the driver to log the last five seconds of data group s operational parameter values into ECM memory The center dash panel also consists of console components for driver comfort and use as well as the transmission controls and Vehicle Information Display 3878859R2 26 27 28 29 30 31 32 33 34 35 Controls Features Auxiliary Power Connectors Cup Holder Ashtray Ignition Cigarette Lighter Accessory Power Outlet Manual Transmission Shift Lever Dash Vehicle Information Display optional Air Brake Valve Controls a Trailer A
127. damaged Both options are serviced in a similar manner NOTE Do not change the air cleaner element configuration from the factory installed configuration If equipped with a single element or dual element that configuration must stay with the vehicle Failure to comply may affect engine performance 3878859R2 Maintenance Instructions NOTE Be careful not to bump the air filter element while it is in the housing this can raise a cloud of dust that 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 to release cover tabs and pull to remove the cover Remove the filter element s carefully and slowly then discard the old element s 2 Wipe the inside of the air cleaner housing with a clean damp cloth Be sure to clean the gasket sealing surface Be sure to wipe out any dust that has fallen into the port to the turbocharger DO NOT use compressed air for this cleaning 3 Visually inspect the air cleaner housing for damage or distortion which could allow unfiltered 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 damaged or nonresilient rubber gasket Inspect the air filter element body for dents or excessive pleat bunching If any of
128. de a heater to prevent the discharge valve from freezing in cold weather Trailer Brake Hand Control The hand control valve should never be used to apply the trailer brakes when the tractor and trailer are parked Air pressure may leak from the system and the vehicle could roll away resulting in property damage personal injury or death The trailer brake hand control is used to apply the trailer service brakes independently of the tractor service brakes The trailer brake hand control operates a valve that provides gradual control of air pressure applied to the trailer service brakes The trailer service brakes can be fully or partially applied but when in a partial position can be overridden by pressing fully on the brake pedal To apply the trailer service brakes utilizing the hand control move the lever clockwise down The further the handle is moved clockwise the greater the air pressure applied to the trailer brakes The trailer hand brake handle will remain in place with the desired brake pressure applied until the handle 155 Operation is manually moved To release the trailer brakes move handle counterclockwise up until trailer moves freely Trailer Air Supply and Parking Brake Modular Controls Ly TO RA A g AN SA os TRAILER lt amp JA AIR SUPPLY PARKING x BRAKE Ba NOT FOR PARKING 8487194 e TRAILER AIR SUPPLY red octagonal knob e PARKING BRAKE yellow diamond knob The PARKING
129. de walls and can come in configurations of one two or three cabinets on each side of select International ProStar Series sleeper models Door Each airline cabinet is provided with its own pull down door to secure stored items Interior Storage Interior storage is provided to secure items away from sight and prevent them from moving around while the vehicle is in motion 3878859R2 Convenience Features General Information The sleeper cab is equipped with additional features that make living on the road easier and more convenient Sleeper Curtain Privacy curtains are available on all International ProStare Series sleeper models to ensure privacy and to darken the cabin from outside light Curtains are designed to separate the back of the driver passenger seats and the sleeper compartment When the curtains are not in use they are easy to store by sliding them to the sides of the cab wrapping the straps around them and securing the straps to the snaps provided on the cab side walls Television Mount Mounted behind the passengers seat and just below the airline cabinet is the optional television mount on select International ProStare Series long sleeper models Straps are provided with the television mount to secure the television to the mount plate A convenient antenna and power socket is located on the side wall next to the television mount Power Inverter The power converter is available on select Internati
130. dies ad bas tee te eins vag sees tes 148 Power Take off Control ccccceeeeee eee eeeeeeeeeeees 148 Rear Axles ia EEA ARRAES AEEA AETI 148 Locking or Limited Slip Differentials 148 Tandem Axle Power Divider Lock PDL Control 149 Driver Controlled Differential Lock 204 150 Rear Suspension 0 ccceeee cece eee ee eens 150 Rear Air Ride Suspension cceee eee eee eee 150 3878859R2 Rear Air Suspension Air Dump 2 20eeeeeee es 150 Air Suspension System FaultS cccceeeee eee 151 SIL e sal veaaia dace T seul eiaaaaa eens 151 General Information ccceeee eee e eee ee eee e eens 151 Downhill Operation 00 152 Air Brake Sraa ces rids cease ed i a s A arian 152 General InformatioN anisar rr areeni araid 152 Air Gauge Low Air Pressure Beeper and Warning Maalat e E T EE TEE 153 Reservoir Moisture Draining csscccccecceccserrerrere 153 Brake Application cc ccseeeeeeeeeeeeeeeeeeeeeeeees 154 Parking Brake cc cece eee eee isidet dia eeeeaaeeeeeeeees 154 Parking Brake Reset 0 cc ccceeeeeee eee eee e nena 155 Parking Brake Alarm 0 cceeeeeeee eee e ee eee eee e es 155 AIR DIVG le sccocccnccschs E 155 Trailer Brake Hand Control ceeeeeeeeeeee eee es 155 Trailer Air Supply and Parking Brake Modular Controls 156 Parking Brake Indicator 0
131. ditions Have the ABS system repaired immediately Take every precaution to prevent wheel lockup which could result in loss of vehicle control causing property damage personal injury or death ABS requires no changes in driving practices For the best stopping performance with or without ABS modulate do not pump the brake pedal until the vehicle slows to desired speed or stops Be aware that ABS on a towing vehicle does not control brakes on towed vehicles Towed vehicles may or may not have ABS ABS will prevent lockup of controlled wheels if you over brake for existing road conditions Optimum vehicle control for existing road conditions will be provided as a result of the ABS preventing wheel lockup at speeds above approximately 4 miles per hour The ABS cannot provide any better braking and steering 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 reduced to compensate for the extended time and distance required to stop or slow the vehicle on slippery roads The wheel hubs carry exciter 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 determine if any wheel s are about to lock If wheel lockup is about to occur 3878859R2 the control u
132. djustment Clutch wear will move the pedal position at clutch brake engagement toward the physical limit of travel The hydraulic clutch system must have proper fluid bleeding before operating usually performed at the factory or at field servicing Hydraulic clutch fluid should be drained and refilled every 2 years of service or after 200 000 miles 322 000 km service interval To prevent vehicle or engine component damage clutch pedal must engage clutch brake before the physical limit of pedal travel When the clutch pedal position at clutch brake engagement is less than 0 5 inch 12 7 mm from the physical travel limit manual clutch adjustment is required for all Eaton 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 82 000 km When utilizing an Eaton EP clutch with a hydraulic clutch actuator 3878859R2 the cab clutch pedal cannot be used to indicate when clutch adjustment is required Drivers may not notice the need for clutch adjustment and continue to drive in such condition Lack of adjustment will eventually lead to yoke interference with the clutch cover causing extensive clutch and or transmission damage When using the clutch brake fully depress the clutch pedal and shift the transmission into either first or reverse gear If the transmission does not go into first gear or r
133. do by pumping the brake pedal Always remember that you are the most important factor to safe operation of your vehicle Steer clear of traffic pedestrians animals or other obstacles while you are in an emergency braking situation The Antilock tractor and truck brake system will allow you to steer the vehicle during braking while it comes to a full stop ABS is not an excuse to take unnecessary risks Always drive carefully and stay a safe distance away from the vehicle in front of you When driving with a single trailer doubles or triples Brake as necessary and watch your trailer s through your mirrors and correct steering as necessary to keep in straight lines If only your tractor has ABS Use your tractors ABS brakes Steer clear of obstacles and watch the trailer through your mirrors to make sure it follows your tractor properly Tractor ABS will help prevent tractor jackknife but will not prevent trailer swing out Automatic Traction Control ATC System General Information The Automatic Traction Control ATC feature is an available option on some models Automatic Traction Control is an integrated addition to the Antilock Brake System This system utilizes input from the individual wheel sensors to determine if 159 Operation drive axle wheel slip is occurring during vehicle acceleration If drive axle wheel slippage is occurring the Controller Relay initiates action to reduce engine power and or to selectively appl
134. down inspection of all wheel end components regardless of condition of lube and 500 000 miles 800 000 km 5 Years wheel bearing end play stunt Reasngs Proper check S mes wing Comestons senos na BCS averstorstanersatey rex dT 212 3878859R2 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Recommended Synchronized Intervals cont Steering Gear Lubricate dust seal if applicable ATTN Install grease slowly with hand pump at low pressure Power grease guns may blow out dust seal Sterna iiernedae Sat Uone om ae AB OOO Steering termediate Sret Jot Bots Creak Tghness __ 180000 mies e000 Km Poner Sterna Fua zcrere rooomestsooom Foner Sieerno Frer Replace omeen Drive Shaft Standard U Joints and Slip Joint identified by non booted sip joint Lubricate NOTE 3 15 000 miles 24 000 km 3 months aces 350 000 miles 560 000 km first lube 100 000 miles 160 000 km thereafter nmin oe CO O Ge J ee ee Aries wd Seca Tato Duin Wate aB E EEO ee EE rn a I O Mamma se oOo O Ar Oye Hera Pug Ve owe a 3878859R2 213 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Recommended Synchronized Intervals cont Air Brakes Air Compressor Discharge Line Check for Blockage aB Cont Brake Shoes NOTE 3 FP As Required Air Dryer Desiccant Replace NOTE 3 AD 9 Model 250 000 miles 400 000 km
135. e Remove the fresh air filter s once each season and check for dirt lint etc Replace if necessary Vehicles operating in unusually dusty conditions may require inspecting and replacing the air filter s more often To reduce costs the filter s may be carefully power washed with a soap 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 replacing the filter s which 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 174 Side Access HVAC Filter 2 8487397 1 Filter Access Door 2 Air Intake Housing Cab HVAC Filter Replacement Side Access 1 Unlatch and remove filter access door 2 Remove filter by pulling filter out of air intake housing 3 Install new filter by sliding filter into air intake housing 4 Install filter access door and latch in place 3878859R2 Front Access HVAC Filter eo FILTER ACCESS na 8487422 1 Air Intake Housing 2 Screws 3 Filter Access Door Cab HVAC Filter Replacement Front Access 1 Turn screws counterclockwise one quarter turn and open filter access door 2 Remove filter by pulling filter out of air intake housing
136. e which could cause property damage personal injury or death Electrical circuits are protected either by the electrical system controller circuit breakers fuses or fusible links For the size and location of circuit breakers fuses and fusible links please refer to the Maintenance Intervals and Specifications section of this manual Fusible links consist of a length of lighter gauge wire in a circuit In case of a short or overload the fusible link opens burns out to protect the remainder of the circuit Repair consists of installing a new fusible link with the same gauge wire as the opened fusible link 131 Operation e Circuit breakers interrupt the circuit when an overload or short occurs Manual circuit breakers Type III can be reset by depressing the reset button on the breaker Headlamp and wiper circuits are protected by the Body Controller Type II circuit breakers will reset automatically if the short is removed from the circuit e The various electrical units in the cab and engine 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 Control and Shedding ELCS Electrical Load Control and Shedding ELCS is an optional feature standard with sleepers intended to provide a convenient means of automatically shutting down electrical loads overnight in order to conse
137. e With Front Wheels Suspended To prevent transmission damage vehicles should not be towed even short 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 forward rear axle may be raised to clear the road surface and secured to the frame by chains or U bolts allowing only rear axle to contact road surface Axle shafts must be removed from rear axle assembly The wheel hub ends must be covered to prevent loss of axle lubricant and entrance of contaminants Use extreme care in securing the chains or U bolts to prevent possible damage of brake lines hoses or other componenis When it is necessary to tow a vehicle with the front wheels suspended extra precautions must be taken to avoid transmission or differential damage Proceed as follows Remove axle shafts from axle assembly to prevent the wheels from driving the differential and the transmission The wheel hub ends must be covered to 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 164 Towing Vehicles With Driver Controlled Differential Lock Removing Axle Shafts Before Towing To prevent differential and or transmission damage vehicles that must be towed to a service facility with the drive axle wheels on the ground it is necessary to
138. e a robbery 3878859R2 e Permanently mount your CB radio or remove it when you will be away from your truck e Do not discuss where your vehicle is located when you are not on the road e Do not share information about your specific destination or the load you are hauling e Be conscious of other vehicles that may be following you over long distances call the police e Be suspicious of motorists that are signaling you to stop or pull over Call the police report the incident and let the police respond Layer 2 Visible or Audible Device e Audible alarm system e Steering wheel locks e Steering column collars e Theft deterrent decals e Wheel locks e Window etching e Mechanical or electronic steering locks that restrict the steering shaft U joint are easy to use and provide a very high level of affordable theft protection 3878859R2 Foreword Layer 3 Vehicle Immobilizer A Fuse cutoffs B Kill switches C Starter ignition and fuel disablers D Fuel cutoff switch Layer 4 Tracking System The final layer is a tracking system that emits a signal to the police or a monitoring service when the vehicle is reported stolen If your vehicle has a tracking system and is stolen it can oftentimes be recovered faster and with less damage VIN Model Year Engine Serial Number License Number Insurance Company Policy Number Phone Number Other Foreword Optional Diamond Logic Electronic Applicati
139. e eee ees 41 Section 4 Controls Features INTRODUCTION s sereen E AANA E SORE ONORA 43 General Information s sssessesrserrenrnnrrenrrsrrrernn 43 EleCthiGal R S TITEN 43 Electrical System sir reerss aaiae AEP Kakat NSSE 43 Dash Component 0 0 cece eee ee cece ee eeeeeeeeeeeeeeees 44 Overhead Console 0 ccc ccceeee cette eee eee eee e ee eaeeeeenes 45 Instrument Panel Gauge Cluster cece cece eee 46 Warning Indicators 66 e cece eee eee eee 48 GAUGES renee T E ve veo eel deve SST 50 Instrument Panel Gauge Cluster Alarms 52 Direct Drive Warning Indicators eeee eee e es 54 Integral Digital Display 00 0 cece cece eee e eee 54 General Text and Warning Messages 0eeeeees 56 Optional Instrument panel gauge cluster Compass Calibration Procedure cc ccceeee settee eee eeaaees 57 Compass Declination Zone Set Procedure 57 Compass Directional Calibration Procedure 60 Integral Digital Display Detailed Information 62 SWICHOS I E E E T E AA 75 Hear S oreraa aeaa sy AA AEEA Raa Ye 75 Daytime Running Lights DRL eeee eee eee 75 Lights On With Wipers cece eee eee eee e eee eens 75 Park LIONE ieat enaena ANIE EE oes aie 75 Panel LMN eenen EE aen Er theese deddhacacaeevnaueee 75 Dome LIOMO rors aar i EE EAEE E ESTI ERUERA 76 Courtesy LIMS ars id
140. e limited to a sulfur content of 15 parts per million ppm Frequently inspect condition of fuel tanks and mounting hardware fuel tank cap and vent fuel lines clips and routing At every PM or daily if necessary drain water and sediment from the fuel water separator filter if equipped If the vehicle is equipped with an optional Davco fuel water separator inspect the level of the fuel in the see through globe and replace the fuel water separator filter element if the fuel level has reached the top of the globe In all cases be sure to use the proper fuel water separator filter element with the correct part number and filter efficiency rating Fuel Tank Draining and Cleaning Periodically annually is recommended drain water and sediment from the fuel tank via the drain plug on the bottom of the fuel tank Drain and flush sediment from fuel tank at least every 12 months or more frequently if fuel quality or type of fuel dictates 3878859R2 Maintenance Instructions Since Ultra Low Sulfur Diesel ULSD fuel tends to absorb more water and engines are operating at higher temperatures microbe growth in the fuel tanks has become more prevalent Microbe growth results in more contaminants in the fuel and reduces fuel filter life Since fuel tank draining does not remove all microbes fuel tank draining alone will not eliminate the problem For vehicle operators experiencing microbe growth in their fuel the following is recommend
141. e of available service publications for this chassis can be found on the internationaltrucks com Web site or by contacting your 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 site s content 3878859R2 availability and fee structure can be obtained by contacting your local International Truck dealer or in the case of a National Account an International Fleet Service Manager The iService DVD contains all currently available chassis and component service information including TSI letters Electrical Circuit Diagrams Electrical System Troubleshooting and other technical information for virtually all International models and MaxxForce engines International Truck Warranty Program Standard Warranty Optional Service Contracts Custom Service Contracts Performance PM Service The International Truck Warranty Program provides International customers with a better choice when it comes to Standard Warranty and Service Contract Coverage The Standard Warranty is the first tier of the International Truck Warranty Program It provides the foundation for all extended coverages Vehicle Coverage Towing Engine and Engine Electronics Major Component and Pre Packaged System Component protection can be obtained under the International Warranty Program through Optional Servi
142. e shallow groove in the top edge of the reservoir prior to cap installation Replace cracked or damaged O rings Refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS for the fluid and filter replacement intervals Tires Tire Warnings 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 field maintenance only inflate and load tires to the maximum of the least rated tire on the axle Failure to adhere to this warning could possibly result in tire malfunction damage to your vehicle personal injury or death 199 Maintenance Instructions 200 Always maintain your tires in good condition Frequently check and maintain correct inflation pressures as specified by tire manufacturers Inspect periodically for abnormal wear patterns and repair replace cut or broken tire casing Always use experienced trained personnel with proper equipment and correct procedures to mount or remove tires and wheels Failure to adhere to these warnings could result in wheel or tire malfunction damage to your vehicle personal injury or death To prevent personal injury or death always follow these instructions when mounting tires on wheels Only personnel who have had proper training and experience should mount or remove tires from rims or wheels Use only heavy duty rims or approved rims for radial tire
143. e the proper transmission gears Vehicles equipped with this transmission do not have a clutch pedal For operating instructions refer to the Transmission Manual Clutch Brake NOTE After engagement of first gear DO NOT use the clutch brake for upshifting and downshifting To do so will shorten the service life of the clutch brake and gear selection shift efforts may be increased A clutch brake is used to stop transmission input shaft rotation so that the initial first or reverse gear selection can be accomplished when the vehicle is at a standstill and the engine is running at idle speed When using the clutch brake fully depress the clutch pedal and shift the 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 on the shift lever until the transmission goes into gear This will provide for a smooth shift into either first or reverse gear Power Take off Control If your vehicle is equipped with a power take off PTO refer to the PTO equipment manufacturer s instructions 148 Rear Axles Locking or Limited Slip Differentials To prevent vehicle damage personal injury or death pay strict attention to the following If your vehicle is equipped with any type of locking or limited slip differential power will be transmitted to the opposite wheel should one of the wheels sli
144. e the ignition switch in ACC Accessory position rotate key counterclockwise to the ACC position Accessory features can now be used without engine operation 123 Operation 9 To terminate ACC Accessory operation rotate the key clockwise to the OFF position After the Engine Starts e Do not increase engine speed until the oil pressure gauge indicates normal pressure e Make sure the engine oil pressure is indicated on the gauge within 20 seconds after starting e Operate the engine for three to five minutes before operating at full power e Try to limit engine idle to 10 minutes Excessive idling reduces fuel economy and may decrease oil life e When starting a cold engine increase the engine speed RPM slowly to make sure adequate lubrication is available to the bearings Engine Shutdown Idle the engine for three to five minutes before shutting down This few minutes of idling allows the lubricating oil and water to carry heat away from components heat soaked by hot combustion exhaust gasses The larger the engine the greater the need for this idling period This will help avoid damage to turbocharger seals or like features of an engine which after shut down will no longer be cooled by the circulation of oil and coolant 124 Place the transmission in the neutral position Apply the parking brake Turn off the headlights and all accessories EC oO N Idle a hot engine for 2 to 5 minutes to al
145. ear ratios Once the highest shift lever position 5th gear is obtained in LO range the operator preselects the range shift lever for HI range The range shift occurs automatically as the shift lever is moved from 5th gear position 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 that is still low enough to start the vehicle moving with engine idling and without slipping the clutch excessively 3 Use the clutch brake to stop gear rotation when shifting into low or 1st or reverse when the vehicle is stationary The clutch brake is actuated by depressing the clutch pedal all the way to the floor 4 Do not make range shifts with the vehicle moving in reverse gear 5 Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving Preselection with the range preselection lever must be made prior to moving the shift lever out of gear into neutral 6 Do not shift from high range to low range at high vehicle speeds 7 Double clutch between all upshifts and downshifts 3878859R2 Operation 8 After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depending on the load grade and road speed Transmissions with a greater number of speeds are optiona
146. ection A 50 50 mixture can be easily created in the shop using undiluted coolant and water and will provide freeze protection down to 34 F 36 7 C if no further dilution is experienced during installation Concentrations greater than 67 are not recommended The use of Shell Rotella Ultra ELC pre mixed to make up for coolant loss will assure the glycol water concentrations stay in balance Always use Shell Rotella Ultra ELC to top off ELC equipped cooling systems Failure to do so may result in the loss of extended life properties and will require periodic testing for SCA levels Should top off occur with conventional coolant s exceeding 10 of the total cooling system capacity either drain and refill with Shell Rotella Ultra ELC or maintain as a conventional coolant system using SCA s at the recommended levels Antifreeze For cooling system capacities coolant part numbers and other information refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS of this manual Fan Clutch Inspect for proper operation secure electrical connections and air supply as appropriate See the Service Manual for details 3878859R2 Start cold engine and view fan to see that it is rotating slower than the fan pulley fan clutch is disengaged Achieve operating temperature and observe that the fan is engaged Fuel System JUU GOVERNMENT REGULATION Diesel fuel sold for use in 2007 and later highway vehicles must b
147. ection requires that no weight is on the tires e Kingpin and kingpin bushing lubrication requires that the vehicle weight is off tires and the front wheels be turned fully to the left or right prior to installing grease distribution e Kingpin thrust bushing lubrication requires that the vehicle weight is resting on the tires e Power grease guns may be used however a hand pumped grease gun is recommended for optimal grease distribution within each component joint 176 3878859R2 e Inspect lubricate and adjust the wheel bearings at regular intervals Refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS for the correct intervals lubricants and torques Normal Maintenance During operation the air and oil inside the hub wheel cavity expands It is normal for a mist of oil to be present on the outside of the hubcap around the vent slit or hole Over time if not wiped off this film may collect dust and appear unsightly If the entire face and end of the hubcap become wet with oil investigate the cause Refer to the Service Manual for repair procedures Routinely clean the hubcap to ensure that the lubricant level can be easily observed through the clear window as intended In situations where the window is clean on the outside but discolored on the inside check the lubricant level by removing the rubber fill vent plug and insert a finger into the hole The specified lubricant level for International clear wind
148. ed 1 Drain and clean the fuel tank s every 12 months or more often Clean the tanks with a professional fuel tank cleaning system available through your dealer or have your local dealer perform the service for you 2 Treat your vehicle fuel tanks and bulk tanks regularly with a biocide from a reputable vendor 3 Purchase fuel only from vendors that pretreat their fuel with biocides 4 Periodically test the fuel supplied by your fuel vendor for the presence of microbes Crankcase Ventilation Filter Refer to the Engine Operation and Maintenance Manual for the proper replacement interval and instructions Frame International chassis are manufactured with frame rails of HSLA steel and each must be handled in a specific manner to assure maximum service life Before attempting frame repair or modification consult the Service Manual or your International Truck Dealer 195 Maintenance Instructions Noise Emissions Exterior Instructions for Proper Maintenance In order to comply with federal exterior noise regulations your vehicle may be equipped with noise emission items Depending upon the vehicle configuration it may incorporate all or some of the following Air Intake System e Air Cleaner should be inspected and its location should not be altered Do not alter inlet and outlet piping Body e Wheel Well splash shields cab shields and underhood insulation should be inspected for deteriorati
149. ed tightly and that the battery is clamped securely in the battery box For best results e Do not mix and match battery models manufacturers in the same battery pack e Do not use batteries with differing CCA ratings in the same battery pack e Do not use batteries with more than one year difference in the installed age of batteries in the same battery pack Battery Cables When working around the terminals and battery use extra care to prevent shorting A good practice is to insulate pliers and screwdrivers Do not check battery condition by shorting flashing across terminals Battery cable terminals must be clean and tight Use a mixture of hot water and common baking soda for removing terminal 3878859R2 Maintenance Instructions 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 spray protectant and reassemble Be sure the terminals are clamped tightly Electrical Charging and Starting System Test At every PM fully charge the batteries using an automatic float charger Then have a qualified technician perform an electrical system test using an International Electronic System Tester Midtronics inTELLECT EXP HD Expandable Electrical Diagnostics Platform available through your local International dealer to catch electrical system problems before they cause further damage
150. ed and wheels chocked 4 Hose or pipes for rust damage deterioration Proper operation of service parking and trailer brake controls 6 The condition and full insertion of the ABS wheel speed sensors wiring and connectors 7 Proper ABS wheel speed sensor to exciter teeth gap Air Dryer General Information NOTE The use of an air dryer does not eliminate the need to periodically drain the air tanks The air dryer removes humidity water air compressor oil and dirt from the incoming compressed air thus protecting the air system against deterioration and restriction The air dryer is installed between the air compressor discharge line and the air tanks The air dryer has a desiccant cartridge 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 levels environmental temperatures air compressor oil 3878859R2 control and desiccant quantity Regularly check the desiccant purge valve and air dryer heater performance Desiccant Filter Open reservoir drain valves and check for presence of water Small amounts of water due to condensation is normal If the wet primary or secondary tanks are collecting an abnormally high amount of water between regular air tank drain intervals replace the air dryer desiccant The air dryer desiccant replacement interval may vary it is g
151. ed coolant with the 2010 cooling packages and will not warrant these cooling systems that have not utilized the recommended coolant The label on the deaeration tank provides additional coolant antifreeze information Consult the Engine Operation and Maintenance Manual for coolant service life details Engine Oil Keep oil level between the ADD and Full marks Never operate an engine with oil level below the ADD mark To obtain an accurate engine oil level reading the vehicle must be parked on a level surface with the engine off for at least five minutes before checking the oil 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 136 When checking the oil level the dipstick must be withdrawn and wiped clean then inserted all the way and again withdrawn for a true check Use only recommended viscosity engine oil Refer to the Engine Operation and Maintenance Manual for engine oil specifications The lubricating oil in a diesel engine becomes dark in color after short periods of engine operation This discoloration is not harmful to engine parts as long as the oil and oil filter element changes are performed at recommended intervals All International ProStar Series vehicles must use CJ 4 or later oil classifications to achieve maximum DPF cleaning intervals Refer to the appropriate Engi
152. ee 5 Reporting Safety Defects cece eee 5 U S Registered Vehicles 0 cceeeee eee cece enna eee 5 Canadian Registered Vehicles 00eceeeeeeeees 5 Safety Recalls and Authorized Field Changes 5 Customer Security Guide for International Trucks 6 Optional Diamond Logic Electronic Application Solutions 8 Section 2 Model Description INtPODUCTION aen en Sear ete tiie ieee eae dann soa Si 9 Available Models cece eee cece eee e eee e etree eeeaaeeees 9 Vehicle Identification 00 cece cece eee eee eee eaaees 12 Vehicle Identification Number VIN 0eeeeeeeeeee 12 Feature Codes 22 c cc cceeeee eee eee teen en neeeeeeeeees 12 Engine Serial Numbet cece cece eee eee ees 13 Line Set Ticket 00ccee cece cece egaine aia 13 Exterior Components 0 00 cece cece eee eeeeeeeeeeeeeeeeeees 14 Cab Entry and Exit c icc aa aer AAE E ee wosened esr 18 3878859R2 Table of Contents POO 424 35s peat ote a E eee batens AT 18 Raising the HOOd c cece eee eee EE eA AEREE 18 Lowering the HOOd 00 c cece cece seen eee eeeee eee ees 19 Tilt Away BUMPEl 0 2 2 eee cece eee nena 19 Lowering the Tilt Away Bumpetl eeeeeeeee es 20 Raising the Tilt Away Bumpet eee eee eeee eee 20 Luggage Box ACCESS cceeeee cece eee ee
153. ee eee eee teen eens 138 243 Index O CONT Operating Instructions cont Ultra Low Sulfur Diesel Fuel Requirements 137 Unacceptable Fuel Blends 2 eeeeeee eee 137 Rear AKES SE E EE EEA EEEE EEIE OO EER RASS 148 Driver Controlled Differential Lock ceeee eee 150 Locking or Limited Slip Differentials 148 Tandem Axle Power Divider Lock PDL Control 149 Rear SUSpensiOn 0ccceeeee ee ee ERIAN ARAKAN tees 150 Air Suspension System Faults cere 151 Rear Air Ride Suspension eeeeeeeeeee eee 150 Rear Air Suspension Air Dump eeee eee 150 SEENT coeeZ is Motes ieee rach EN ERENER EAER 128 Adjustable Steering Column ceeeeee eee e eee 129 TRANSMISSIONS e o tetera thoes phieeseee EETA Tae 142 Clute BARO eer eaaa e ane EEA PFR EKIRA ERRE aiai 148 Clutch Froca UNOS errie arts r aa AOO TE RERS 145 Double Clutch Procedures scscceccccererrerreren 145 Eaton AutoShift Transmissions Optional 146 Eaton UltraShift Transmissions Optional 148 Engaging the Clutch cc eeeeeeee eee eee eee es 143 Hydraulic Clutch Actuation System 0eee 144 Manual Transmissions 00ccceeeeeeeeeeeeeeeeeeees 142 Power Take off Control ccceeeeee eee eee eee anes 148 Operation aer aAA cert Mane i EERE 119 Operation Safety
154. ee eeeeteneees 115 General Information 0cc cece eee eee e cent ences 115 Sleeper Curtain 2 eect eee 115 Television MOunt cc cece cence eee e eens eeeeteeeeees 115 POWEMMINVEFE epaian a E Aea 115 P wer Sockets ronan a 115 SPCAKEIS vie cere cee EEEE AE ENEE SEKE PE 115 Floor COveriNG aviv ev boned reve ek AATE SEEE EEEE 115 sleeper Fanas a E eeeeeee 115 Section 6 Operation Operation Safety 0 0 0 cece eee Ea aE EEEE OERE 117 General Information cce cece eee ee eeeeeeeees 117 Cab Controls enarek eee aaa AREER 118 Seat BeltSis ss ces anagaeeaiatecaasacesdds iadaaed A AAA AA AR 118 General Information ccce cece eee ee eee eeeeees 118 General Information ccce cece eee eee eee eeeeees 119 Operatora ertsia AA irene eae ed EEE RAW EPERE RES 119 Care of Seat Belts 0 cc cece cece eee e eee e eee ee ees 120 SEALS at a ae Gane anguneencdea auresd acre Aa NN E enn vacs 121 General Information ccce cee cee eee e eee eteeees 121 Starting ProcedureS cece eee eee teen eee eeeeeee ees 123 General Information ccce cece cece ee eeeeeeeees 123 Engine Starting aaisen ia didada EARRA 123 After the Engine Starts 00 cece ee eeeeeee errr eee ees 124 Engine Shutdown e cece cece ee eeeeeeeeeeeeeees 124 Table of Contents Emergency Starting c cece eee eee ee eee teen
155. eeeeeeeeeeeeeeeeeeeees 98 Accent Light Dimmer Switch cece eee eee 99 Accent Light SWIC sri arara rAr AAAA AAAA ASETET ETON 99 Electronic Climate Controller cceeeeee eens 100 Engine Control SVO A RARAN SEE SA 99 245 Index S CONT Sleeper Control Panel cont Manual Climate Controls 00 cc ceeeeee eee e eee e teens 100 Power Receptacle 0cccceeeeeeeeeeeeeeeeeeee teenies 101 Radio Remote Control eceeeeeeeeee settee teens 101 Remote Power Inverter Panel ceeeeeeee eee eens 101 Sleeper Dome Floor Light Switch 0 cceeeee eee 99 Sleeper Curtain 0 cece A E eee eee eeeeeeeeees 115 Sleeper Dome Floor Light Switch 2 eeeeeeee eee 99 Sleeper FAN estceasvoopeeuseeeeeeeeee ys be bebe E teem nedd 115 Sleeper HVAC Filter cece cece eee aeeeeees 176 SmartWave Display ccceeee cece cece cece eee nran 89 SmartWave Tire Pressure Monitoring System TPMS 202 SPEAKS oee aE A T KEEA TEE EEEE ia A TRR O Ge 115 Stability Control Systems Bendix RSP WABCO RSC Bendix ESP EEEE AEE AE EEST 160 Starting FroCOdUrES sia ross 2 arrant aiana TACE TERTERA 123 After the Engine Starts cc cc ceeeeeeeeeeeeeeeeeeeeees 124 Cold Weathel cece ee EnaA EE KINRARA ERANA ar 125 Cold Weather Operation 00 ccceeeeee eee ee eee eee 126 Cold Weather Starting 00 cece ce
156. eeeeeeeeeees 1 Cautions and WarningS e cece cece eee e eee eeeeeeees Center Dash Panel Wing Panel 00 eeeee eee ee eee eee Climate Control 0 2 cece cece cece eee E GAASE Air Conditioning 0 cece ceeeeeee eee e teeter eee TERAN Dehumidification 0 0 ccc cece cece eect eee e ee eee nena GAUGES vs fe cases nee pte ee ahaa ie ete rede seeens oie harenes OWILCHES ie 2s atest a treed Made td yhoo teensy Certified Clean Idle ccc eeeeee cette eee teen teen eaaeees 1 Charge Air Cooler ccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 1 Charge Air Cooler And Radiator Core Inspection And ClO AN ING ss scene cian E cc teage E E se fee baeber sees uaaleen ed 1 Inspection and Cleaning eee eeeeeeeeeee 1 Chassis Lubrication cc cece eee eee EEES 1 Chassis SkintS eiga Ea PIIA REE LADEE EASE ESIA ATEA RERA Extended Chassis SkirtS 0c cceeeeee eee e Installations TEE as ale anedlev ind letra EE Removal ii persiera s Ia dies ALAKEN ERATE E eter uy needed 3878859R2 Index C CONT Checking Mhath scissors enspiris dd iiaa a S AT 201 Circuit Breakers Fuses and Fusible Links 131 Cearn aE wee vege EARE RNAAR REEE EPEN ERa 197 Climate Controls crre a ara EEA A AEDA 86 Air COndMomMiM estie deed ai a ERER 88 Deh midificatiOn ereraa ee EAEE EEEn 89 Clute hirssin orn a a a EAEE EDA EED 183 Hydrauli CAU nna aranan eer ey hide ee
157. eels With the clutch pedal released extended the clutch is engaged driving the transmission and rear wheels Depressing the clutch pedal releases the clutch permitting transmission gear changes Clutches will last many thousands of miles if properly used and maintained EXCESS HEAT IS A CLUTCH S WORST ENEMY 142 Almost every early clutch failure can be traced to excessive friction heat Do not ride or slip the clutch Once a clutch is fully engaged there is no 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 engagement is lengthened causing unnecessary heat and wear and reduced clutch life The International ProStare Series has many transmission options available Refer to the Transmission Manual for information on the transmission available in your truck P E 2 4 p iV E 10 Speed Manual Transmission standard The gear shift lever mechanically engages and disengages five forward gears and one reverse gear in the transmission front section The range lever on the Roadranger Valve allows the operator to control an air shifted auxiliary section to provide a LO range and HI range The five forward gear shift positions selected in LO range are used again in HI range to provide the 10 progressive 1 High Range 2 Low Hi Range Lo 6 a 8487192 3878859R2 forward g
158. eens 106 Entering The Upper Bunk eeeee eee eee eens 107 Exiting The Upper Bunk cceeeeeee eee teen eens 108 Use of Tre Chains cers adors edoren t euie 205 V Vehicle Identification rosas 0 0 cece rorirori eee eee a aia 12 Engine Serial Number ssssassasssrerrsrrrrrsrenrerrerane 13 Feature Codes srren aa ox Phot ASE aa 12 Line Set Tickets e Eep EEA e USEANA Ene 13 Vehicle Identification Number VIN 0000eeeee eee eee 12 Vehicle Identification Number VIN 0 ee cece eens 12 Vehicle Storage Instructions 0 ccc cece eee eee eee e ees 2 Storage Duration One Month or Less 2222 005 2 Storage Duration Over One Month ceeeeeeeeee ee 3 Storage FacilitieS 0 cccceeee eee cece seen cette eee kerra 4 Vent WNION iea otto ESETE AA ERETTA bees 92 Ww Warning Indicators 00 cc ceeeeeeee eee eee eee eee enna aee 48 Warning Messages sssssersrrsrrsrrsrrsrrrrrerrerrrnn 74 Washing and Waxing ssesssssssesresrierrrerrrsrrerrrerrnnt 182 3878859R2 W CONT Walia ces d Se ksens ont ede m hap sewe E EE EEA A AAEE EREN E aod 204 Irregular Weal 2 2 0 cece ERAEN ANAE EEEE SAKES 205 Wheel and Tire Balancing cc cece cece eee e eens 204 Wheel and Wheel Nut Maintenance and Installation 205 Hub Piloted Wheel Installation Procedures 206 Wheel Nut Torque Maintenance
159. ehicles are lubricated at the factory After the vehicle 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 contribute to the frequency of lubrication intervals Thorough lubrication and maintenance at the specified intervals will insure Outstanding Life Cycle Value and will reduce overall operating expense In some types of operation and where operating conditions are extremely severe such as in deep water mud or unusually dusty conditions the vehicle may require re lubrication after every 24 hours of operation Only lubricants of superior quality such as Fleetrite lubricants should be used The use of inferior products will reduce the service life of the vehicle or result in failure of its components Navistar Inc recommends the use of Fleetrite lubricants and OEM original equipment parts The lubrication intervals specified should be performed at whatever interval occurs first whether it is miles kilometers hours or months These intervals are provided in SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS 173 Maintenance Instructions Air Conditioning Service Checks Have your air conditioning system serviced each spring The refrigerant charge cleanliness of condenser evaporator cores cab filter and belt condition are essential to air conditioning performanc
160. either call the Regional Service Manager Canadian Sales Region 905 332 2357 or write to Navistar Inc Canada 5500 North Service Road Box 5337 Burlington Ontario L7L 5H7 To contact Transport Canada Defect Investigations and Recalls you may call 1 800 333 0510 or write to Transport Canada ASFAD Place de Ville Tower C 330 Sparks Street Ottawa Ontario K1A ON5 Safety Recalls and Authorized Field Changes Safety Recalls and Authorized Field Changes are two campaigns that are used to notify owners of modifications that may involve Foreword their vehicle If you receive such notification PLEASE FOLLOW ALL INSTRUCTIONS PROVIDED IN THE CUSTOMER LETTER If your vehicle is part of a Safety Recall campaign the recall service procedure must be completed to ensure safe operation of your vehicle As a vehicle owner you must provide International dealers with address corrections and changes to ensure that you receive all notifications Please verify that your local dealer has your correct address Dealers will also have a record of any outstanding campaigns that affect your vehicle Customer Security Guide for International Trucks This guide has been prepared to help you protect your vehicle investment from theft We realize the financial commitment you have made is significant and that you depend on that vehicle to generate profits and a livelinood Vehicle theft can be more than an economic crime Protecting your vehicle from thef
161. el bearings and seals The oil level should be at the lower edge of the level inspection hole when the vehicle is on level ground Add oil as necessary Refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS for additional information 177 Maintenance Instructions Locking Differential Vehicles which have a locking differential have the appropriate operators manual supplied with the vehicle Refer to this manual for maintenance checks Brakes General Information WARNING To prevent personal injury or death prevent breathing brake lining fiber dust Always use a respirator while performing brake maintenance Follow precautions listed below Always check and maintain brakes in proper condition and adjustment Out of adjustment brakes could cause reduced braking ability and result in property damage personal injury or death All new International vehicles use nonasbestos brake linings However exposure to excessive amounts of brake material dust may be a potentially serious health hazard 178 Follow these precautions Always wear a 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 through assembly Never use compressed air or dry brushing to clean brake parts or assemblies Clean brake parts and assemblies in the open air During disassembly careful
162. eleased In this situation the rear wheels are driving the disc through the multiplication of the rear axle and transmission ratios This can result in over 10 000 RPM which is beyond the burst strength of the facing material Something as simple as coasting down an unloading ramp can burst a driven disc Re engaging a clutch after coasting causes tremendous shock to the clutch and the whole drivetrain It can result in internal engine damage and or clutch and flywheel failure Always report unusual clutch operation promptly Proper maintenance performed on time will greatly extend the life of the clutch The driver should report any change in free pedal free travel slippage or any strange feel to the clutch operation Helpful Hints to Operate Vehicles with Ceramic Clutch Facings 1 Driver must start vehicle in first low gear 2 While operating a ceramic clutch the driver has to engage the clutch before giving the engine any fuel at idle 144 3 The driver should not try to slip the ceramic clutch by raising engine RPM s and riding or feathering clutch pedal since the vehicle will experience erratic engagement Erratic engagement can cause engine stalling and potential serious damage to your vehicle s drivetrain components i e clutch transmission driveshaft s rear axle Hydraulic Clutch Actuation System Clutch brake engagement occurs in the last 2 inches 50 mm of pedal travel after initial clutch setup a
163. enerally recommended that the desiccant be replaced every 12 months for small air dryers like the Bendix AD IP or every 24 months for large air dryers like the Bendix AD 9 or Bendix AD IS If experience has shown that extended or shortened life has resulted for a particular installation then the interval should be increased or reduced accordingly Purge Valve Check that the purge valve opens and expels moisture when the air governor shuts off the air compressor Air should escape rapidly and then quickly stop If the purge valve does not open or you can hear a slight audible air leakage past the valve for longer than 30 seconds the valve may be sticking and should be rebuilt Purge valves may also stick if the air dryer heater has failed and ice is clogging the valve Heater Check that the air dryer heater activates at temperatures below freezing With the vehicle in a cold environment and before the 3878859R2 Maintenance Instructions 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 heater element or the wiring powering it should be serviced Air Reservoir Tanks Moisture Draining Moisture taken in with the air through the compressor inlet valves collects in the airtanks The wet tank is the first tank to receive air from the air dryer and therefore collects most of the remaining mo
164. entalsssssssisisisssrieesssssseyo uretara 178 Bra KOSE rio a EETA O NIAI E COE E E EA SS 178 General Information assssessssnererrerrrrrrrrsrnnrnnne 178 Ait Bra KO Seiren aTr CEN EITE EER eee 179 Inspection and Adjustment cece essen eee eee 179 Alt DIV 6 hisses seh tis de AAAA ARAO 2 OERE EERS 180 General Information cc cceeeeeeeeeeeeeeeeeeeee 180 Desiccant Filter cece cece eee eee eee eee 181 Purge Vale sees vias ACAN En degen RA RRA ARREA SSS SENCAS 181 Heat niisan veseechteee tne suena aA EIER detente 181 Air Reservoir Tanks Moisture Draining 181 ABS Connections and Sensors eeeeeee eee 182 1 o ey Ae PE caer AO ESS PEN HO a 182 Care of Vehicle 02 c cece cee eeeee eee TERAS 182 Washing and WaxXing 00 cece eeeeeee eee eee e teen tees 182 Bright Metal Care 0 cece cece cece teen ee ee eens 182 Upholstery Care ccc cece cece e cece cece e ee eee cette eens 182 Exposed Rubber and Unpainted Plastic Parts 182 S ie e EEEE EI weave bey NET ei el aad enema er 183 Pedal Free Travel cece cece cece EEKE KEERI 183 Hydraulic Clutch 0 cece e cece ee eee eee teens 183 Electrical ceucy E E SS ceareed oorat tiaw tetera Sees 184 Batteries wis tcocecgunceeeccecccccccccegppnpngagegeeeeseeences 184 Battery Cables cccceec cece cece eeeeeeeeeeeees 185 Electrical Charging and S
165. eossde duakeun aaye eu a 76 Steering Wheel Controls cc cece eee ee eee eeees 77 Cruise Control 2 cece cece cece eeeeeeeeeeeeeenees 78 ii Steering Column and Switches ee eee eeeee eee es 78 Center Dash Panel Wing Panel 0 eeeee seen eee e eee 81 GAUGES E aa ea E nas ee eee aah eae eden 82 SWITCHES i ce cre NW legen teen ced seed A Greases sever oewed Shae 82 Climate Control saai wera teenie seek son aye ee AAAA EEEE 86 Air Conditioning cc cece cece cece eee eeeee eens 88 Dehumidification arreirar rera cece eee eee eee ee eaeeees 89 Electronic Vehicle Monitoring cccceeeeeeeeeeeeeeeeeees 89 Base Displays ccics E AAEE peeve RAAE RR 89 Premium Display cccceceee cece eect eee e eee eeeees 89 SmartWave Display cceeeeee cece cence eee eeeeeeees 89 Door and Window Controls seeeeee cence eee eee e eens 90 Door Lock Unlock 0 0 c cece eee eee eee eee eee e teens 90 Cab Doors and LOCKS 00 ccceeeeee eee eee eee eae 90 Remote Keyless Entry Operation Optional 90 Lock Unlock From Interior cccceeee cece eee e teen tees 91 Automatic Door Lock Function eeeeee eee eee 91 Driver Passenger WindOWS eeeeeeee eee e eens 91 Manual Operation ccceeeeeee eee eee eeeeeteeteeees 91 Power Operation 0cccceee cece eee e eee e eee e eee ESSR
166. ered amount of ether prior to engine cranking The ether injection system is mounted to the left frame rail under the hood Engine Block Heater For cold climates an optional engine block heater is available The block heater utilizes an external 125 Operation power source to keep the engine coolant warm and a 120 volt socket for connecting to the external power source The 120 volt socket is mounted below the driver s side door Cold Weather Operation In order to operate the engine in temperatures of 32 F 0 C or lower observe the following instructions 126 Make certain that batteries are of sufficient size and in fully charged condition Check that all other electrical equipment is in optimum condition Use permanent type engine antifreeze solution to protect against damage by freezing At the end of each daily operation drain water from fuel water separator if equipped Fill fuel tank at end of daily operation to prevent condensation in fuel tank Be sure to use proper cold weather lubricating oil and be sure crankcase is at proper level At temperatures of 20 F 6 C and below it is recommended that you use an engine block mounted coolant heater to improve cold starting If operating in arctic temperatures of 20 F 29 C or lower consult your International Truck dealer for information about special cold weather equipment and precautions Engine Idling Because diesel engines are high
167. es Feature Codes are the basis for identifying the components used on International Trucks They are used by sales personnel to order the truck by manufacturing to build that truck and by parts personnel to service the truck Many items in this manual are identified by codes Feature Codes are a combination of numbers and or letters These codes are listed on the Vehicle Line Set Ticket which is sometimes known as the vehicle specification card or code sheet 3878859R2 Engine Serial Number The engine dataplate provides the engine serial number as well as other engine information For the location of this plate and more information about engine components and engine identification refer to the Engine Operation and Maintenance Manual Line Set Ticket NOTE Be sure to return Line Set Ticket to vehicle after obtaining parts 3878859R2 Model Description Each vehicle is provided with a Line Set Ticket code sheet which lists identification code numbers of component units used to build the vehicle One copy of the line set ticket is included in the literature provided with the vehicle When replacement parts are required take this copy with you to positively identify vehicle components to be sure of getting the correct parts 13 Model Description Exterior Components 8487433 14 3878859R2
168. es If the proper gear selection was not made and the brakes were overused then stop the vehicle and wait for the brakes to cool After the brakes have cooled continue down grade in a lower gear range 152 e The common rule to follow in using the engine and transmission rear axle to control vehicle speed is to select a lower gear going down the hill than would be required to ascend the hill There are some exceptions such as going down a short hill with good visibility and no hazards e The service brakes should be used to supplement available vehicle retardation methods When descending long grades requiring use of the brakes short applications three to five seconds duration should be made rather than long continuous applications This minimizes temperature rise brake fade and air consumption of air brake system Air Brakes General Information 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 brake system repaired immediately Loss of braking capability could cause an accident and result in property damage personal injury or death The truck types covered in this manual are equipped with a split brake system The purpose of this split system is to provide a means of stopping the vehicle should a failure occur in either the primary or secondary brake system In the event air pressure loss 3878859R2 o
169. et Grab the front bunk rail with your left hand and front edge of the airline cabinet with your right hand and place your weight on the top step Step down with your right foot to the bottom step Keeping a firm grip on the front bunk rail and the front edge of the airline cabinet step down to the cab floor with your left foot followed by your right foot You can now release the front bunk rail and front edge of the airline cabinet 3878859R2 Cabinets Storage Always remove all loose items from the interior and store appropriately when vehicle is in motion Falling items can be a distraction to the driver or a projectile during an accident which could result in personal injury or death General Information 3878859R2 Sleeper Features NOTE The following will describe and illustrate the standard cabinets and their storage functions for the International ProStare Series long sleeper Your vehicle may not have all of these features The sleeper compartment is designed to accommodate several different types of cabinet configurations to fit all needs 8487414 1 Optional Dresser Cabinet or Optional Refrigerator Cabinet 2 Airline Cabinets 3 Rear Wardrobe 4 Tower Wardrobe 109 Sleeper Features Cabinets Refrigerator Cabinet 6 4 8487139 1 Refrigerator Top The top of the refrigerator cabinet serves as a desk top 110 Release Knob A release knob is used to open the work table
170. everse toothbutting may be occurring Slowly release the clutch pedal while applying light pressure on the shift lever until the transmission goes into gear This will provide for a smooth shift into either a forward or reverse gear NOTE After engagement of first gear DO NOT use the clutch brake for upshifting and downshifting To do so will shorten the service life of the clutch brake and gear selection shift efforts may be increased Clutch brake application occurs in the last 2 inches 50 mm of pedal travel Double Clutch Procedures In order to properly upshift or downshift be sure to do the following e Depress the clutch pedal to disengage the clutch 3878859R2 Operation e Shift the transmission into neutral e Release the clutch pedal e If upshifting wait until the engine speed matches the transmission speed of the gear you desire to shift into e If downshifting accelerate the engine until the engine speed matches the input speed of the gear you desire to shift into e Depress the clutch pedal immediately and shift into the desired gear e Release the clutch pedal to engage the clutch Clutch Precautions Maintain specified clutch adjustment Regularly inspect clutch control linkage for tightness When adjustment of the clutch is necessary it is extremely important that the work be properly performed otherwise early failure of the clutch will result and a costly clutch overhaul will be necessary
171. evident Loss of steering or suspension could cause loss of vehicle control and result in property damage personal injury or death NOTE Retread tires are not recommended for use on steering axles of trucks 1 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 2 Shock Absorber Check for cracks leaks and missing or broken mounting bolts or bushings 3 Air Suspension if equipped Check for air leaks loose components and damage to air bag Inspect stabilizer bar for worn loose or damaged components 3878859R2 Wheel and Lug Nuts Check for damaged or bent wheel Check to see that all lug nuts are present and not loose look for rust trails around nuts Ensure that no cracks or damage are present at wheel mount holes Tire Check tread depth tire inflation and note if tread is evenly worn Minimum tread depth is 4 32 inch on steering tires Look for cuts or other damage to the tread or sidewalls See if valve caps and stems are missing broken or damaged Hub Check for obvious leaks on outside or inside of wheel Verify correct oil level in hub Steering Linkage Inspect connecting links arms and rods for worn damaged loose or missing components 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 mi
172. fth wheel press the top portion of the switch in The switch indicator will illuminate steadily when the fifth wheel is unlocked NOTE The fifth wheel cannot be unlocked above a preset speed normally 2 mph 8 km h Attempting to unlock the fifth wheel at any higher speed will cause the switch indicator to flash slowly once per second The fifth wheel lock automatically engages if it has been unlocked and the vehicle speed exceeds the preset value To lock the fifth wheel once the desired position is reached press the lower portion of the switch The switch indicator will turn off when the fifth wheel is locked 3878859R2 Operation NOTE A fast flashing twice per second switch indicator signifies a problem in the fifth wheel lock system Hook Up 1 2 Fifth wheel jaws must be opened fully Tilt fifth wheel back to prevent body damage when tractor is backed under trailer Block trailer wheels and be sure trailer spring brakes are adjusted and applied Never chase a trailer Make sure brake hoses and light cords are clear of the fifth wheel Back tractor squarely under trailer engaging fifth wheel jaws on trailer kingpin Always back slowly making sure trailer is neither too high nor too low Avoid backing under trailer from an angle Connect service and parking brake hoses and trailer light connector Refer to the Warning located in the Tractor Trailer Connections information Use a three point stance when
173. g the vehicle 137 Operation Dual tank systems are equipped with dual draw and dual return fuel line systems to equalize the fuel temperature and level between the dual tanks When refueling be sure that both tanks are filled completely as both tanks cannot be filled from one side Fueling Precautions Federal Motor Carrier Safety Regulations require the driver or any employee of a motor carrier to observe the following requirements 1 Do not fuel a motor vehicle with the engine running except when it is necessary to run the engine to fuel the vehicle 138 2 Do not smoke or expose any open flame in the vicinity of a vehicle being fueled 3 Do not fuel a motor vehicle unless the nozzle of the fuel hose is continuously in contact with the intake pipe of the fuel tank 4 Do 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 of accessories shall be carried on any motor vehicle except in a properly mounted fuel tank or tanks 3878859R2 Exhaust Diesel Particulate Filter Regeneration This vehicle is equipped with a Diesel Particulate Filter DPF to meet 2010 emissions requirements The DPF traps exhaust particulate matter generated by normal engine usage Periodically the engine control system will perform a cleaning of the filter known as Normal Regenerat
174. ged A B System Insulation C E asi ah rin rar Clutch ee R 200 000 miles 322 000 km 2 years Shit Selecor Linkage Cheek Function OOO O f AB SSCS Neuve Sten Swich OheckFunaton OOO f AB SSS Transmission Fluid Synthetic Replace NOTE 3 500 000 miles 800 000 km 5 years Fransmisson Fier Regee rero Teomision Maal Transmission Fluid Mineral Replace a Tanorissin Manvel Wim Suds Rawrqus a OOOO meee a Te 3878859R2 215 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Recommended at ML Intervals ll Door Hinges Latches Strikers Lubricate Check Link Use Seer Multi purpose lithium grease or light engine oil Do Not use silicone lubricant Windshield Wipers Replace EEE 12 months or as required Seat Adjuster Slides Lubricate NOTE 3 100 000 mites 160 000 km Sleeper HVAC Fiter Replace oroen sooo mesoo Low Air Pressure Warning Alarm Check A B 216 3878859R2 Maintenance Intervals and Specifications Lubrication and Fluids Charts Fluid Check and Fill Notes NOTE The components requiring lubrication and fluid check and CAUTION fitlaghams alesypieal rapresentations Use only recommended viscosity engine oil Lubrication Notes Refer to the Engine Operation and Maintenance Unapproved lubricants can cause premature component failure Refer to the Lubricants and Sealer Specification table for proper lubricants Wipe clean
175. he Line Set Ticket which is sometimes known as the vehicle specification card or code sheet Line Set Ticket Each vehicle is provided with a Line Set Ticket code sheet which lists identification code numbers of component units used to build the vehicle One copy of the Line Set Ticket is included in the literature provided with the vehicle When replacement parts are required take this copy with you to positively identify vehicle components to be sure of getting the correct parts Be Sure To Return Line Set Ticket To Vehicle After Obtaining Parts Vehicle Storage Instructions When a vehicle is not used for an extended period of time precautions must be taken to prevent deterioration of vehicle components Vehicles that are out of service for extended periods of time can experience corrosion and other undesirable effects Drive vehicle monthly to exercise the brakes driveline and steering Run the vehicle long enough for the engine to reach operating temperature NOTE Losses occurring to a unit while it is in storage will not be considered for warranty reimbursement Storage Duration One Month or Less 1 Wash vehicles as necessary Always wash vehicles that have been exposed to road salt 3878859R2 NOTE Washing Instructions Wash the vehicle with warm water and mild soap then wipe wet surfaces with a chamois or soft cloth DO NOT use hot water or strong soaps or detergents DO NOT wash the vehicle in direct sun
176. heel should have less than 10 degrees free play approximately 2 inches at rim of 18 inch steering wheel Seats Be sure seats are firmly engaged to avoid forward or rearward movement when starting or stopping Make sure that seats and tether straps are free from damage and secured to floor Horn s Check to see that horn s operate properly Mirrors Check mirrors for proper adjustment damage cleanliness and proper mounting Check optional power mirrors and optional heated mirrors for proper operation Doors Ensure windows are clean and operate properly and smoothly in both doors Windshield and Wipers Check windshield for cracks dirt illegal stickers or other obstructions to view Ensure wipers and windshield washer are functioning properly Lighting Indicators Check to see that dash indicators illuminate when corresponding lights are turned on Heater Defroster Check to be sure that heater defroster is working Verify adequate air flow from louvers and vents Operate Temperature and Mode controls to verify proper operation 41 Inspection Guide 42 16 Air Brake Check Check the air brakes in the following manner a Chock wheels if necessary Push in parking brake and start engine Check for air compressor or governor cut out pressure at 125 to 135 psi 862 to 931 kPa Shift into a low gear and gently pull against service and parking brakes separately to make sure they hol
177. hen in this mode Bi Level Air Conditioning Mode In this mode 75 of the airflow is directed to the panel air outlets and 25 of the airflow is directed to the floor 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 Vent Mode In this mode all airflow is directed to the panel air outlets and fresh outside air is circulated inside the vehicle Floor Mode In this mode all airflow is directed to the floor air outlets and fresh outside air is circulated inside the vehicle 87 Controls Features Mix Mode In this mode 50 of the airflow is directed to the defrost and side demist air outlets and 50 of the airflow is directed to the floor 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 reduce 8487149 Defrost humidity levels and help reduce moisture buildup on the windshield In this mode all of the airflow is directed to the defrost and side demist 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 reduce humidity levels and help reduce moisture buildup on the windshield 8487150 To remove stale air or smoke while air conditioner is operating you may want to open a vent window for a short period of time Always park in
178. hol and or alcohol to diesel fuel This mixture creates an extreme fire and explosion hazard which could result in property damage personal injury or death Blending of gasoline and or alcohol with diesel fuel is not recommended due to the hazards of fire explosion and the detrimental effects on engine performance As little as two percent volume gasoline mixed with diesel fuel will create a flammable explosive mixture in the fuel tank vapor 3878859R2 Operation space which will pose an extreme fire explosion hazard during refueling or engine operation Additional Unsafe Practices To prevent engine damage do not mix propane with diesel fuel Warranty claims will not be honored against engines that have used propane To prevent engine damage do not mix engine oil with diesel fuel Warranty claims will not be honored against engines that have used fuel mixed with oil Fuel and Lubricant Additives International trucks are designed and built to operate satisfactorily on fuels and lubricants of good quality marketed by the petroleum industry Use of any supplementary fuel or lubricant additives is not recommended Malfunctions attributed to the use of such additives or failure to follow recommended fuel or lubricant recommendations may not be covered by any applicable warranty Fueling Procedures NOTE If your vehicle is equipped with dual fuel tanks be sure to read and understand the following information before refuelin
179. hould not be allowed to become underinflated Increased 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 201 Maintenance Instructions tire components i e ply and tread separation and reduced retreadability Underinflation is also the primary cause of blowouts In addition low inflation causes an increase in rolling resistance This results in reduced fuel mileage a loss in tread life and uneven wear due to increased tread movement To determine proper inflation refer to the tire inflation range stated on the tire sidewall and the tire manufacturer s tire load pressure charts SmartWave Tire Pressure Monitoring System TPMS SmartWave tire sensors can be broken when mounting and dismounting a tire unless specific instructions are followed If tire work is done by a non SmartWave authorized facility please let them know that a tire pressure monitoring system is installed on the vehicle before they remove a tire from a wheel Refer to http www smartire com support manuals for complete owner s manual The optional SmartWave Tire Pressure Monitoring System TPMS warns the driver that tire pressure is below set pressure Air pressure sensors are installed on the inner rim of each wheel The standard user interface is a round display located in the center dash panel If the vehicle is equipped wi
180. i tEn aaee ERARE TETA TE 133 Engine fluids and contaminated material 187 Epone Olli isos wee Fi reese ead ei eas eter eae eee 136 Engine Performance ProblemS eeee eee eee 136 Fuel System ereas ra E EETA AE eel eee ies 195 Fuel Tank Draining and Cleaning 0eeeeeee ees 195 239 Index E CONT Engine cont MaxxForce 11 13 and 15 Engine Brake With Eaton AutoShift UltraShift Transmissions Special Driver IMStRUCTIONS aa EE aaan EIAN tenance detects oe 1 MaxxForce Engine Features 1 Scheduled Maintenance cs eeeee cece eee e eee cece 1 Self Diagnostics 00 cece eee ceee eee eee E RETAS 1 Troubleshooting 0 cece cece eee e eee eee eeeeeeeeeeeeeees 1 Engine Brake sssri arra ccnend SAUNIA RAEADR RAGNE es bk yee 1 Engine Control SWitch 00 c cece cece cece eee teeters Engine fluids and contaminated material 4 1 Engine Idle Shutdown Timer Optional 4 1 Engine IdM dissesse aabt A EE tues EATA 1 Engine Noise Shields Blankets uccsccccsecereeenenn 1 Engine Okere an Eno EKDE ELE aa AEA aiiai 1 Engine Performance ProblemS eeeeeeeeeeeeeeees 1 Engine Serial NUMber 0 cece cece eect eee e te ee teens Engine Shutdown ccc eeeeeeeeee eee ee ee ee ee EAEE 1 Engine Starting cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 1 Entering The Upper Bunk
181. ift is completed When the transmission is in manual mode engine protection upshifts are disabled This could result in an undesirable engine overspeed condition It is the operator s responsibility to prevent 133 Operation mechanical damage to the truck Under these conditions use service brakes and select the appropriate gear as required to keep the engine rpm within operating limits MaxxForce Engine Features The MaxxForce engines are electronically controlled diesel engines The engine Electronic Control Module ECM monitors and controls the injection 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 warning indicators Since many of the engine performance features are owner selectable and electronically programmable some of the operating parameters will vary from vehicle to vehicle Some of these standard and optional monitored engine operating functions and warning indicators include Some standard features e Engine Warm Up Control ECM adjust injector operation as required e Cold Ambient Protection CAP to aid engine warm up and maintain engine temperature e Cruise Control provides vehicle speed control Some Optional Features e Engine Warning System this system illuminates the Red Engine indicator and actuates a beeper when warning thre
182. ift release handle locks the door shut 5 Internal Light The internal light is mounted on the tower wardrobe cabinets that are equipped with a door This automatic light turns on as the door is opened and turns off when the door is closed 8487141 1 Rear Wardrobe The rear wardrobe cabinet is mounted on the rear wall of International ProStar Series sleeper models and provides storage for hanging clothes When an upper bunk is installed in the sleeper compartment the rear wardrobe cabinet is not installed 2 Gas Shocks The rear wardrobe is fitted with two gas shocks to aid in opening closing and supporting 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 3878859R2 113 Sleeper Features 114 Hanging Closet Provides storage locations for hanging clothes Mirror A mirror is provided with the rear wardrobe Logo Button The logo button is used for opening the rear wardrobe cabinet To open push the logo button with one hand while lifting the door with the other hand To close lower the door to the closed position apply pressure to the bottom latch area and the door will lock shut Airline Cabinets 8487419 Airline Cabinets These airline style cabinets are mounted at the top of the si
183. ight when opening the doors Used to either turn on the sleeper dome or floor light 3878859R2 Steering Wheel Controls N ia a WN re J sew f COAST i ACCEL AA tl aa J an D i The steering wheel contains a variety of push button switches to aid in the operation of the vehicle SET COAST Used to set the speed e desired on the cruise control or coast to ura a lower desired speed When parked used to decrease idle RPM HEADLIGHT INT Used to momentarily turn off interrupt the headlights when 8487157 pressed 3878859R2 RESUME ACCEL 8487159 aes 2 MARKER INT 8487152 Controls Features RESUME ACCEL Used to resume the desired speed set on the cruise control or accelerate to a higher desired speed When parked used to increase idle RPM OFF ON Used to turn the cruise control ON and OFF HORN Used to activate the city horn RADIO Optional Adjusts radio volume and station selection lt gt with the radio turned on AIR HORN Used to activate the air horn MARKER INT Used to toggle the park lights and markers on or off depending on park light switch position If the park lights are on it will toggle them off If the park lights are off it will toggle them on 77 Controls Features ENG BRAKE ON OFF Optional Used d A slight tap on the brake or clutch pedal will deactivate ONDE to turn engine brake on or off the cruise but hold
184. ign material on face of cooling package Carefully brush away collected materials without bending cooling fins to maintain proper airflow through cooling package Air Lines and Wiring Check air Lines and electrical wiring for proper security and for damage and chafing Listen for audible air leaks Leaks Check for signs of fluid puddles under vehicle or wet components in the engine compartment 3878859R2 Inspection Guide Left Front of Tractor A WARNING 3 NG Do not operate vehicle if any of the following 7 8 9 conditions are evident Loss of steering or suspension could cause loss of vehicle control and result in property damage personal injury or death NOTE Retread tires are not recommended for use on steering axles of trucks J z 10 1 Steering Linkage Inspect connecting links arms rods and steering intermediate shaft for worn damaged loose or missing components 8487002 2 Steering Gear Look for missing or loose fasteners power steering fluid leaks and damage to power A WARNING steering hoses 3 Frame Check for cracks or bends in frame Make sure If wheels or tires must be changed obtain expert there are no loose cracked bent broken or missing tire service help Mounting and demounting crossmembers or crossmember fasteners of tires should only be performed by qualified personnel using necessary safety procedures and equipment otherwise the result could be property damage personal injury
185. ilers ee E EEEE nie es 136 Engine Performance Problems 05005 136 E A E eisai earn Ce ious A atte pedis eee ee bree 137 Ultra Low Sulfur Diesel Fuel Requirements 137 Unacceptable Fuel Blends 2 2ceeeeeeeeeeee 137 Hazards of Diesel Fuel Gasoline Blends 137 Additional Unsafe Practices ccc eee e eee e eee 137 Fuel and Lubricant Additives eee eee 137 Fueling Procedures 000cceeeeeeeeeeeeeeeeeeeeees 137 Fueling Precautions cece eee eee 138 Reserve Fuels curri nan aTe RE ATNA ER KAARTE A 138 Exhaust Diesel Particulate Filter Regeneration 139 Parked Regeneration Procedure 22 eeeeee 141 Regeneration Inhibit Switch cc eee ee eee eee ee 141 Two Position Regeneration Inhibit Switch 142 Three Position Regeneration Inhibit Switch 142 TRANSMISSION sr arteci ies ineane ee eee sted ia eter tte ete 142 Manual Transmissions 0ccceeeeeee eee eee e eee ee 142 Engaging the Clutch cece cece eee 143 Hydraulic Clutch Actuation System 060 144 Double Clutch Procedures 0 cece cece eee e ees 145 Clutch Precautions cece eee eee Paaa a 145 Eaton AutoShift Transmissions Optional 146 Eaton UltraShift Transmissions Optional 148 Clutch Brake scosowviesi
186. in property damage personal injury or death A WARNING When installing the tire and rim assembly on disc brake equipped axles make sure the tire valve stem clears the brake caliper The use of either an International truck valve stem retainer or a tire manufacturer s stem forming tool is the only acceptable method of obtaining clearance 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 mounting nuts to the proper torque Loose nuts or overtightened nuts can lead to premature wear and possible failure of the wheel rim and or mounting hardware Hub Piloted Wheel Installation Procedures Use only the same type and style wheels and mounting hardware to replace original parts Failure to do so may result in an assembly which looks fine but does not fit together properly This could cause wheel or fastener failures and result in property damage personal injury or death Out of round tires and wheel assemblies can sometimes be corrected by reclocking the tire relative to the wheel Tightening procedure for disc wheels with flange nuts hub piloted 1 Clean the mating surfaces of the hub drum and wheel s as well as the wheel studs and wheel nuts with a wire brush prior to assembly Lubricate the two piece wheel nuts by putting two drops of oil in the slot bet
187. indicator does not illuminate or if it stays on with the parking brake not engaged seek 707 Meee service immediately Illuminates Green to assist operators in determining when it is appropriate to 8487411 shift the transmission to a higher gear in order to maximize driving fuel economy ENGINE llluminates Yellow to indicate engine BRAKE brake capability has been activated 3817059 llluminates Yellow when a trailer antilock brake system malfunction has been detected If the ABS indicator stays illuminated or continues to flash have the system serviced immediately 3878859R2 Controls Features control system is turned off It also system malfunction has been detected TO IIluminates Yellow when the traction SERVICE Illuminates Red when a parking brake illuminates momentarily when the If the Service Parking Brake indicator 3813047 F 8487088 traction control system is on and is stays illuminated have the system limiting wheel spin Indicator blinks if serviced immediately slippery road conditions exist If this Optional indicator illuminates Red happens adjust your driving accordingly p immediately after ignition is turned on to Refer to the Operation section for more remind operator to fasten seat belt i information 8487073 Optional Seat Belt Reminder with Seat i Belt Monitoring causes initial visual 13 E 5 IIluminates Yellow when exhaust system indication then flashes with audible Lp component
188. ing with Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed as follows A Air Intake System Removal of air cleaner intake silencer or piping B Acoustical Shielding Body Removal of wheel well splash shields cab shields or acoustical underhood insulation C Cooling System 1 Removal or rendering inoperative the fan clutch 2 Removal of fan shrouds D Engine and Driveline System 1 Removal or rendering engine speed governor inoperative so as to allow engine speed to exceed manufacturer specifications 2 Removal of engine 3878859R2 block shield oil sump shield or transmission enclosures E Exhaust System Removal or rendering inoperative exhaust system components including muffler resonator or tailpipe Use the following Maintenance Record Noise Control form to log Noise Emission Maintenance of at a minimum the above systems Emission Control Systems NOTE Federal and California e
189. ints refer to the Service Manual 3878859R2 NOTE When attempting to readjust slide the position of the tractor fifth wheel or the trailers tandem axles with the tractor and trailer fully connected leave the tractors PARKING BRAKE pushed in and pull the TRAILER AIR SUPPLY out This will apply the trailers parking brakes and keep it stationary while the tractor is moved forward or reverse Parking Brake Indicator Driving with the parking brakes applied can lead to excessive heat build up and fire resulting in property damage personal injury or death The Parking Brake indicator is operated in conjunction with the parking brake With the ignition switch on and the Parking brake set the PARK indicator will illuminate If the indicator does not illuminate with the Parking brake set the indicator may be inoperative 3878859R2 Operation Bobtail Proportioning System Bobtail proportioning is available with tractor air brake systems for export only with code 04092 with or without ABS or ABS Traction Control Systems The proportioning valve senses when trailer brakes are not connected to the vehicle air brake system and automatically adjusts rear braking power when operating in the bobtail mode then returns full braking power when a trailer is attached When operating in the bobtail mode bobtail proportioning provides more braking control and shorter stopping distances particularly on wet and slippery road surfaces It shou
190. ion This process is transparent to the operator and occurs during normal vehicle operation In some cases the engine control system is unable to manage soot levels in the DPF through Normal Regeneration When this occurs the DPF indicator will illuminate solid YELLOW on the instrument panel gauge cluster advising that action must be taken At this time the vehicle should then be driven at highway speeds or pulled over to perform a Parked Regeneration See Parked Regeneration Procedure If no action is taken the DPF indicator will begin to flash indicating that the filter is full The vehicle should then be pulled safely off the roadway and a Parked Regeneration should be performed If the vehicle is driven beyond the initial two warning stages a loss of engine performance de rate will occur Ignoring the need for a Parked Regeneration when required can result in a warning for excessive exhaust temperatures and a 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 disabling and result in the vehicle being towed See the following information for a detailed explanation of DPF indicators and the corresponding procedures that must be followed 3878859R2 Operation Failure to perform a Parked Regeneration when exhaust filter indicator is ON will cause the engine to lose power and eventuall
191. iption Flash Yes No Warning Indicator Messages Association Warn Engine Priority 1 or 2 1 Message is displayed when MaxxForce 11 13 or 15 1 Red warning indicator Mt CM turn on the Red warning indicator 2 Yellow warning 2 Message is displayed when MaxxForce 11 13 or 15 indicator ECM requests the Yellow warning indicator and not the Red warning indicator Stop Hybrid Message is displayed when Hybrid system turns on and Yes Red warning indicator requests the Red warning indicator HV Batt Off Line Message is displayed when Hybrid system battery is off a line Check Hybrid Message is displayed when Hybrid system turns on the Yellow warning indicator Yellow warning indicator while conditions for HV Batt Off Line message are not met Low Engine Oil Level Message is displayed when engine oil level is less than Yes No or equal to 80 Change Engine Oil Message is displayed when engine oil change is detected Yes No as necessary Message is displayed when water in fuel is present Yes NO Refuel Message is displayed when fuel level is low MaxxForce Yes No 11 13 or 15 engines only High Fuel Temp Message is displayed when fuel temp is high MaxxForce Yes 11 13 or 15 engines only Electrical Fault Priority 1 or 2 1 Message is displayed when when EGC requests the 1 Red warning indicator warning indicator 2 Yellow warning 2 Message is displayed when when EGC requests the indicator Ye
192. ir Supply b Parking Brake Radio Stereo Automatic Transmission Push Button Shifter optional 85 Controls Features Climate Control Never drive the vehicle unless the windshield and all other windows are clear A fogged ice snow covered or dirty windshield or window limits vision which could cause an accident resulting in property damage personal injury or death To improve defroster efficiency remove ice and or snow by hand from the windshield and windows with a non metallic scraper To clear system of humid air operate blowers for 30 seconds at high speed with the AIR FLOW AIR CONDITIONER knob on the normal heating position before selecting the DEF position This will prevent fogging the glass which can occur if humid air is blown onto a cool windshield NOTE The vehicle may be equipped with 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 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 a a e Fan Speed Control Use this control to regulate the amount of air provided to the vents in any mode you select Turn the knob clockwise to increase fan speed Turning the control to the OFF position will shut off the fan but does not prevent outside air from entering the vehicle On vehicles
193. isture that was not removed by the air dryer Drain the wet tank reservoir every day at the end of the trip Drain the primary and secondary tanks periodically Periodically manually drain each reservoir by opening the drain cock located either on the bottom of the tank or in the end of the tank Make sure the drain passage is not plugged For ease of draining some or all air tank drain valves may be equipped with optional pull cords There must be some air pressure in the system to ensure proper drainage Close the drain cocks after all moisture has been 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 tank is the wet tank drain all tanks daily On vehicles equipped with automatic drain valve s moisture and contaminants are automatically removed from the reservoir to which it is connected It operates automatically during each compression cycle and requires no manual assistance or control lines from other sources The Bendix AD IS air dryer has an integral wet purge tank which automatically purges itself and the desiccant of collected water at the end of each compressor cycle 181 Maintenance Instructions ABS Connections and Sensors Periodically push together the ABS wiring connections to ensure they are fully seated Press the wheel speed sensors into their mounting collars to ensure
194. k to see that brake linings where visible are not worn excessively thin less than 1 4 inch 6mm or contaminated by lubricant Frame Check for cracks or bends in frame Make sure there are no loose cracked bent broken or missing crossmembers or crossmember fasteners 3878859R2 5 Wheel and Lug Nuts Check for damaged or bent wheel Check to see that all lug nuts are present and not loose look for rust trails around nuts Ensure that no cracks or damage are present at wheel mount holes Tires Check tread depth tire inflation and note if tread is evenly worn Minimum tread depth is 2 32 inch on all drive tires Look for cuts or other damage to the tread and sidewalls See if valve caps and stems are missing broken or damaged Check dual spacing to ensure that dual wheels are evenly separated and that tires are not touching one another Hub Check for obvious leaking on outside 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 3878859R2 10 Inspection Guide 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 Torque Rods and Shock Absorbers Check to see that torque rods are not cracked broken or missing Check shock absorbers for cracks or leaks There should be no missing or broken m
195. l Bearings Check End play Air Suspension if equipped Check Ride Height See Service Manual Axle U bolts Retorque NOTE 3 At first 1 000 miles 1 600 km then every 36 000 miles 58 000 km thereafter 100 000 miles 160 000 km 12 months Wheel Bearing Oil including synthetic Change Axle Shocks NOTES S 300 000 miles 480 000 km Axle Shocks NOTE 3 211 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Recommended Synchronized Intervals cont System mom O ee Speci terval mites en nour month Roar Ave Lubicat LewiGnesis S ase FangeNus Rates T PSS Air Suspension if equipped Check Ride Height See Service Manual Axle U bolts Retorque NOTE 3 At first 1 000 miles 1 600 km then every 36 000 miles 58 000 km thereafter Rear Axle with Petroleum Oil Change ane 100 000 160 000 12 Rear Axle Wheel Ends Inspect for leaks lube 100 000 160 000 12 Also at brake lining service level condition and check end play with dial indicator If wheel end play is found to be outside the 0 001 in to 0 005 in specification or lube condition is contaminated or low then perform a full wheel end tear down Inspect bearings spindle and spindle nuts for excessive wear and replace as necessary Rear Axle with Synthetic Oil Change Dana 250 000 400 000 km 36 Meritor 500 000 800 000 48 Rear Axle Wheel Ends Full tear
196. l 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 through cooling package 3 Windshield Washer Fluid Level Inspect the reservoir and verify that the fluid level is not empty and has enough fluid to accomplish the upcoming mission If additional fluid is required see Lubricant and Sealer Specifications chart in the Maintenance Intervals and Specifications section for the correct fluid type before filling Do not use water in freezing climates 4 Drive Belts Inspect all belts for frays cracks loose fibers or visible signs of wear With engine off press on all belts to test for proper belt tensioner performance 5 Cowl Vent Ensure air inlet cover is free of dirt and debris Air Lines and Wiring Check air Lines and electrical wiring for proper security damage and chafing Listen for audible air leaks 3878859R2 e Leaks Check for signs of fluid puddles under vehicle or wet components in the engine compartment Right Side of Cab 3878859R2 8487007 Inspection Guide Maintain adequate clearance between all parts of the exhaust system and all hoses wires and lines for engine cooling brake system fuel system power steering system and electrical system Heat damage to hoses wire
197. ld 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 when in a brake system without bobtail proportioning 157 Operation Antilock Brake System ABS Antilock brake systems are designed to enhance overall vehicle safety when a vehicle is driven within its safe operating limits ABS cannot compensate for a vehicle that is being driven beyond the physical limits of control Drivers Operating an ABS equipped vehicle should employ safe driving practices and assume no additional driving risks Failure to do so could result in property damage personal injury or death A WARNING Do not rely on the ABS system to interrupt vehicle engine brake on slippery road surfaces Turn these devices off during hazardous driving conditions Failure to follow this warning may cause wheel slippage and or loss of vehicle control which could result in property damage personal injury or death General Information The Antilock Brake System is a mandated feature added to the standard air brake system It electronically monitors vehicle wheel speed at all times and only engages when wheel lock is imminent The standard air brake system controls normal braking when the ABS is not engaged 158 ABS Operation If the ABS warning indicator comes on stopping distances may increase under certain braking con
198. le can be found on the internationaltrucks com Web site or by contacting your local Form No 3878859R2 International dealer It is the policy of Navistar Inc to improve its products whenever itis possible and practical to do so We reserve the right to make changes or add improvements at any time without incurring any obligation to make such changes on products sold previously 2010 Navistar Inc All rights reserved 3878859R2 Printed in the United States of America Operator s Manual ProStar Series Printed in the United States of America 3878859R2 Section 1 Foreword Preface m soaeteansccanieeeeoed sed de DEEA AAE eevee eee coccees cea 1 Cautions and WarningS e cece cece eee e ee eeeaeeee eens 1 Assistance Guide 22c ceee cece ceeeee eee eee eee eeeeeeeeees 1 Component Code Numbe s cece cece cette eee e ees 2 Line Set Ticket ayani aumaia EEEREN eeeeressu tak 2 Vehicle Storage Instructions 00 cc ceeeee eee eee e ees 2 Storage Duration One Month or Less 4 2 Storage Duration Over One Month 00000 3 Storage Facilities 0 cece eee neee ees 4 Exterior Noise EmisSions 2 0cceeeeeee eee esse eeeeees 4 Tampering with Noise Control System Prohibited 4 Emission Control Systems cece ee ceeeee eee eee teens 5 Maintenance Record Noise Control 2 eeeee e
199. les in the vehicle 43 Controls Features Dash Components 44 a fF oO DN Instrument Panel Gauge Cluster Center Dash Panel Wing Panel Fuse Panel Cover Control Switches Transmission Gear Switch with Hi Lo Range Switch and Optional Hi Lo Splitter Switch 8 9 3817002 Tilt Telescoping Steering Column Push Button Gear Selector for Optional Automated Manual Transmission City Horn Pad Ignition Switch 10 Vehicle Information Display optional 3878859R2 Controls Features Overhead Console The overhead console contains storage area for the operator and other items for driver comfort SS De fana ABS __ E N a oa 8487420 1 Overhead Storage 4 Sun Visors 2 CB Radio Mount 5 Map Lights 3 Storage Compartment 6 Cab Dome Lighting 3878859R2 45 Controls Features Instrument Panel Gauge Cluster The instrument panel gauge cluster includes the instrument gauges warning indicators and an Integral Digital Display that provide odometer transmission gear indication and compass 46 heading and outside temperature displays This instrument panel gauge cluster displays the crucial operational functions of the vehicle The following are descriptions and illustrations of the gauges warning indicators and integral digital display options 3878859R2 Controls Features LJ E qe
200. level until a new value is received or until the instrument panel gauge cluster detects that it has not received a response to the SPN request in which case it shall display the word data n a within the bar graph Quadrant 2 Text and Warning Messages These messages inform the driver of vehicle conditions If the message flashes it will flash for 3 5 seconds and then will be displayed for an additional 3 5 seconds If more than one message is viewable the displayed message will be followed by 3878859R2 an asterisk indicating multiple messages To view additional messages press and release the Display Control button to proceed to the next message The following is a list of the routine Text and Warning messages that can be displayed 67 Controls Features Quadrant 2 Display Description Flash Yes No Warning Indicator Messages Association Parkd Regen Active Message is displayed during a parked regeneration Load Shedding Message is displayed when electrical load control and Yes No shedding feature is implemented Washer Fluid Low Indicates low washer fluid level Electrical Fault When instrument panel gauge cluster s ability to display Yes No diagnostic codes is enabled this message is displayed when there are active diagnostic codes Check A C Indicates a fault in the HVAC System Ys Nid Parkd Regen Inhibited Message is displayed when parked regeneration has been requested but is not
201. lide Switch Optional eeeeeeee 167 Hook UD erener riana EEE EEA ATERPE IT AALBERS 167 UNFHOOK e E A A AAA EEEE 168 Fifth Wheel Jaw Unlock Control sscccccscceceeceenn 168 Fifth Wheel Jaw Monitoring eeeeeee eee 169 Section 7 Maintenance Instructions INtFODUCTION 00 cece cece een eee e cece EE ER E 171 Maintenance GuidelineS cc cece eee cece cece eeeeees 171 Supporting Your Vehicle for Service 22 eeeeee eee 173 Chassis Lubrication ccce cece cence eee e ee eeeeeteeees 173 Air Conditioning Service CheckS cc ceeeeeeee eee ees 174 HVAC FINES ieri pa ae eed adieu aoe beua ened Daia 174 Side Access HVAC Filter 0 ccee cee ennnen 174 Front Access HVAC Filter cece cece eee eeeeeees 175 Recirculation Filters cc cece cee e cence eee eneeees 175 Sleeper HVAC Filter 00 cece cece cece eee e eee e eens 176 AXIOS occa Zc a ne a ea a vee ho NORTA AAC RANEE A 176 FrONtAXl6 ss 6254 vs ceatidue th Sodddee need biddad oohennae es oad feds 176 Inspection and Lubrication cece scence eee 176 Normal Maintenance ccce cece cece eee e eee eeees 177 v Table of Contents AliQnime tesco ch ria eek ee vee ste eas oe a ini Eee ae 177 ROGAN ANIC arrire rrara AAAA TAAA AA IAAT IA RAATIRA EEO EEE 177 Inspection and Lubrication secseceecreerreereernn 177 Locking Ditter
202. limate Manual heater ventilation and air Controls conditioning HVAC Controls 3 Power Standard 12V power socket Receptacle o 4 Radio Remote Can be used to control the functions of the Control dash mounted radio from the sleeper O Inverter The inverter control panel is used for Control Panel controlling the power inverter that allows the use of items such as a TV VCR microwave hair dryer etc Climate Optional LED electronic heater ventilation Controls and air conditioning HVAC Controls 8487134 98 3878859R2 Accent Light Dimmer Switch This switch is used for adjusting the brightness and dimness of the sleeper compartment accent lights e Up position brightens the accent lights e Down position dims the accent lights Accent Light Switch This two position switch operates the four accent lights located in the long sleeper ceiling or two accent lights located in the short sleeper ceiling Acer e Press on the top of the switch to turn the accent lights on 8487125 e Press the bottom of the switch to turn the accent lights off Sleeper Dome Floor Light Switch This two position switch operates the large fluorescent dome light located in the sleeper ceiling and the three red floor lights located under the lower bunk and the dash center panel 8487122 e Press on the top of the switch to turn the dome light on or off e Press on the bottom of the switch to turn the floor lights on
203. lled in the vehicle some of these features may not apply 3878859R2 Operation 8487100 121 Operation Seat Controls and Adjustments em Canto SSCSC S Fore and Aft Movement Press the lever sideways to unlock the seat and adjust the fore aft position Back Cycler Pressing this button activates the lumbar massage feature 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 Cycler is manually turned off prior to shutdown Ride Height Push the switch up to inflate the air bag and increase the ride height Push the switch down to deflate the air bag and lower the ride height Seat Cushion Side Support Push the switch up to inflate the seat cushion side supports Push the switch down to deflate the seat cushion side supports Backrest Side Support Push the switch up to inflate the backrest side supports Push the switch down to deflate the backrest side support Triple Lumbar These three switches operate the three chamber lumbar supports Push each switch up to inflate either the upper middle or lower chamber and push each switch down to deflate the chambers 122 3878859R2 Starting Procedures Never start the engine unless you re sure the transmission selector is in neutral and the brake is applied otherwise accidental movement of the vehicle can occur which could result
204. llow warning indicator 70 3878859R2 Controls Features Quadrant 2 Display Description Flash Yes No Warning Indicator Messages Association Check Trans Message is displayed when transmission needs to be a Yellow warning indicator serviced Trans Temp Message is displayed when transmission turns on Yellow warning indicator the Yellow warning indicator Not available with all transmissions Gen Trns FIt Message is displayed when transmission turns on Red Yes see description 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 Trans Oil Life Message is displayed when transmission oil needs Yes No changed Not available with all transmissions Trans Oil Filter Message is displayed when transmission oil needs Yes No changed Not available with all transmissions Trans Service Message is displayed when transmission needs service Yes No Not available with all transmissions DPF Ash Service Required Message is displayed when diesel particulate filter ash Yes No level requires service cleaning See Visor For Info Message is displayed indicates the particulate trap Yes Yes see description indicator must be on or must flash 3878859R2 71 Controls Features Quadrant 2 Display Messages ECM TCM Shift Selector ABS Retarder Driveline EGC Compass Module ESC VSM
205. lly available They may include the use of a splitter selector switch in addition to the range selector switch Engaging the Clutch Always start in the proper gear An empty vehicle can be started in a higher gear than a fully loaded one But starting in a gear too high for the load can cause too much clutch slippage generating excessive heat and unnecessary wear A gear that will start the vehicle moving with the engine at idle speed is usually correct If the engine must be revved up to prevent stalling the gear selection is too high As the clutch pedal is released and the clutch begins to engage the engine speed will drop slightly When this happens fully engage the clutch and increase the engine speed Increasing the engine speed before fully engaging the clutch can damage the clutch and drivetrain Do not upshift until the engine has reached proper speed Upshifting before the vehicle has reached the right speed will lug the engine When approaching a hill depress accelerator smoothly to start the upgrade at full power then downshift as needed to maintain vehicle speed 143 Operation e Never hold a vehicle on a hill with the clutch To hold on a hill with the clutch requires that the clutch be purposely slipped By doing this enough heat can be generated to burn up the clutch e Never coast with the clutch disengaged This can cause clutch failure by the very high RPM encountered when coasting in gear with the clutch r
206. low the turbocharger to cool 5 Rotate the key counterclockwise to the OFF position and remove key from the ignition switch A WARNING The following procedures must be performed exactly as outlined otherwise a fire or a battery explosion could result in property damage personal injury or death To prevent damage to vehicle electronic components voltage supplied to a vehicle s electrical system must never exceed 16 0 volts This voltage must not be exceeded when the ignition switch is in the OFF ACC or IGN position or during engine cranking The most reliable means for jump starting a vehicle is to connect charged 12 volt batteries so as to provide controlled voltage Never use an electric welder Emergency Starting 3878859R2 NOTE The International ProStar Series vehicle is equipped with a remote jump start stud located on the back of the battery box that eliminates the need to remove the battery box cover when jump starting is required 1 To prevent shorting of the electrical system remove metal rings or watches and do not allow metal tools to contact the positive terminal of battery or jumper cables 2 Place transmission in Neutral and set parking brake in both the discharged and booster vehicle Shut all electrical loads in both vehicles Eye protection should be worn if available If not available shield eyes when near either vehicle s batteries 5 DO NOT permit vehicles to touch each other
207. ls ccc ccc ee cece eeeeeneeeenees 100 Manual Operation cceeee cece cece eee e eee Eaa 91 Manual TransmiSSiOns cccecce eee eee eeeneeneeeaes 142 MaxxForce 11 13 and 15 Engine Brake With Eaton AutoShift UltraShift Transmissions Special Driver INStFUCTIONS Heise vars vd cee bea ede ouen VAKER EENKEER ee 133 MaxxForce Engine Features sseeeeee eee eee eee 134 Mirror Controlsixs vxsudends cal iiaesessssessseiberennnnnnnnt eaves 92 N No Restriction Reading Table cece e eee 191 Noise Emissions Exterior ceeeeeeeeeeeeeeeeeees 196 Air Intake System 2 02 c cece cece ence eee eeeeeeeeees 196 BOdY seis stig AEE EE eee ee AELA 196 Engine Noise Shields Blankets eeeeeeeee 196 Exhaust Systm vssseenenn pikie anas ANS neeaaea hs 196 Instructions for Proper Maintenance 196 Normal Maintenance ssssssssruerrrrnnrrerrerrrerrerre 177 0 Operating Instructions eee eeeeeeee ee 128 Electrical vi c hneicnecenes et AAEN iad EEA E AA EET 130 3878859R2 Index O CONT Operating Instructions cont ANEMIO eai eaa EE AANE EATE CERERA TIRITA 130 Battery EA EE A A T T T 130 BATTERY ON Indicator 2 cece cece eee eiii 131 Circuit Breakers Fuses and Fusible Links 131 Electrical Load Control and Shedding ELCS 132 ENGINE yess ccicerses tage es EKET eUivba
208. ly efficient they use very little fuel while idling As a result idling in cold weather will not heat the engine to its normal operating temperature This in turn can cause a build up of heavy deposits of carbon and rust on valve stems causing them to stick Sticking valves can cause significant valve train damage The colder the ambient temperature the more likely this will occur The following cold weather idling guidelines must be followed Avoid extended idling beyond 10 minutes whenever possible to maximize engine and Diesel Particulate Filter DPF life See Exhaust Filter Regeneration in this section for more information Use a minimum 40 Cetane diesel fuel or utilize Cetane Index improvers from a reputable manufacturer Maintain engine cooling system Do not shut engine down after extended idling period Drive the vehicle under load for several miles at normal operating temperatures to burn off any accumulated carbon and varnish in the exhaust DPF Consider use of engine block heaters and approved winter fronts where conditions warrant 3878859R2 Operation Engine Idle Shutdown Timer Optional This vehicle may be equipped with an optional Idle Shutdown Timer that will limit engine idle time to comply with certain state and local regulations and or owner operator preferences If the optional Idle Shutdown Timer is enabled the engine will shutdown after a pre programmed time of extended idling This will also shut
209. ly place all parts on the floor to avoid getting dust into the air Use an industrial vacuum cleaner with a HEPA filter system to clean dust from the brake drums backing plates and other brake parts After using the vacuum remove any remaining dust with a rag soaked in water and wrung until nearly dry Never use compressed air or dry sweeping to clean the work area Use an industrial vacuum cleaner with a HEPA filter system and rags soaked in water and wrung until nearly dry Dispose of used rags with care to avoid getting dust into the air Use an approved respirator when emptying vacuum cleaners and handling used rags Worker cleanup Wash your hands before eating drinking or smoking Vacuum your work clothes after use and then launder them separately without shaking them to prevent fiber dust from getting into the air 3878859R2 Air Brakes Inspection and Adjustment WARNING Always chock the wheels when manually releasing the spring brakes or the vehicle could roll causing property damage personal injury or death A WARNING Under no circumstances should the spring brake section of the spring and brake chamber be disassembled Disassembly will release a powerful spring which could result in property damage personal injury or death 3878859R2 Maintenance Instructions Brake Automatic Slack Adjusters ASA s should not need to be manually adjusted in service ASA s should not routinely have to be adjusted
210. mance Maintenance Intervals Maintenance intervals provided in this manual are for normal highway and environmental service conditions 3878859R2 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 conditions are extremely severe such as in deep water mud or unusually dusty conditions the vehicle may require lubrication much more frequently than specified in this manual The synchronized A and B service intervals are designed to coordinate maintenance activities and to provide the appropriate levels for servicing components Following the service intervals minimizes the number of times per year that the vehicle must be brought into the shop In addition to the A and B service intervals the Special Service Interval column is provided for items that need infrequent servicing In most cases these service intervals represent the recommended maximum intervals For some components however the manufacturer s recommended maintenance intervals may have been shortened to allow synchronization with other maintenance tasks The maintainer may wish to synchronize engine related items with other lubrication maintenance intervals in order to reduce downtime even though the recommended intervals in the Engine Operation and Maintenance Manual may be longer Engine Operation a
211. manually released caged A WARNING Failure to comply with the following may result in property damage personal injury or death e Always chock the wheels when manually releasing the parking brakes or the vehicle can roll e For towing make sure the vehicle is securely connected to tow vehicle and tow vehicle parking brakes are applied before releasing the disabled vehicle s parking brakes e To ensure release of parking brake always cage the spring in the brake chamber e Under no circumstances should the spring brake chamber be disassembled for the purpose of releasing the parking brake In the event it is necessary to move the vehicle after an emergency application before air pressure can be restored the parking spring can be compressed mechanically to release the brake A release stud spring caging tool is furnished with the brake chamber assembly The release stud engages in the spring pressure plate and its nut is tightened to compress cage the spring and release the brake Remove release stud assembly from carrying pocket 3878859R2 Apply a light coat of antiseize to the threads of the release stud to avoid any unnecessary wear of the threads Remove the access plug from the end of the spring chamber Insert the release stud through the opening in the chamber and into the spring pressure plate Turn the release stud one quarter turn to engage the tangs on the release stud into the slot in the pressure pla
212. minimize bird and insect stains D Park away from railroad tracks paint shops smoky industrial areas and locations of possible road splash contact E Ifa vehicle is parked on an incline block the wheels Exterior Noise Emissions Many operators and owners of the type of vehicles described herein are subject to Federal Motor Carrier Safety Regulations and Noise Emission Requirements All owners and operators are urged to obtain a copy and comply with these regulations Copies of these regulations can be purchased from Superintendent of Documents U S Government Printing Office Washington D C 20402 Navistar Inc warrants to the first person who purchases this vehicle for purposes other than resale and to each subsequent purchaser that this vehicle as manufactured by Navistar Inc was designed built and equipped to conform at the time it left Navistar Inc control with all applicable U S Environmental Protection Agency Noise Control Regulations This warranty covers this vehicle as designed built and equipped by Navistar Inc and is not limited to any particular part component or system of the vehicle manufactured by Navistar Inc Defects in design assembly or in any part component or system of the vehicle as manufactured by Navistar Inc which at the time it left Navistar Inc control that cause noise emissions to exceed Federal standards are covered by this warranty for the life of the vehicle Tamper
213. mission system warranties are found in your Engine Operation and Maintenance Manual Maintenance Record Noise Control Chassis Model Vehicle Identification Number Maintenance Maintainer Location Date Performed Name Reporting Safety Defects U S Registered Vehicles If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration 3878859R2 Foreword NHTSA in addition to notifying Navistar Inc To notify Navistar Inc see regional numbers listed in the front of the manual If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Navistar Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 202 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the hotline Canadian Registered Vehicles If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately contact Navistar Inc Canada and then Transport Canada To contact Navistar Inc Canada you may
214. modifications not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment The remote keyless entry key fob is used to lock and unlock both cab doors from a distance of 30 feet Click once to unlock the driver s door click twice to unlock both cab doors Whenever the doors are locked or unlocked using the key fob the city horn sounds momentarily chirps Also the optional keyless entry key fob turns on the interior light for a time period when its 3878859R2 Unlock button is pressed and turns off the light dims gradually to off when its Lock button is pressed The Panic emergency button when pushed causes the horn to chirp on off for three minutes in unison with the headlights and park lights flashing This feature works only when the ignition switch is in the OFF position Lock Unlock From Interior To help reduce the risk of personal injury in the event of an accident keep doors locked when vehicle is in motion 8487165 3878859R2 Controls Features 1 Lock Unlock Button Door Control Panel Driver Side Power Window Control 2 3 4 Passenger Side Power Window Control 5 Window Lock Control Locking 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 Unlocking the Door To unlock push the lock unlock
215. n or missing crossmembers or crossmember fasteners Air Lines and Wiring Check air Lines and electrical wiring for proper security damage and chafing Listen for audible air leaks 3878859R2 Right Rear of Tractor A WARNING If wheels or tires must be changed obtain expert tire service help Mounting and demounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment otherwise the result could be property damage personal injury or death 3878859R2 Inspection Guide Brake Chamber and Hoses Check for cracked worn or frayed hoses and for 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 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 between push rod and adjuster arm should be approximately 90 degrees when brakes are applied 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 6mm or contaminated by lubricant Wheel and Lug Nuts Check for damaged or bent wheel Check to see that all lug nuts are present and not loose look for rust trails around nuts Ensure that no cracks or damage are present at wheel mount holes 35 Inspection G
216. n will often wear off the irregularities and they can be moved back to the steer axles or run out to retread stage on the rear axle e Another rotation possibility for fleets with rib tires in all wheel positions is to break in the new steer tires in the drive axle positions then move them to steer axles This will wear away tread rubber relatively quick in the early life of a tire when it is most likely to develop an unusual wear pattern e Drive axle tires may be placed on the other end of the same axle so that direction of rotation is reversed This is often helpful if a heel and toe or alternate wheel nut wear pattern has developed Rotation Is Advisable 1 If front steering axle tires become irregularly worn move to rear position 203 Maintenance Instructions 2 Ina dual assembly reverse the position of the tires if one tire wears much faster than its mate 3 Onthe drive axle if heel and toe wear or alternate wheel nut wear occurs rotating the tires from one end of the axle to the other end of the axle may help even out this wear Tire Replacement NOTE Retread tires are not recommended for use on steering axles of trucks e Front Steering Axle Tires must be removed when tread is worn to 4 32 inch 3 mm or less Retread or rotate worn tires to drive position e Rear Axles Tires must be removed when tread is worn to 2 32 inch 2 mm If rib tire is used on front axle and lug or off road type on rear
217. na aees 196 Instructions for Proper Maintenance 0e 196 Air Intake System 2 0 cece Ennan AARAA NAAA ERARE 196 BOY spite E oad an bad aby Meee E E 196 Cooling SyStem cceeeeeee eee 196 Engine Noise Shields Blankets 000eeee 196 Exhaust System eee ee eeeeee eee ee ee eeeeeeeeeees 196 Diesel Particulate Filter DPF cc cece cece eee ee ee 196 Regeneration ciicseveeeeeeebt el deh ieee es aiit 196 SEa a E E E A aanweraiiinn te 197 Drive Shalsi iiine aneii i NATEK AAAA sk 197 3878859R2 Table of Contents Suspension Air and Steel Springs eeeeee eee es 197 Front SUSPENSION d yy ie erronei taeae eees 197 Rear SuUSpensiOn 2 eeeeeee cece ee eee eee diore 198 Steri csecssehcVadavecsicunss case needs Cera ore yee dees eee S 198 General Information cceeeeee EECA eens 198 Tightening Steering Intermediate Shaft Joint Bolts 198 Lubrication Points 0 0 cceeeee eee eee eee eee enna 199 Power Steering c cc ccceeeeee eee ee eee eeeeeeaenes 199 TWWGS ict eienosc See reacted rack beeen aa eae ea et ee tae 199 Tire WaN cai o sk cot nanahnnann ame gerne yy esse ee geeedee 199 Tire Maintenance cece eee eee eee eee eee ee 201 Checking Inflation cece cee eeeee eee eee eens 201 Underiniflation issns naayon tee aopanatecoetens 201 SmartWave Tire Pressure Monitori
218. nd Maintenance Manual maximum intervals based on the actual operating conditions specified in that manual must never be exceeded 209 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Chart Symbols Key Lubrication and Maintenance Interval Chart Notes Interval Definition EVERY 25 000 miles 40 000 km 600 hours 3 Months 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 zerk with the vehicle weight on the tires EVERY 50 000 miles 80 000 km 1 200 hours 6 Months SPECIAL INTERVAL AS SPECIFIED Kingpin bushings must be lubricated through the upper and lower kingpin grease zerks with the vehicle weight off of the tires NOTE 3 Certain services are performed at Special Intervals or in addition to A or B Service when the interval dictates 210 3878859R2 Pre Trip Inspection Front Axle 3878859R2 Maintenance Intervals and Specifications Lubrication and Maintenance Interval Recommended Synchronized Intervals Pre trip Inspection Items listed in SECTION 3 INSPECTION GUIDE Wheel Bearing Oil Type Check Level Suspension Fasteners Components Check Tie Rod Ends Lubricate NOTE 1 Drag Link Ends Lubricate NOTE 1 King Pins and Bushings Lubricate NOTE 1 and NOTE 2 A B A B Shock Absorbers Inspect Whee
219. nd possibly burn resulting in a fire which could cause property damage personal injury or death Vehicle electrical systems are complex and often include electronic components such as engine and transmission controls instrument panels antilock brakes etc While most systems still operate on battery voltage 12 volts some systems can be as high as 90 volts or as low as 5 volts Refer to the Electrical Circuit Diagram manuals available from your International dealer to ensure that any body lights and accessories 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 186 Fuses and Relays Fuses and relays are located inside the cab within the fuse panel cover Refer to the schematic located on the 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 fuse or relay replacement Engine General Information NOTE For complete operation and maintenance information pertaining to your engine refer to the Engine Operation and Maintenance Manual provided with the vehicle For effective emission control and low operating cost it is important that maintenance operations be performed at the specified periods or mileage intervals indicated in the Engine Operation
220. nd the orange marker can be seen protruding from the chamber when the brakes are applied the brakes require adjustment Slack adjusters should also be checked to ensure proper operation of the adjuster mechanism at every interval Push rod travel should be less than the maximum allowed stroke without brakes dragging Inspect brake linings every maintenance interval When brake shoes or pads are worn to within 1 16 inch 1 6 mm of rivets or backing plates as indicated by a line or other feature on the edge of most brake shoes or pads brake shoes or pads must be replaced This inspection or adjustment should only be performed by qualified service personnel and must be in accordance with instructions provided by the Service Manual NOTE Do not overlook the brakes on the trailer either Brake condition on a trailer is just as important as the tractor Proper brake balance on trucks and tractor trailers is essential for good braking At least once a year the entire 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 missing components etc 180 2 Condition of drums brake chambers and slack adjusters for wear corrosion maladjustment cracks missing components etc 3 For air leaks No air leakage is permissible Also check for air leaks with parking brake disengag
221. nd then not move unless vacuum line has a leak Leak in gauge Repeat above except close gauge connection airtight Engine airflow too low to generate a Turbocharged engines must be full load to pull full engine airflow restriction reading Air cleaner element split open Visually inspect element High Restriction Reading Heavy snow or rain Temporary high restriction can occur during a rain or snow storm it disappears after drying out If gauge is locked up at red zone check elements for damage Reset gauge Reuse element recheck gauge reading 3878859R2 191 Maintenance Instructions Charge Air Cooler And Radiator Core Inspection And Cleaning Inspection and Cleaning With the engine off visually inspect the charge air cooler core and radiator core assembly for debris and clogging of external fins Prior to engine operation remove any debris blocking the core The cores may be cleaned by externally backflushing them with compressed air and or water Use high pressure air or water Thexton radiator cleaning wand with 90 degree tip P N 4106 NAV available from you International dealer for best results Cooling System Coolant Level Check To prevent personal injury or death from hot coolant or steam use only the following procedure to remove the pressure cap from the radiator or expansion tank Allow the engine to cool first Wrap a thick heavy cloth around the cap Unscrew the cap slowly to allow pressure to rele
222. ne Operation and Maintenance Manual for proper oil viscosity choice Engine Performance Problems e Low engine power can be the result of a plugged fuel filter Fuel filters can plug prematurely due to the use of fuel that is contaminated with a high amount of sediment microbial growth or water Fuel that has been stored for longer periods of time may also reduce engine performance e Failure to maintain the vehicle as required in the Maintenance Instructions and Maintenance Intervals and Specifications sections of this manual as well as any separately available Engine Operation and Maintenance Manual can cause engine performance problems Too low of cetane number could cause hard starting and slower warmup and could increase engine noise and exhaust emissions 3878859R2 Fuel Ultra Low Sulfur Diesel Fuel Requirements Ultra Low Sulfur Diesel ULSD fuel is required for all on highway diesel 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 vehicle Unacceptable Fuel Blends Biodiesel blends having more than 5 percent pure biodiesel are not within ASTM D975 diesel specifications To determine acceptable biodiesel and biodiesel blends refer to the Engine Operator and Maintenance Manual for the applicable engine Hazards of Diesel Fuel Gasoline Blends Never add gasoline gaso
223. ng System MEMS ist ccigietert icant deere sti ads oo ey 202 INSPOCHOM vee See eet eo Rel ae en 202 boada e Ee ee rer errr errr rrrrrrr rrr rr rere rrr rere rere 203 Dual Tires Matching 0cceeeeeeeeeeeeeeeeeeeeeeees 203 Dual Tires MiXiING 0 ccceeeee eee eect eeeeeeeeeeees 203 Rotations i vsece eee EAE TEE TEPEE 203 Rotation Is Advisable cece cece eee eeee eee 203 Tire Replacement c eeeee cece eee deaketan 204 Wheel and Tire Balancing eeeeee eee e eee 204 WEIT arepe chun ui atau enna seh AGGA ARKAE ees 204 Irregular Weal 0 0 cc cceeeeeee eee ee ee eee eee e eee eanenees 205 Use of Tire Chains 00 ccc ceeeeee eee eee eee eaees 205 WheelSi istic vars eta ees eee ee habe Duna headed See 205 Wheel and Wheel Nut Maintenance and Installation 205 Wheel Nut Torque Maintenance 0ceeeee eee 206 Hub Piloted Wheel Installation Procedures 206 Transmission 0 cece eee eee eee e eee es 208 3878859R2 Section 8 Maintenance Intervals and Specifications Lubrication and Maintenance Intervals 005 209 Maintenance Intervals 62 eeeeeeeeeeeeeeeeees 209 Lubrication and Fluids Charts 0 cceeeeeee eee e eee es 217 Components Requiring Lubrication 218 Components Requiring Fluid Check and Fill 219 Unit Refill Capacities eesis viran ika KEEA EF
224. ng in an accident that could cause property damage personal injury or death NOTE The load rating of the tires installed on your vehicle at the time of your vehicle s production is at or in excess of the Gross Axle Weight Rating GAWR generally found on a label on the B pillar of your vehicle When replacing tires be sure that the replacement tire load rating listed separately in pounds and kilograms on the tire sidewall for single or dual applications multiplied by the number of tires on that axle is equal to or higher than the specific listed Steer Axle or Drive Axle GAWR Failure to do so will adversely affect maximum load carrying capacity Tires with the same size specification do not always have the same load specification Dual Tires Matching Dual tires should be matched using tires of equivalent size Tires which differ more than 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 3878859R2 Maintenance Instructions Dual Tires Mixing NOTE Never mix bias and radial tires on this vehicle It is recommended for best overall performance that only radial tires be used on this vehicle Never mix different tire sizes or constructions on the same axle Rotation e Steer tires that have developed some type of irregular wear pattern can be rotated to drive axles if rib tires are being used on all wheel positions Applying steer tires to a drive positio
225. ngaged position Applicable RR DIFF or FR DIFF ENGAGE indicator must be illuminated in the instrument panel gauge cluster to validate 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 reinsertion 3878859R2 Operation 3 Install right hand and left hand axle shafts as follows a Place gaskets on wheel hub studs b Push right hand axle shaft into wheel end and housing until shaft stops against differential shift collar c Push axle shaft further into housing until shaft stops against differential side gear d Push down on axle shaft flange and rotate shaft until splines of shaft and side gear are engaged e Push axle shaft completely into housing until axle shaft flange and gasket are flush against wheel hub f Install left hand axle shaft and gasket into wheel end 4 If tapered dowels are required install them at each stud and into flange of axle shaft Use a punch or drift and hammer if needed 5 Install fasteners and tighten to correct torque value Refer to the appropriate Service Manual Section Towing Vehicle With Rear Wheels Suspended To prevent damage to cab roof or air deflector when towing the vehicle backwards rear wheels suspended the air deflector must be removed 165 Operation Whenever possible it is preferable to tow a disabled vehicle from the
226. nge condition When the ignition switch is turned on the gauge indicators will be on If any indicator fails to go out after starting engine stop engine 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 50 Indicates the transmission lubricant temperature in degrees Fahrenheit F optional Indicates the engine lubricant temperature in degrees Fahrenheit F optional Indicates engine coolant temperature in degrees Fahrenheit F Indicates engine oil pressure in pounds per square inch PSI The tachometer indicates engine speed RPM The engine 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 The speedometer indicates the vehicle speed in miles per hour MPH and kilometers per hour Km h Indicates the approximate fuel level in the fuel tanks 3878859R2 Controls Features Indicates the battery voltage VOLTS Provides indication of air pressure when the ignition switch is in the ON available for the primary air brakes in position pounds per square inch PSI Provides indication of air pressure available for the secondary air brakes in pounds per square inch PSI 3878859R2 51 Controls Features Instrument Panel Gauge Cluster Alarms The instrument panel gauge cluster will sound an audible alarm
227. nit commands the appropriate modulator valve to adjust air pressure delivery to prevent wheel lockup ABS Self Check Bendix ABS Checkout A yellow warning indicator on the instrument panel indicates the antilock system status The indicator comes on and the system goes through an ABS self checkout sequence each time the ignition is turned on The system is working normally when ignition is turned on indicator comes on then flashes twice and remains on for several seconds before going out During the self checkout the modulator valves will cycle around the vehicle twice in the following pattern 1 Right Front 2 Left Front 3 Right Rear 4 Left Rear A fault has been detected in the ABS if the warning indicator does not come on with ignition does not flash fails to go off or comes on again at any other time If over braking causes wheel lockup on the rear drive axles while engine braking devices are in operation the ABS will interrupt and disable the engine brake until the lockup situation has stopped If the ABS warning indicator on the instrument panel is lit consult your nearest International Truck service center for further assistance in maintaining and repairing your ABS 3878859R2 Operation Antilock Driving Tips Brake just the way you always have Apply brakes as normal to stop in time The ABS monitors the brake application electronically and automatically controls the brakes much faster than a driver could
228. no advance warning Failure to observe these precautions could result in vehicle damage personal injury or death 3878859R2 If vehicle is equipped with an automatic transmission have a qualified technician regularly check operation of transmission neutral start switch If unit starts in gear the vehicle may inadvertently move which could result in property damage personal injury or death To be sure your vehicle is ready to operate conduct a pre trip inspection at the beginning of each work period This section gives the operator suggested guidelines to be used in performing tractor and trailer pre trip inspections Safety is the most important and obvious reason for doing a pre trip inspection Depending on the optional features of the vehicle being used and any possible aftermarket items installed on the vehicle these guidelines should be modified to include other necessary inspection points Follow the steps in this section and check them off to assure a proper vehicle inspection procedure The pages in this section may be reproduced locally and used on a regular basis If any component or system does not pass this inspection it must be corrected before operating the vehicle Take your time going through the pre trip inspection Remember that a careful pre trip inspection saves time by eliminating unscheduled stops to correct a faulty item Illustrations in this section identifies key locations of inspection items The illust
229. o the driver 3878859R2 JAW LOCK 8487226 Operation One indicator JAW LOCK has a green that illuminates f when the trailer is fully locked onto the fifth wheel L The other indicator JAW UNLOCK has a red that saw illuminates when the trailer is not fully locked onto the fifth wheel If neither indicator is illuminated this 887227 indicates the jaw is unlocked and the tractor is not connected to a trailer and is in Bobtail mode If the JAW UNLOCK indicator is flashing this indicates the jaw is locked and the trailer is not connected to the fifth wheel If both indicators are flashing this indicates a system error or failure Both indicators will illuminate briefly when the key is turned to the ON position as a check of function 169 Operation 170 3878859R2 Maintenance Instructions SECTION 7 MAINTENANCE INSTRUCTIONS Introduction If the owner operator of the vehicle is a skilled technician and intends to perform the vehicle maintenance and servicing he she is strongly urged to purchase and follow the appropriate International service manuals or Diamond ISIS CD ROM Ordering information is included at the back of this manual Failure to properly perform maintenance and servicing procedures could result in property damage personal injury or death Your vehicle has been engineered and manufactured to provide economical service However it is the owner s responsibility to see that
230. of turbocharger boost pressure in pounds per square inch PSI 8487058 82 Switches Up to 23 optional switches can be located in the center and lower right side of the center dash panel Location of these switches will vary depending on the options installed Blank cover plates will be used in spaces that do not have switches installed at those locations tem Ne tem Desin MIR HEAT ON A momentary switch that when pushed and released turns the mirror heating element ON OFF SLPR TEMP Controls the temperature in the sleeper compartment SLPR FAN Controls the on off and fan speed of the temperature control in the sleeper compartment ENG BRAKE 1 2 3 A three position switch that selects the amount of engine braking 1 Low 2 Medium 3 High 8487103 3878859R2 FOG LIGHT ON Turns on Fog Lamps when headlight switch is on and high beams are off OFF ROAD Bendix This switch enables and disables the ABS traction control feature MUD SNOW Wabco This switch enables and disables the ABS traction control feature FAN OVRD ON With the switch in the ON position the engine fan mode is switched from auto to the constant on PDL LOCK 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 ON PTO OFF 8487184 ON PTOA OFF 8487186 ON PTOB OFF 8
231. oid injury a decal is attached to the top on each side of the bumper to identify the location not to place hands when raising and lowering the tilt away bumper 19 Model Description Lowering the Tilt Away Bumper 20 P oO N Ges ee 8487027 Bumper Support Latch Hood Support Cables Tilt Away Bumper 1 Raise the hood to the fully upright position 2 While standing on the driver side of the Tilt Away bumper support the bumper with the left hand and release the bumper support latch with the right hand Walk around to the passenger side of the Tilt Away bumper 4 Support the Tilt Away bumper with the right hand and release the bumper support latch with the left hand 5 Grasp and slowly lower the Tilt Away bumper until it is supported by the support cables Raising the Tilt Away Bumper 1 While standing on the passenger side of the Tilt Away bumper lift the bumper with the right hand and secure the bumper using the support latch with the left hand 2 Walk to the driver side of the Tilt Away bumper 3 Secure the Tilt Away bumper using the support latch with the right hand 4 Lower and latch the hood 3878859R2 Luggage Box Access Driver and Passenger Side 8487024 NOTE Driver and passenger luggage boxes open in the same manner NOTE Luggage box doors automatically lock when closed Make sure you do not accidentally place and lock keys in the luggage box Open the luggage box door
232. on Fully and Maintenance Formulated Manual Coolant Transmission Transmission Mineral Gear Oil API GL 1 Rust and Oxidation Oil Inhibited Fleetrite P N 991061C1 Heavy Duty Engine Oil API CJ or Cl Synthetic Oil Emgard 2979 Synthetic Lubricant 3878859R2 Above 0 deg F 18 deg C 18 deg C 18 deg C 18 deg C Below 0 deg F Above 0 deg F Below 0 deg F All Temperatures 225 Maintenance Intervals and Specifications Component Vendor Lubrication Type Applicable Temperatures Rear Axle Rear Drive Mineral Oil Gear oil meeting MIL PRF 2105E 75W 40 F to 15 F 40 C to 26 C Axle s API Mete GL 5 75W 80 40 F to 80 F 40 C to 27 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 F and above 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and above 26 C and above 85W 140 10 F and above 12 C and above Synthetic Emgard 2837 and Emgard All Temperatures FE Synthetic Lubricant NOTE Do not mix conventional mineral bases lube with synthetic oil Terminals Fleetrite 472141 C1 Lubricant Sealing Grease Connectors NYOGEL 760 G Dielectric Grease 226 3878859R2 Maintenance Intervals and Specifications Torque Specifications U BOLT NUT TORQUE CHART Torque Feature Code Rear Suspension Capacity and Type 14SAN 23 500 Ib 10 659 kg Capacity RR Springs Single Vari Rate 260 3
233. on Solutions A WARNING This vehicle may be equipped from the factory with electrical switches intended to operate equipment that was installed by a truck equipment manufacturer TEM Instructions Cautions and Warnings for this additional equipment will NOT be found in this manual Read and understand the appropriate manual for the specific equipment in question before operating Failure to observe this warning may cause property damage personal injury or death NOTE This vehicle may be equipped with electronic application specific options not described in this Operator s Manual Many of these features are supplied with rocker switches that have custom labels applied The presence of these options as factory installed can be verified from the Line Set Ticket included with the vehicle A truck equipment manufacturer TEM however may have installed some of these options after production In that case they will not appear on the Line Set Ticket If installed by a TEM you should receive an operating guide and or training for the specific functions provided Familiarize yourself with all of the switches that control chassis engine and body equipment and seek adequate training on the function of all features before operating this vehicle 3878859R2 Model Description SECTION 2 MODEL DESCRIPTION Introduction 4 x 2 Day Cab with Full Aero Package The International ProStare Series Truck is available in two models the In
234. on dislocation and orientation and repaired or replaced as necessary Cooling System e Check fan for damage to blades Replace if damaged with manufacturers recommended parts Inspect for fan to shroud interference and any damage to shroud such as cracks and holes e Fan speed ratio should not be changed and fan spacer dimensions and position should not be altered e Inspect for proper operation of fan clutch making sure that the fan is disengaged when cooling of engine is not required 196 Engine Noise Shields Blankets e Engine valve covers oil pans and block covers are made to damp out engine mechanical noise and if needed should be replaced with original equipment parts Exhaust System e Inspect for leaks at various joint connections and tighten clamps Make visual inspection for cracks or holes in muffler and tailpipe Always replace with manufacturer s recommended parts Tailpipe elbow or offset tailpipe orientation must not be changed from standard position as originally received e To avoid abnormal changes in vehicle sound level it is necessary for the owner to perform inspections and necessary maintenance at the intervals shown in the maintenance schedules and record them on the inspection verification form provided Diesel Particulate Filter DPF Regeneration Collected soot particles in the Diesel Particulate Filter DPF are automatically burned off through normal regeneration initiated by no
235. on fuel economy 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 failing to meet the standards The following driver reward visual indications appear in the form of text messages in the gauge cluster digital display e Expected Reward indication which results in higher vehicle speed limits e Good Reward indication which results in higher vehicle speed limits 94 Excellent Reward indication which results in higher vehicle speed limits Penalty Penalty indication which results in lower vehicle speed limits Increasing Informs the driver that the vehicle speed limit will soon be increased Decreasing Informs the driver that the vehicle speed limit will soon be decreased 3878859R2 Sleeper Features SECTION 5 SLEEPER FEATURES Introduction Common features on the International ProStar Series 56 inch 142 cm short sleeper model General Information There are three trim versions of sleepers available the ProStare Series the ProStar Eagle Series and the ProStar Eagle Series Suite The International ProStar Series sleeper compartment comes in two sizes 56 inch 142 cm short sleepers and 73 inch 185 cm long sleepers Main Features The sleeper compartments are designed to accommodate 6 different needs and your sleeper may or may
236. onal ProStare 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 hair dryers etc can be used within the sleeper compartment Refer to the Power Inverter Manual for more information 3878859R2 Sleeper Features Power Sockets Several 120 volt AC power sockets for using electrical appliances within the sleeper are distributed throughout the sleeper compartment Speakers There are two standard coaxial speakers mounted on the rear wall of the sleeper compartment just above the lower bunk An optional 10 inch subwoofer speaker is available for the sleeper compartment along with an amplifier that mounts under the lower bunk driver side luggage compartment Floor Covering The standard floor covering for the International ProStaret Series sleeper compartment is a durable rubber mat with cushioned insulation under the rubber mat An optional carpet insert is available on select International ProStar Series sleeper models It can easily be removed for cleaning Sleeper Fan The optional sleeper compartment fan is mounted on the headliner just behind the passenger seat The sleeper fan is equipped with a push button switch for turning the fan on off and adjusting the fan speeds 115 Sleeper Features 116 3878859R2 Operation SECTION 6 OPERATION Operation Safety General Information Operation of a
237. ont bunk rail with your left hand The bunk area is designed for your head to be at the driver s side of the bunk Step up on the bottom step and place your 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 Release your right hand from the front edge of the airline cabinets and grasp the front bunk rail Step up on the top step with both feet and while keeping a firm grip with both hands on the front bunk rail swing your right hip over onto the upper bunk Release your left hand from the front bunk rail and grip the front edge of the upper bunk along side your left hip Swing your legs up and to the right positioning your body in the center of the upper bunk 107 Sleeper Features Exiting The Upper Bunk 108 a fF oO DN 8487417 Bottom Step Airline Cabinet Front Bunk Rail Top Step Upper Bunk While keeping a firm grip with both hands on the front edge of the upper bunk sit up on the upper bunk positioning your body above the top step and your legs over the front of the upper bunk Grab the front bunk rail with your right hand and the front edge of the upper bunk with your left hand Pivot your body to the left swinging your left leg down and placing your left foot on the top step 4 Release the front bunk rail with your right hand and grasp the front edge of the airline cabin
238. or cece cece e eee eee eee ees 111 Hot Weather Operation 0 cece eee cece ee ee eee ee eee ees 127 Hub Piloted Wheel Installation Procedures 206 HVAG Filterst ii si is EEEE cream women teams 174 Hydraulic Cutena aa E TTET 183 Hydraulic Clutch Actuation System cceeeee eee eee es 144 Hydraulic Clutch System 00 cceeeeee eee eee eee e ee neeeees 220 l INSPOCHION 3 2 scee sees eee attik ka r EREEREER ERRER ki 202 Inspection and Adjustment 0 ceeeee eee eee ee ee ees 179 Inspection and Cleaning ccceeeeeeeeeeeeeeeeeeeeeees 192 Inspection and Lubrication cc ceeeeee eee ees 176 177 Installation jc s2istei vee eee die eases babb renee didit ets ai 22 Installing Axle Shafts cece cece e cece eee eee eee ees 165 Instructions for Proper Maintenance e0eeee es 196 Instrument Panel Gauge Cluster eee cece eee e eee 46 Direct Drive Warning Indicators cece eee eee eee 54 GAUGES A E ANTEA EAA AAEE 50 Instrument Panel Gauge Cluster Alarms 0006 52 Integral Digital Display 00 ccc cece cess eee 54 General Text and Warning Messages 5 56 Integral Digital Display Detailed Information 62 Optional Instrument panel gauge cluster Compass Calibration PrOGOdUie aiin aanere AE A sends vistas poetics 57 Compass Declination Zone Set P
239. or any reason you do not feel you are receiving these services in connection with the operation of your vehicle or the sales transaction you should return to your selling dealer so that these matters can be corrected to your satisfaction If the matter is not resolved at that time it is suggested that the following steps be taken Contact a Member of Management at the Dealer Discuss the details of the difficulty In most instances any problem can be resolved to your satisfaction by the owner or manager in charge Foreword Contact Closest Navistar Inc Regional Sales Office Addresses of Regional Sales Offices are found in the front of this manual Should you desire to contact any of these offices it is important to include the following information in your communication e Name under which new vehicle was purchased address and telephone number of purchaser e Vehicle model year vehicle identification number component code and serial number e Vehicle delivery date and present mileage e Location where purchased e Details of the problem Component Code Numbers Code numbers are the basis for identifying the components used on International trucks They are used by sales personnel to order the truck by manufacturing to build that truck and by parts personnel to service the truck Many items in this manual are identified by codes Code numbers are a combination of numbers and or letters These codes are listed on t
240. or is in Neutral e Refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS for information on transmission fluids and fluid change intervals 208 3878859R2 Maintenance Intervals and Specifications SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS Lubrication and Maintenance Intervals All new vehicles are factory lubricated Once the vehicle is in operation regular lubrication and maintenance intervals based on the type of service and road conditions must be established and performed Load weight vehicle speed road conditions and weather conditions all contribute to lubrication frequency Performing thorough lubrication and maintenance at the specified intervals will ensure an outstanding vehicle life and will reduce overall operating expense The LUBRICATION AND MAINTENANCE INTERVAL CHART contains an extensive list of components and systems Listed items and systems must be regularly inspected serviced and or replaced to maximize vehicle availability and minimize unexpected failures Recommended synchronized intervals are shown for each item This chart can serve as a convenient one stop reference to research most maintenance needs Only lubricants of superior quality such as Fleetrite lubricants should be used The use of inferior products will reduce the service life of the vehicle or result in failure of its components International Truck recommends the use of Fleetrite lubricants for optimum perfor
241. or when the sheet metal is hot to the touch This will streak the finish DO NOT wipe dirt off dry surfaces as this will scratch the finish NOTE When vehicles are stored outside particularly in coastal areas salt water and high humidity atmosphere or other areas of corrosive environment paint and bright metal may require frequent washing and waxing to prevent deterioration Determining washing frequency is the customers responsibility NOTE For vehicles exposed to ultraviolet rays of the sun apply a coating of Bon Ami soap or similar product to the inside surfaces of the windshield and windows to shade the interior and prevent fading of the interior trim 2 Inspect painted surfaces touch up all exposed primed or raw metal areas to prevent rust 3 a thick coat of wax to prevent discoloration from the elements wax all chrome and stainless steel metal parts 4 Check the radiator coolant for proper level and adequate freeze protection 20 F 29 C is standard for medium duty models and bus chassis 40 F 40 C is standard for heavy duty models Cover open ends of vertical exhaust stack s Drain air brake reservoirs and close the drain cocks 7 Lubricate all exposed transmission auxiliary transmission and PTO shift rails 3878859R2 Foreword 8 Check state of charge eye in batteries and re charge if open circuit voltage is below 12 6 volts Disconnect battery ground cables to prevent accidental starting
242. ost common applications Custom Service Contracts are designed to meet your individual needs HOW TO OBTAIN International Truck Warranties Standard Warranty Your new International vehicle is automatically registered in the International Truck Warranty system at the time of delivery No further action on your part is required Optional Service Contracts Custom Service Contracts or Performance PM Service These programs are sold exclusively through your International dealer The vehicle must also have coverage remaining under the Standard Warranty For extended warranty purchases between 181 through 365 days from DTU and lt 100 000 miles 160 000 km an additional fee will be assessed If you would like the predictable cost of ownership and peace of mind provided by the International Truck Warranty Program please contact your International dealer today 3878859R2 Index SECTION 10 INDEX A ABS Connections and Sensors 000eeeeeeeeeee eens 182 ABS Operatie rra AEE eae ee eva aavebine scan EA a eds 158 ABS Self Check cncscacsvetdetitedetmoet idderddveered i 159 Accent Light Dimmer Switch cece cece eens 99 Accent Light SWitch 0 cccceeeeee eee eee ee eee nena anes 99 Accent EIME ao a AEAEE EEO ARRARIR 97 Accessory Feed Connections csscssccereereereerreree 186 Additional Unsafe Practices cseececeereereere eren 137 Adjustable Belts s c ic00 eves sven CEEI KE
243. ounting bolts or worn bushings 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 for proper security damage and chafing Listen for audible air leaks 39 Inspection Guide Fifth Wheel and Coupling Area 1 Sliding 5th Wheel if equipped Check for loose or missing pins in the slide mechanism If air powered check for air leaks Make sure that 5th wheel is not so far forward that tractor frame or mud flaps will strike trailer landing gear during turns 40 Lubrication Make sure that top surface face of the 5th wheel has a coat of grease Mounting Bolts and Release Handle Look for loose or missing mounting brackets clamps bolts or nuts All locking pins must be in place and free of damage Ensure that release handle is in the engaged position and the safety latch is functioning and free of damage Deck Plate and Access Steps Check to ensure that the deck plate and steps are clean securely bolted in place and clear of loose objects Trailer Coupling Cords Inspect air lines and electrical cord for cuts chafing damage and proper security Check air lines for audible air leaks Work Light s Check operation and clean as needed 3878859R2 Cab Interior Inspection 1 Safety Emergency Equipment Prior to entering cab verify that vehicle is equipped wi
244. ow type hubcaps is from the minimum line to 5 16 inch 8 cm above the minimum line If the lubricant level suddenly drops dramatically below the minimum level see the Service Manual for diagnostic procedure Alignment Maintaining front axle alignment is very important to achieving maximum tire life and vehicle control Inspecting steer axle tires in the first 3 000 4828 km to 10 000 16 094 km service miles will generally show if tires are wearing normally 3878859R2 Maintenance Instructions e Rapid outside shoulder wear on both tires indicates too much toe in e Rapid inside shoulder wear on both tires indicates too much toe out e Excessive wear on the inside or outside of one steer tire but not the other can indicate a toe in or toe out condition coupled with a misaligned front or rear axle e Pulling to the right or left can indicate misalignment of the front or rear axle unequal tire pressures or a damaged mismatched tire Refer to the Tires subsection for additional related information Rear Axle Inspection and Lubrication Check to make sure that the rear axle mounting U bolts attaching or mounting bolts and nuts are securely tightened Loose or misaligned rear axles will affect vehicle alignment tire wear and handling Refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS for torque specifications Check the rear axle oil level Proper oil level minimizes gear wear heat and damage to the whe
245. p Both wheels must be raised free of the ground should it be necessary to operate one wheel with the vehicle stationary otherwise the wheel that is not raised will pull the vehicle off its support possibly resulting in personal injury or death A WARNING To prevent vehicle damage personal injury or death pay strict attention to the following Care should be taken to prevent sudden accelerations when both drive wheels are on a slippery surface This could cause both drive wheels to spin and allow the vehicle to slide sideways resulting in loss of vehicle control 3878859R2 Tandem Axle Power Divider Lock PDL Control Do not operate the vehicle with the PDL engaged on dry pavement 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 inter axle differential action when backing under a trailer with a tractor starting on a slippery surface poor traction operating off highway in mud etc poor traction or when traveling on slippery highways poor traction Failure to lock the power divider under these conditions may result in power divider failures and costly repairs If you encounter wheel spin conditions the PDL switch should be moved to the LOCK position Engage the PDL only when stopped or moving at low speed Never try to engage the PDL while the wheels are spinning as this ma
246. p 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 GAL B PTO TRP L A PTO TRP LB 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 3878859R2 65 Controls Features Engine PTO Trip Fuel Used The display value shall be the calculated Engine PTO Trip Fuel Used Display Format 100 000 0 ENG PTO TRP GAL ENG PTO TRP L Trip Idle Fuel 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 approximate value of Axle Load for the front and or rear axles NOTE Axle load readings are most accurate on a level surface with parking brake released Display Format approx 45 0 FT LBSX1000 FT KGX1000 RR LBSX1000 RR KGX1000 66 3878859R2 Controls Features Diesel Particulate Filter Level The instrument panel gauge cluster shall display the relative Diesel Particulate Filter DPF Level The instrument panel gauge cluster displays the following graph DPF z k 8487412 With L low on the left and H high on the right the graph is shown by bars each representing a 10 percent increase decrease in soot level The instrument panel gauge cluster displays the last received
247. pass display will go blank or have dashed lines present 3817052 1 Press and hold the display control knob until the End Calibration command is displayed End NOTE IF the End Calibration command will not show up turn OFF the vehicle restart it Calibration x 3 and return to Step 1 3817051 NOTE The following steps 4 through 6 must be completed within 3 minutes to lock in the new calibration Do not press the display control knob or turn the key OFF until these steps are completed or the calibration process will be cancelled 60 3878859R2 3878859R2 Stop the vehicle and wait shortly The End Calibration message should reappear on the display Push and HOLD the display control knob until the End Calibration command disappears The calibration should now be complete IMPORTANT Just pressing and failing to hold the display control knob inward until the End Calibration command disappears will cancel the calibration procedure and you must start over at Step 1 Test the compass calibration Turn the vehicle ignition key OFF and then restart the vehicle Wait 10 seconds to for the compass to complete its self test Drive the vehicle in acircle and note the compass readings If the lower left quadrant of the Instrument Panel Gauge Cluster Display shows the correct compass vehicle heading the compass calibration is now complete If the compass readings are incorrect inspect for correct Declination Zone number turn OFF the vehicle re
248. pection Guide 1 Lights and Reflectors Check to see that reflectors and lights are clean Make sure none are missing or broken Rear running 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 flaps Inspect rear mud flaps and mountings for damage and proper security Air Lines and Wiring Check air Lines and electrical wiring for proper security and for damage and chafing Listen for audible air leaks 37 Inspection Guide Left Rear of Tractor 38 8487031 If wheels or tires must be changed obtain expert tire service help Mounting and demounting of tires should only be performed by qualified personnel using necessary safety procedures and equipment otherwise the result could be property damage personal injury or death Brake Chamber and Hoses Check for cracked worn or frayed hoses and for 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 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 between push rod and adjuster arm should be approximately 90 degrees when brakes are applied Brake Lining and Drum With brakes released chec
249. perated In the event of a vehicle accident or sudden unexpected movement failure to properly use an occupant restraint system could result in personal injury or death WARNING Always use the ashtray s provided for disposing of cigar cigarette or pipe ashes and tobacco Failure to use an ashtray is a fire hazard and could result in property damage personal injury or death 117 Operation WARNING When parking your vehicle do not leave transmission in gear Always use parking brake When parking on a grade chock wheels and turn front wheels to keep the vehicle from rolling into the traveled portion of the roadway Failure to follow these procedures could cause an unattended vehicle to move resulting in property damage personal injury or death Exhaust gases from engines contain hazardous compounds Do not operate engines in enclosed areas without abundant forced ventilation with garage doors and windows wide open Maintain exhaust system in good operating condition Breathing exhaust gases could result in personal injury or death This section contains information concerning the safe operation of your vehicle It is extremely important that this information is read and understood before the vehicle is operated Cab Controls The cab controls and features are described in detail in the Controls Features section of this manual Read and understand the entire Controls Features section of this manual before o
250. perating this vehicle 118 Seat Belts General Information WARNING To prevent personal injury 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 properly adjusted WARNING Failure to properly inspect and maintain seat belts could result in personal injury or death WARNING Any seat belt in use during an accident must be replaced When replacement of any part of the seat belt is required the entire belt must be replaced both retractor and buckle sides Belt failure could result in personal injury or death NOTE Periodically inspect the seat belts for wear and function Replace any parts whose performance is in doubt 3878859R2 General Information Safety belts must be worn by the driver and all passengers at all times Before adjusting or fastening the safety belt move the seat forward or backward and adjust the seat height as necessary Sit erect and adjust 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 installed on all suspension type seats Tether straps help secure the seat to the floor and are intended to restrain the seat and safety belt in case of an accident or sudden stop The tethers are not adjustable and do not
251. personal injury or death Hood Raising the Hood A a Hood Hood Latch Cowl Hood Handle Hood Restraining Shock 3878859R2 To prevent personal injury or death never put any part of your body beneath a raised hood unless the hood is all the way forward in its range of motion and is fully settled in the over center position To prevent damage to the windshield wipers return them to their normal position before opening or closing hood Follow this procedure to prevent damage to the hood and or painted surfaces NOTE To avoid pinching do not lift or lower the hood from the side 1 Before opening the hood make sure that there is enough room in front of the vehicle for the hood to open completely without pinning or pinching yourself between the hood and any other structures Release the latches on both sides of the cowl With both feet firmly on the ground grasp the hood handle and pull the hood forward over center and allow it to settle into the raised position Make certain that the hood restraining shock is fully extended before releasing hood 3878859R2 Model Description Lowering the Hood 1 3 Make sure that the hood has no tools parts or people in its path of motion Place both hands on the top edge of the grille and push the hood backward over center and allow it to settle into lowered position Engage hood latches at both sides of cowl Tilt Away Bumper 8487225 To av
252. play accurate headings NOTE When calibrating recalibrating the compass you must select the Declination Zone which corresponds to the geographic location where the compass calibration is being performed It can be reset later to match the Declination zone where the vehicle will be operating For vehicles that regularly operate coast to coast or in several different Declination Zones either choose a Declination Zone in the geographic center of the vehicle s operating area or change the Declination Zone daily to match the present Declination Zone To begin the Declination Zone set procedure the vehicle must be stopped with ignition key ON Refer to Zone Map for determining the proper Declination Zone number 57 y m F P A A a Z ZZ eee L TA AAA _ aera ar SSS e i z ET EE T sae TAT f N E P A C eee E pmo z N Z gf POLE ery 12 cE A LE lt a _ A AA Fit ol amp i 5 i X E T 5 a A 3 1 Ea En a Ea 3878859R2 Controls Features Select Quadrant 2 lower right on the display by turning the display control knob either clockwise or counterclockwise Select the Compass Declination message by pressing and releasing the display control knob until this message appears Compass Declination 3817053 Press and hold the display control knob until any Declination Zone number 0 10 is 3817054 Turn the display control knob clockwise o
253. ptions Refer to the chart on rear side of fuse cover NOTE Do not use lubrication on dry threads Where excessive corrosion exists a light coat of lubricant on the first three threads of stud is permitted Keep lubricant away from nut and rim clamp contact surfaces 228 3878859R2 Maintenance Intervals and Specifications Typical Interior Fuse Panel Layout F3 D F5 D O Crs sw F8 D CFs Fio 0 wiper ien JQNITION The AER SEE NOTE 4 LIGHT an mA ol Sa ECU arel m 2 arrg F3 C rse 0O O ree F5 L o rec Q Fa 6 Fio c Q O OO Cs me OO eer m aner jiii PN OPEN ACERS water 5 Fa A FS A 10 Ge Ges FO A Cree k Fio A JENE F2 D F2 H F4 D F4 H F4 M F7 D F7 H F9 D F9 H TRAILER tenition a 00 ban FUEL TRAILER OU INTERNATIONAL oO RST RELAY 1 HEATER STOP ENGINE zc Fes F4 C O ree ree F7 C Cee F c Fe 6 0O res rF 0O re O0 O rer F4a K F768 0O O AF O res For S O rex Fae O ra D D ee F4a J PU center PIN Fa O OF Dee O rex FO E le fel fel fl j jej je LOCATION Ame STD70PT DESCRIPTION LOCATION AMP STO O
254. r counterclockwise until the desired Declination Zone number is displayed Refer to Declination Zone Map to determine the proper Dec Zone 6 number for the current geographic location l 3817055 NOTE If no Declination Zone number is selected within 15 seconds the display will return to the Compass Declination message NOTE If the compass is being calibrated recalibrated the Declination Zone must be set to the Zone number for the location where the compass calibration recalibration is being performed regardless of the location where the vehicle will eventually operate Press and HOLD the display control knob until the Compass Declination message appears this indicates that the new Declination Zone number has been programmed Compass into the compass Declination 3817053 59 Controls Features Compass Directional Calibration Procedure To begin the Compass Directional Calibration Procedure stop the vehicle in an area large enough to permit driving in complete circles and perform the following steps Select Quadrant 2 lower right on the instrument panel gauge cluster display by turning the display control knob either clockwise or counterclockwise Select the Calibrate Compass message by pressing and releasing the display control knob until this message appears Calibrate Compass 3817050 Immediately following the End Calibration command being displayed drive the vehicle in 3 complete circles during this time the com
255. r ees rr ERESSE 101 Power Sockets cee eee cece eee eeeeeeeeeeeeeeeeeeeees 115 Power Steering 0cccceee cece PEREIRA AREIRES TEIR AA 199 Power Steering SyStEMS 0 cceeeeee eee eee eee e ee eaaes 220 Power Take off Control ccceeee eee eee ee eee eeeeeanaees 148 Preface ceccecevdveeiiieavies ces eeeeeind teeter eeeea ed sede es 1 Premium Display ies ss cicinie oases rnEeE EEE AIAN AEEA coder 89 Pr paration tsscceccesceceaccuagetrreciessadee ry enmmnmedddddanieat 24 ProStare Series Light Information 2 0eeees 231 Purge Vales ierta dened dicted SSUES SEPARERE NERS 181 Q Quadrant 1 Informational Displays 05 62 Quadrant 2 Text and Warning Messages 0eeeeee 67 3878859R2 Q CONT Quadrant 3 Display MessageS eee cece ene e ees 74 Quadrant 4 Transmission Gear Displays 5 75 R Radio Remote Control 0 ceeeeeeee eee eee eee ee eee 101 Raising the HOOd ccc eeeeeee eee eee eee eeeeeeeee teens 18 Raising the Tilt Away Bumpet cceeeeeeeeeeeeeeeee 20 Reading Liga eere aon nnannanersaaaagaeninaddauaaanins 97 Rear Air Ride SUSPENSION cceeeee eee ete e eee e eee ees 150 Rear Air Suspension Air DUMDP cece eee e eee 150 Rear Axle cacou Anese eusi sees of CUERO VAAKA RRE Rate eee 177 Inspection and Lubrication eeeeee eee
256. rations herein are typical and may not represent all engine applications 23 Inspection Guide Tractor Inspection Exterior Lights Check Perform an automatic check of all exterior lights by doing the following steps Preparation NOTE Perform the following procedures prior to conducting the pre trip inspection 1 Place the ignition key in the ON or ACC position place the transmission in neutral and apply the parking brake f 2 Pressing the WORK LIGHT switch for approximately two e Apply parking brakes seconds before releasing will activate this feature e Turn on parking lights and hazard lights 3 The exterior light check will now cycle all vehicle lights e Unhook the hood latches raise the hood unlatch and lower except the back up light s The test flashes the exterior the tilt away bumper lights on and off in three two second cycles The first f two second period illuminates park lights clearance e Check under the vehicle for oil fuel coolant leaks or other identification side marker and license plate lights signs of damage turn signal lights low beam headlights fog lights e Use pull cables or open drain cocks to allow air tanks to expel The second two second period illuminates park lights any existing water Release pull cables or close drain cocks clearance identification side marker and license plate a lights high beam headlights brake lights work lights Chock wheels on tractor and trailer if at
257. rear suspension should be regularly inspected for loose worn or broken components Rear suspensions axles should be checked periodically for proper alignment to promote maximum tire life The optional International Truck Ride Optimized Suspension IROS components including air bags height control valves air lines and fittings should be inspected for wear damage and audible air leaks Steering General Information Always follow recommended procedures for steering system maintenance Failure to maintain the steering system in proper condition can cause reduced steering ability resulting in property damage personal injury or death 198 Have a technician examine the steering mechanism Minor adjustments could head off further problems Check tie rod ends drag link ends and king pins Joints and fasteners must be tight Articulating joints must be well lubricated Check for installation and spread of cotter pins and tightness of nuts at both ends of tie rod and 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 column joint bolts and steering linkage particularly for body to chassis clearance NOTE Have any steering problems corrected at once by a qualified service technician Tightening Steering Intermediate Shaft Joint Bolts As a good maintenance practice i
258. remove the axle shafts before the vehicle is towed Do not use a chisel or wedge to loosen axle shafts and dowels The chisel or wedge can damage hub axle shafts and oil seals if used NOTE One of the axle shafts has two sets of splines One set to engage with differential side gear and one set to engage with shift collar for the differential lock It may be necessary to rotate shaft slightly to align side gear spline teeth with clutch collar teeth in order to remove axle shaft 1 Shift main differential to the locked engaged position Applicable RR DIFF or FR DIFF ENGAGE indicator must be illuminated in instrument panel gauge cluster to validate 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 reinsertion 2 Remove cap screws and washers or stud nuts and washers from flanges of both axle shafts 3878859R2 3 Loosen tapered dowels in flanges of both axle shafts by holding a 1 1 2 inch diameter brass drift or hammer against axle shaft center and hitting it with a five to six pound hammer 4 Remove tapered dowels and both axle shafts from axle assembly 5 Assemble a cover over openings of both wheel ends to prevent loss of lubricant and keep dirt from the wheel bearing cavities Installing Axle Shafts 1 Remove covers from wheel ends 2 Shift differential lock to the locked e
259. result in property damage personal injury or death 3878859R2 The Eaton VORAD Collision Warning System may provide little or no warning for some hazards such as pedestrians animals oncoming vehicles and cross traffic Failure to heed this warning could result in property damage personal injury or death System Description The Eaton VORAD system uses forward looking radar and optional side looking radar to constantly monitor vehicles ahead and in the blind spot area respectively The Vorad Collision Warning System determines the distance and relative speed of the object in front of the vehicle to warn the driver of potentially dangerous situations through visual and audible alerts The SmartCruise feature works with the vehicle s cruise control system to attempt to automatically maintain a fixed following distance between the host vehicle and a vehicle ahead The Side Object Detection system can detect moving or stationary objects in the lane next to the vehicle and alert the driver of their presence Visual and audible alerts are provided by the Driver Interface Unit located in the dash panel where it is easily visible and accessible Refer to the Driver Instruction manual for complete operating instructions Driver Reward The driver reward feature is designed to give the operator programmable incentives for driving more efficiently This 93 Controls Features is accomplished by measuring the drivers habits based
260. resulting in personal injury or death 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 wear fraying or weak spots The retractor latch and buckle should be checked for proper function and all seat belt mounting bolts should be tight at all times 3878859R2 Seats General Information WARNING Do not adjust drivers seat while vehicle is moving The seat could suddenly or unexpectedly move causing the driver to lose control of vehicle which could result in property damage personal injury or death A WARNING Reckless operation of this vehicle over rough roads or surfaces can cause loss of vehicle control and result in property damage personal injury or death 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 conditions as the seat may move up and decrease the available space There are several seat options that can be used in the International ProStar Series vehicle If a different seat assembly than the one listed below is installed in your vehicle see your authorized International Truck Dealer The air suspension seats for the driver and passenger are equipped with features that adjust for maximum comfort and safety Depending on which models are insta
261. rmal exhaust heat during the normal operation of the vehicle If conditions for normal regeneration cannot be achieved it may be necessary to perform a parked regeneration as indicated by the instrument panel gauge cluster warning indicators See the Parked Regeneration Procedure in SECTION 6 OPERATION 3878859R2 Cleaning If on vehicle regeneration is unsuccessful at removing soot from the DPF the DPF may need to be removed from the vehicle and be cleaned with the appropriate machinery and processes Ash residue in the DPF comes primarily from fuel and oil additives and will not burn or pass through the DPF Ash residue accumulates very slowly in the DPF but must eventually be removed to prevent excessive exhaust backpressure If the DPF needs to have nonregenerable soot or the ash residue removed please take the vehicle to an International dealer Drive Shafts At the regular lubrication interval check universal joints slip joints slip joint boot and carrier bearings for any evidence of wear or looseness Should drive shaft vibrations occur stop the vehicle immediately to avoid possible hazardous consequences or damage to other components Suspension Air and Steel Springs Do not adjust air suspension height to any setting other than the specified setting Altering the height setting will change the driveline angle and may result in unwarrantable component damage such as transmission component damage Verify drive
262. rn on ignition without starting the vehicle This opens the electrically actuated LTR coolant flow valve Fully open cab heater coolant shut off valves and coolant system vent valve Remove fill cap and pour a 50 50 mixture 75 25 if it has been flushed with water of the proper Nitrite Free Shell Rotella Ultra Extended Life Coolant coolant concentrate and demineralized or distilled water into the de aeration tank A 50 50 coolant mixture will achieve a 34 F 37 C freeze point A 53 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 Because the radiator fills slowly it is important to continue to top off the system for two minutes following the initial fill Close coolant system vent valve start the engine and continue to add enough coolant to keep the coolant level between the COLD MIN and COLD MAX levels marked on the deaeration tank Replace the deaeration tank cap tightly after adding make up coolant for two minutes Run engine at governed speed until engine fan has fully engaged for 5 minutes Do not exceed 220 F 104 C Let engine completely cool Re check coolant level and concentration freeze point with a refractometer and top off as needed to achieve a coolant level at the COLD MAX line when cold 193 Maintenance Instructions Coolant and Optional Coolant Filter The cooling system in vehicles with MaxxForce 11 13 and 1
263. rning indicator out of range reading illuminates Forward Rear Axle oil temperature gauge 5 BEEPS Instrument panel gauge cluster warning indicator out of range reading illuminates 52 3878859R2 Controls Features Alarm Conditions Audible Alarm Pattern Additional Comments Auxiliary air pressure gauge out of range 5 BEEPS Instrument panel gauge cluster warning indicator reading illuminates Gauge sensor faults 3 BEEPS Gauge pointer goes to 6 o clock position and gauge warning indicator illuminates Primary Air Pressure gauge out of range and REPEATING SINGLE BEEP Instrument panel gauge cluster warning indicator air pressure sensor fault illuminates Secondary Air Pressure gauge out of range REPEATING SINGLE BEEP Instrument panel gauge cluster warning indicator and air pressure sensor fault illuminates Red warning indicator illuminates REPEATING SINGLE BEEP Indicates what module is requesting the red stop indicator Electrical system fault 10 BEEPS Electrical system fault illuminates Turn Signal Alarm Optional CONTINUOUS TONE Alarm sounds if either turn signal is on for more than one mile Will not activate when hazard flashers are on Headlight Warning Alarm 5 BEEPS Sounds one time immediately after ignition switch is turned to OFF position when headlight switch is on and the drivers door is closed REPEATING SINGLE BEEP Sounds when headlight switch is on ignition switch is in OFF psition and the drivers door is
264. rocedure 57 Compass Directional Calibration Procedure 60 SWINCHOS cence ride sah msada Laeger tee e lE N EEE ia siaaanes 75 Courtesy Lights 0 0 cece cece ee ee eee eeeeeeeeeeeees 76 Daytime Running Lights DRL cc ceeeeee eee ees 75 241 Index CONT Instrument Panel Gauge Cluster cont Dome Lighting 0c cece eee EAE EAT ASE 76 HeadlightS i 3 enra Stake ees 444 40 coaccccaaesapee pean ENSS 75 Lights On With Wipers 0 cece eee eee eee 75 Panel Liginde nauraa tt k Vaawemeta re deeadsges 75 Park LIONS errr iasdseds aranana hhh ihe tounnnn A 75 Warning Indicators cc cece EISSES ESETET 48 Instrument Panel Gauge Cluster Alarms 005 52 Integral Digital Display ce cece e eee e eee eee ees 54 General Text and Warning Messag s ee eee 56 Integral Digital Display Detailed Information 62 Outside Temperature and Compass Displays Optional 74 Outside Temperature Reading cece eee eee eee 74 Quadrant 1 Informational Displays eeee 62 Quadrant 2 Text and Warning Messages 67 Quadrant 3 Display Messag s 0 0eeeeee eee ee 74 Quadrant 4 Transmission Gear Displays 75 Warning Messages 22 cee eeeeeee eee e ee eee eeeenaaaees 74 International Truck Warranty Program
265. ructions Air Induction System To prevent personal injury or death when performing maintenance and repairs to any turbocharged engine with engine air inlet piping disconnected a turbocharger compressor air inlet protective shield should be installed over the turbocharger air inlet Once each year perform a complete inspection of the air induction system In areas where road salt is used the inspection consists of disassembling the joints of each metal component and inspecting for salt build up that can cause particles to flake off and enter the engine combustion chambers If evidence of corrosion is found usually appears at the pipe connections use a wire brush to clean the inside of the pipes and inside of the rubber hoses If the intake pipes are pitted at the joint ends use RTV Silicone to seal the joints Be certain that no excess material that can be pulled into the engine is on the inside of the pipe If the service condition of the pipes hoses or clamps is questionable replace those parts e Check for loose hoses and clamps e Check for ruptured bulging or collapsed hoses e Check air cleaner housing for cracks 187 Maintenance Instructions Air Restriction Gauge The air restriction gauge indicates how much engine air cleaner filter capacity has been used and how much filter capacity remains It measures maximum restriction of the filter element when the engine is operated at full load and locks at that point
266. rve energy and deliver sufficient power to start the engine The system is active when the engine is not running regardless of key state The ELCS system does not include provisions for shutting down 120VAC circuits The ELCS will begin a sequence of events when the measured battery voltage is at or below 12 1VDC for a period of 30 seconds The sequence of events will first start with providing the visual alert Load Shedding to the vehicle operator for at least 30 seconds An audible alert which consists of a continuous tone greater than 3 seconds and less than 6 seconds in duration will coincide with the start of the visual alert The audible alert can be disabled by a vehicle maintainer if desired The sequence will then disable a predefined group 132 of features electrical loads These will remain disabled until the vehicle s key switch transitions to the Accessory or ON positions and the measured voltage is above 12 1VDC Engine The engine for this vehicle is an electronically controlled diesel engine A separate ECM electronic control module monitors and controls all engine functions This ECM also communicates with the body electrical system which will generate or activate the necessary warning indicators to alert the driver of out of range operating conditions For complete information on the engine in this vehicle and it s optional features refer to the Engine Operation and Maintenance Manual supplied with thi
267. s e Only personnel that have had proper training and experience should mount or remove tires from rims or wheels e Use only heavy duty rims or approved rims for radial tires It may be necessary to contact your wheel and rim distributor to determine if your rims are approved for radial tires e If a tube is to be used make sure special radial tire tubes are used because of the increased flexing of the sidewalls on radial tires e Never use antifreeze silicones or petroleum based lubricants when mounting radial tires Only an approved lubricant should be used as an aid for mounting tires e Always inflate tires in a safety cage 205 Maintenance Instructions 206 Do not mix stud piloted wheels or fasteners with hub piloted wheels or fasteners Premature wheel failure can result in property damage personal injury or death Do not mix foreign not made in North America wheel mounting parts with domestic made in North America parts Many foreign wheel components look similar to but are not exactly the same as domestic made components Mixing components can cause wheel or fastener failures and result in property damage personal injury or death Do not change from aluminum wheels to steel wheels or vice versa without changing the mounting hardware In some cases with flange nut mounting systems changing the hub and stud assembly may be required Mixing components could cause wheel or fastener failures and result
268. s Cold Weather cs vis saesacncntceraeseidesamassnongee eens eeeeds General Information cccceeeeee eee eeeeeeeeenee Cold Weather Starting 2 cc ceeeeeeee eee eee eee Cold Weather Operation ccceeeeeeeeeeeeeeee Engine laing aiioe es oy icaceaseehente shied gates Engine Idle Shutdown Timer Optional Winter Front Usage 22 cece eee eee eeee eee teen eens Hot Weather Operation cccceeee eee eee eee eaees Operating Instructions 0 0 ceeee eee eee eee eee ened General Information cccceeeee eee eeeeeeeeennee DIOSTING eap AE AAEN KENES cagceegueee ea pee enoeese Adjustable Steering Column ceeeeee eee teens General Information cc cceeeeeeeeeeeeeeeeeenee Electrical en a aa ct istanciisenat eats uve TEA AOAO ea ee errr Ge reee eth ennbnenegbnes Battery E N siatin die aa oP eae E AEEA BATTERY ON Indicator 0 cece eee eee eee es Engine Brake cccceeeee eee eee eee eee LENTERA SA MaxxForce 11 13 and 15 Engine Brake With Eaton AutoShift UltraShift Transmissions Special Driver Instructions 6 eeee eee eee MaxxForce Engine Features Certified Clean Idle cece eee eee eee Self Diagnostics cece cece cece eee eee eens Air Compressor Cycling ccceeceeeeeeeeee eee e eters Cooling SysteM cece eee eee eee Engine O
269. s It may be necessary to contact your wheel and rim distributor to determine if your rims are approved for radial tires If a tube is to be used make sure special radial tire tubes are used because of the increased flexing of the sidewalls on radial tires Never use antifreeze silicones or petroleum based lubricants when mounting radial tires Only an approved lubricant should be used as an aid for mounting tires Always inflate tires in a safety cage 3878859R2 e Do not mix stud piloted wheels or fasteners with hub piloted wheels or fasteners Premature wheel failure can result in property damage personal injury or death e Do not change from steel wheels or a steel inner and aluminum outer wheel combination to aluminum wheels without changing the mounting hardware since the thicker aluminum wheels require longer studs In some cases with flange nut mounting systems changing the hub and stud assembly may be required Improperly mixing components could cause wheel or fastener failures and result in property damage personal injury or death Do not mount tube type tires on tubeless wheels or tubeless tires on tube type wheels To do so could result in tire or wheel failure and cause property damage personal injury or death Tire Maintenance Preserving proper inflation pressure is a very important maintenance practice to ensure safe vehicle operation and long life for the tires Failure to maintain correct inflation
270. s Two large drawers are provided for storage Magazine Pocket Provides a storage area for books magazines and maps Dresser Cabinet The dresser cabinet is available on select International ProStarg Series long sleeper models and is located behind the passenger s seat Small Drawer One small drawer is provided at the top of the dresser cabinet for storage Work Table Pull out work table Important A release latch is located on the right hand work table guide to allow the table to be stowed To close simply depress the release latch and slide the work table shut Tower Wardrobe Cabinet w ae D oH 3 8487140 Tower Wardrobe The tower wardrobe cabinet is available on select International ProStare Series long sleeper models and is located behind the drivers seat The tower wardrobe cabinet provides hanging clothes storage When equipped with the upper bunk option the tower wardrobe cabinet provides steps for access to the upper bunk Magazine Pocket Provides a storage area for books magazines and maps 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 3878859R2 Sleeper Features 4 Lift Release Handle The optional door is equipped Rear Wardrobe Cabinet with a lift release handle To open the door lift the handle from the front and open the door To close push the door shut until the l
271. s are operating under normal alarm when ignition is on parking brake TEMP conditions and exhaust gases are at is released and seat belt is not fastened L oeno Moh emperaire s Notused S f i e a ee e f OC S indicator Illuminates Yellow Solid i E or Flashing to indicate the need to 20 PTO llluminates Yellow when the PTO regenerate the Diesel Particulate Filter 8487082 function if installed is activated See Exhaust Regen in the Vehicle 21 Iluminates Yellow when an antilock Operation Section s brake system malfunction has been 5 Engine Emissions Control System wont oo detected If the ABS indicator stays Malfunction Indicator Lamp MIL illuminated or continues to flash have ol the system serviced immediately 3813053 llluminates Yellow when an emissions problem has occurred i a a E E l 23 Flashes Green when the left turn signal lt a or the hazard lights are turned on 8487092 3878859R2 49 Controls Features 8487094 8487093 Iluminates Blue when the high beam head lamps are turned on Flashes Green when the right turn signal or the hazard lights are turned on NOTE If the MIL is illuminated it is the vehicle owners responsibility to have the engine repaired or face fines Gauges There are 10 gauges in the instrument panel gauge cluster to help monitor the vehicle while in service Most gauges have in gauge warning indicators which turn on if the gauge pointer moves into an out of acceptable ra
272. s may cause vehicle malfunction that could result in property damage personal injury or death Cab Structure Check body panels such as doors fairings air shield and cab extenders for signs of breaks or damage Check condition of cab mounting brackets and tilt hood latches Fuel Tank Check to see that the fuel tank and cap are secured and make sure there is no damage or leaks at the tank or fuel lines Eaton VORAD sensor if equipped Check for damage and proper mounting Ensure sensor s view is clear of mud dirt ice or any material or objects 33 Inspection Guide Right Side Under Vehicle 34 A WARNING Maintain adequate clearance between all parts of the exhaust system and all hoses wires and lines for engine cooling brake system fuel system power steering system and electrical system Heat damage to hoses wires or lines may cause vehicle malfunction that could result in property damage personal injury or death Drive Shaft Ensure that all shaft couplings are secure Exhaust System Check to see that all component parts are securely mounted and no cracks holes or severe dents are visible Evidence of soot build up around clamps or connections is a clear indicator of a leak being present Ensure that all hoses wires and air lines are secured away from exhaust components Transmission Inspect for leaks Frame Check for cracks or bends in frame Make sure there are no loose cracked bent broke
273. s that the power inverter is in standby mode and the batteries are being charged Fault Indicator Light This light is used to notify the operator that a fault exists with the power inverter A solid red light indicates the power inverter is in Over Temperature Overload or Battery Low Mode No light indicates that no fault exists For more information on the remote power inverter panel refer to the Power Inverter Manual 101 Sleeper Features Windows General Information Make sure windows are closed before washing the cab Water can enter the cab through the window opening 1 Sleeper Window 2 Handle 2 a N j 8487131 102 The sleeper compartment is equipped with a window on each side that can be opened for ventilation e Lift the handle to open the window e Lower the handle to close and lock the window Optional privacy curtains are provided to cover the sleeper windows To install the curtains place the curtain over the window and secure the curtain loops to the window frame When not in use store the curtains in one of the storage compartments 3878859R2 Bunk Restraint System Always use occupant restraint system when vehicle is moving Any location in the vehicle not equipped with a seat belt bunk restraint belts or sleeper berth restraint webbing should not be occupied when the vehicle is being operated In the event of a vehicle accident or sudden unexpected movement failure to properly
274. s vehicle NOTE For information pertaining to fuel and requirements refer to the Engine Operation and Maintenance Manual provided with the vehicle Charge Air Cooler All MaxxForce engines are equipped with a charge air cooling system The function of the charge air cooler is to cool the hot compressed air before it enters the engine s intake manifold This system uses ambient air as the cooling medium by allowing the intake air to pass through a network of heat exchanging fins and tubes prior to entering the combustion 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 3878859R2 Electronic Engine Controller Each vehicle contains an Engine Operation and Maintenance Manual in the drivers door pocket Refer to the Engine Operation and Maintenance Manual for detailed information on these engine control systems Do not use the engine brake on slippery road surfaces Doing so may cause wheel slippage and or loss of vehicle control which could result in property damage personal injury or death Engine Brake NOTE The engine brake should never be considered a substitute for the vehicle service brakes The service brakes should always be viewed as the primary vehicle braking system The engine brake cannot bring the vehicle to a complete stop Only the service brakes can bring the vehicle to a complete stop ENG
275. sholds for coolant temperature engine coolant level and or low engine oil pressure are exceeded 134 e Engine Shutdown System this system shuts down the engine after 30 seconds of operation beyond critical threshold values for coolant temperature and or oil pressure e Throttle Control for PTO Operation e Road Speed Limiting Governor programmable maximum speed e Idle Shutdown Timer shuts down engine after 5 minutes of idle time Certified Clean Idle MaxxForce 11 13 and 15 engines have been designed to meet the new California Air Resources Board CARB idle reduction standards by generating less than 30 g hr NOx emissions when idling These engines can be identified by the Certified Clean Idle decal located on the left side of the hood or driver door Self Diagnostics All MaxxForce engine operating parameter Warning Indicators are located on the instrument panel gauge cluster When the ignition switch is turned ON the Engine Warning 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 vehicle needs service When the warning indicator is illuminated a Diagnostic Trouble Code DTC will be generated Take the vehicle to a service center as soon as possible as some optional features and or engine power may be lost while the indicator is lit 3878859R2 Operation Air
276. should be between 1 25 and 1 75 inch 32 mm and 44 mm and the release bearing should contact the clutch brake with 1 2 to 1 inch 13 mm to 25 mm of clutch pedal travel remaining Free pedal and clutch brake should be adjusted by lengthening increases free pedal and decreases clutch brake squeeze or shortening decreases free pedal and increases clutch brake squeeze the horizontal rod if outside of this specification Contact your International Truck dealer for proper linkage adjustment procedures NOTE Proper clutch and linkage adjustment will provide adequate clearance between the release yoke fingers and the release bearing as well as between the release bearing and the clutch brake for proper operation Improper adjustment may cause improper clutch operation reduce clutch life and may void the clutch warranty Clutch cross shafts and throw out bearings must be lubricated each time the vehicle chassis is lubricated to ensure smooth clutch activation and long life 3878859R2 Maintenance Instructions All new International ProStar vehicles use non asbestos clutch linings However exposure to excessive amounts of clutch material dust whether asbestos or non asbestos fiberglass mineral wool aramid ceramic or carbon is a potentially serious health hazard To prevent personal injury or death prevent breathing clutch lining fiber dust Always wear a respirator when doing clutch lining maintenance Persons who handle
277. sition lights will switch to Hi Beam position When pulled again they will revert to Lo Beam 79 Controls Features Headlight Flash To Pass When the turn signal lever is pulled with the headlights OFF the Hi Beam lights will come on and stay on as long as 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 When the Hi Beam headlights are ON the Lo Beam lights can be made to flash if the lever is not lifted past the click or dimmer position 80 7 Washer Wiper Control The windshield washer along with the windshield wipers is controlled by the WASHER WIPER knob on the turn signal switch lever To operate the windshield washer push in on the wiper knob to spray solution on the windshield Wipers will start wiping and continue for two cycles 3878859R2 Controls Features Center Dash Panel Wing Panel 3878859R2 81 Controls Features Gauges There are four optional gauges in the instrument panel gauge cluster of the center dash panel to help monitor the vehicle while in service J Provides reading of brake application air pressure in pounds per square inch PSI Provides monitoring of temperature of forward rear axle lubricant in degrees Fahrenheit F Provides monitoring of temperature of rear rear axle lubricant in degrees Fahrenheit F Provides reading
278. smissions eeeeeeeeeeee cette teens 142 Power Take off Control 0 cceeee cece eee e eee e eens 148 Troubleshooting cece eee eee eee e NEI EAEEREN Sd 191 High Restriction Reading Table eee 191 No Restriction Reading Table 2 cc ceeeeee eee ees 191 Two Position Regeneration Inhibit Switch 142 Typical Interior Fuse Panel Layout 22 2eeeeeeeee 229 Typical Luggage Compartment Fuse Panel Layout 230 U U Bolt Nut Torque Chart cc ceceeeeeee cece ee eeeeeeeeees 227 U S Registered Vehicles cc cceeeeeeeeeeeeeeeeeeeeaeee 5 Ultra Low Sulfur Diesel Fuel Requirements 137 UN HOOK AA E E I EE 168 Unacceptable Fuel Blends 0ccceeeeeeeee eens 137 248 U CONT Underintlationy lt sssscnsrkeaxees EEEE 201 Unit Refill Capacities 0 cece cece eect eee eeeees 220 Cooling System Refill Capacities cece eee 220 Crankcase and Oil Filters cece eeeeeeee eee 220 Hydraulic Clutch System cceeeeeeeeeee eee 220 Power Steering Systems eceeeeee eee eee 220 Rear Axle Unit Refill Capacities 00 cece cece eee eee 222 Unlocking the DOor cece eee cece cece tenet eee e eect teens 91 Upholstery Care ss TEENETE AARAA eee eeteeeeeeeeees 182 Upper Bunk cc cece eee eee t
279. ss to the luggage compartments can be Compartment achieved from the interior with the lower bunk in the raised position 105 Sleeper Features Sleeper Allows air to enter sleeper HVAC unit Do not HVAC block HVAC air intake Intake Sleeper Replaceable cleanable filter cleans air and HVAC Air protects heat exchanger from becoming Intake Filter plugged with lint and debris Upper Bunk General Information The optional upper bunk is hinged and can be raised and locked 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 to the upper bunk is provided by steps that are attached to the driver side tower cabinet 106 pes fll J ORK 8487416 1 Release Latch 2 Upper Bunk Frame 3 Upper Bunk NOTE The sleeper compartment is equipped with a dome light to aid entry and exit into the upper bunk The dome light on off switches are located on the dash instrument panel and on the sleeper control panel 3878859R2 Sleeper Features Entering The Upper Bunk 8487417 Bottom Step 2 Airline Cabinet 3 Front Bunk Rail 4 Top Step 5 Upper Bunk 3878859R2 Begin by facing the bottom step placing your right foot on the bottom step and grasp the front edge of the airline cabinet with your right hand and grasp the fr
280. ssing parts Check for cracked worn or frayed hoses and for secure couplings 3878859R2 10 11 Inspection Guide 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 between push rod and adjuster arm should be approximately 90 degrees when brakes are applied 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 6mm or contaminated by lubricant Frame Check for cracks or bends in frame Make sure there are no loose cracked bent broken or missing crossmembers or crossmember fasteners 31 Inspection Guide Right Engine Compartment 32 A WARNING To prevent personal injury or death from hot coolant or steam use only the following procedure to remove the pressure cap from the radiator or expansion tank Allow the engine to cool first Wrap a thick heavy cloth around the cap Unscrew the cap slowly to allow pressure to release from under the cap After the pressure has been released the pressure cap may be removed 1 Coolant Level Do not remove pressure cap unless coolant is cool Ensure fluid level is between the minimum and maximum fluid level range as marked on the plastic translucent reservoir 2 Radiator and Charge Air Cooler Check for loose mounting and damage Inspect condition of al
281. start the vehicle wait 10 seconds and perform another circle while periodically noting the compass readings If readings are still incorrect restart the compass calibration procedure Controls Features End Calibration 3817051 3817056 61 Controls Features Integral Digital Display Detailed Information Quadrant 1 Informational Displays NOTE The available display screens are dependant on the configuration of the vehicle Odometer The odometer displays the total distance traveled 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 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 engine is running NOTE This display function cannot be reset Display Format 100 000 0 HOURS 62 3878859R2 Quadrant 1 Display Messages Trip Hours Machine PTO A or B Hours Machine Trip PTO A or B Hours Engine PTO Hours 3878859R2 Controls Features The Trip Hour display provides a record of elapsed engine hours since the last reset NOTE The trip hours and trip miles are independently reset Display Format 100 000 0 TRIP HOURS This display will provide a record of the total accumulated Machine PTO hours
282. t or hijacking can be crucial to the safety and security of the country and economy While no system or device is 100 percent effective our intention is to provide some tips that you or your drivers can use to reduce the risk of theft If you suspect vehicle theft activity take a minute to tell the National Insurance Crime Bureau NICB at 1 800 TEL NICB You can make the free call anonymously and you might be eligible for a reward To learn more about vehicle theft and how you can protect yourself visit the NICB s Web site www nicb org Add Layers of Protection Four layers of protection are recommended for your vehicle the more layers of protection on your vehicle the more difficult it is to steal Layer 1 Common Sense e Lock your doors e Remove your keys from the ignition e Close your windows completely e Park in well lit areas e Drop a business card with your name on it between the glass and doorframe This can aid in identifying the truck when it s recovered e Keep a copy of the lineset ticket in a location other than your truck for reporting purposes and a copy of the VIN in your wallet e Photograph the interior and exterior of your truck from various angles and keep these photographs in a safe nontruck location or send them to your insurance agent e Report a theft as soon as it s discovered to the local police and to your insurance company e Post a driver has no cash sign on your door to discourag
283. t is recommended that steering intermediate shaft joint bolts be checked for tightness every 120 000 miles 193 000 km or annually whichever occurs first 3878859R2 Lubrication Points NOTICE Grease 3 zerks per Operators Manual lt lt Lower amp Upper U Joint gt lt Slip Joint 8487171 The steering shaft is lubricated at the three points shown in the illustration above For the correct maintenance interval refer to SECTION 8 MAINTENANCE INTERVALS AND SPECIFICATIONS Power Steering Whenever the power steering system has been drained and refilled for any reason air must be bled from the system before returning the vehicle to service Failure to properly bleed the hydraulic system can result in degradation of power system performance Consult your International Truck dealer who is aware of the proper procedures for filling and bleeding the system 3878859R2 Maintenance Instructions The power steering fluid filter is located inside the power steering reservoir To remove the filter unscrew the large cap on the power steering reservoir and unscrew the filter Reverse the procedure to install the new filter With time the large square cut reservoir cap O ring seal may shrink slightly To assist in reinstallation of the cap the O ring may need to be stretched To stretch the O ring pull on it while pinching it between your thumb and finger It must be large enough to stay completely in th
284. table Important A release latch is located on the right hand work table guide to allow the table to be stowed To close simply depress the release latch and slide the work table shut Horizontal Refrigerator 12 3 4 5 8487418 An optional horizontal refrigerator is available on select International ProStar Series sleeper models and is located under the lower bunk k Control Knob Thermostat Power Indicator Drawer Refrigerator Cabinet a fF oO DN Lift Release Handle 3878859R2 Sleeper Features Dresser Cabinet 8 _ rE 8487137 1 Dresser Top The top of the dresser cabinet serves as a desk top 2 Release Knob A release knob is used to open the work table To open depress the knob the knob will extend from the work table then pull the work table open To close the work table depress the tab along the left side of the work table and slide the work table shut Once the work table is closed the knob needs to be pressed in to a flush position with the work table this prevents the knob from getting hung on your clothing and other items as you move around in the sleeper compartment 111 Sleeper Features 112 Lift Release Handle All drawers are equipped with lift release handles To open the drawers lift the handle from the bottom and slide the drawer open To close push the drawer shut until the lift release handle locks the drawer shut Large Drawer
285. tached The third two second period turns off all lights This e Start the engine and allow the air pressure to build up to cycle repeats until deactivated by the operator normal operating pressure of 115 to 130 psi 793 to 896 4 Walk around vehicle and inspect illumination of lights kPa Stop engine To cancel this feature do one of the following either press the brake pedal manually turn on any external light turn the key to OFF or release the parking brake The feature will automatically cancel approximately 10 minutes after activation if not deactivated by the operator 6 Checking the backup lights requires two people and 24 the engine running Depress the clutch if applicable and select reverse while the second person observes backup light operation 3878859R2 Left Side Cab Area 4 5 8487001 NOTE If the vehicle is equipped with side skirts it will be necessary to remove the left rear skirt to gain access to the battery box 3878859R2 Inspection Guide Inspection Items 1 Cab Structure Check body panels such as doors fairings air shield sunshade and cab extenders for signs of breaks or damage Check condition of cab mounting brackets and tilt hood latches Wipers Check windshield wiper arms for proper spring tension and wiper blades for damage Windshield Check for damage to windshield an
286. tarting System Test 185 Terminal Inspection Cleaning Corrosion Protection 185 Accessory Feed Connections seeeeeeee eee 186 Fuses and RelayS eeceeeeeeeeee iar eaa 186 EDOMO 2 sevens TEERAA ed deu eid EREKE REAA 186 vi General Information ccceeeee eee ee eee e eens 186 Engine fluids and contaminated material 187 Scheduled Maintenance cceeeeeeeee eee eens 187 Air Induction System cc cece seen eee e eee e eee 187 Air Restriction Gauge cece cece eee e eee e eee e eens 188 Air Cleaner Element Service 189 Troubleshooting istre erra ra EEE KAASAR 191 Charge Air Cooler And Radiator Core Inspection And Cleanings iiusts eari aK tended CE ERARA 192 Inspection and Cleaning eee cece eee eee ees 192 Cooling System ee aA E eee eens 192 Coolant Level Check cece eee eee ee eeeeennee 192 Filling Instructions 00 c cece cece eee eee eee eee eens 192 Coolant and Optional Coolant Filter 5 194 Coolant Concentration Freeze Point cee eee 194 AntitreeZei eae sea EPERERA AE E UE ee 194 Fan CIVIC eree aanne r E EI AARAA 194 Fuel Syste n e anaa eee AASS EF 195 Fuel Tank Draining and Cleaning eee es 195 Crankcase Ventilation Filter 195 FMO eaa rne TEE AAE ARE ESN mood adda ee 195 Noise Emissions Exterior eeeee cece eee e ne
287. te Install the nut on the release stud Be sure tang on release stud stays engaged with slot on pressure plate while installing the nut Tighten the nut with a wrench to compress the spring Parking Brake Reset Charge spring brake chambers with air pressure Loosen nut and remove the release stud and nut from the spring housing and re install the access plug in the chamber opening Re install the release stud and nut in the carrying pocket on the brake chamber housing Parking Brake Alarm If the parking brake alarm sounds horn continuously blows when driver s door is opened press the service brake pedal Then after turning the ignition switch to the ON or ACC position make sure that the parking brake is set For a more detailed description of the alarm see the Parking Brake Alarm in the Electrical section above Air Dryer The function of the air dryer is to collect and remove moisture and contaminants before the compressed air reaches the air 3878859R2 Operation reservoirs This protects the air system components from malfunctioning including blockage corrosion and freezing For air tank draining requirements 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 dryer includes a replaceable desiccant cartridge and oil blocking filter that is periodically serviced It also may inclu
288. ternational ProStare Series International ProStare Eagle Series This operators manual covers all versions Illustrations in this manual are used for reference only and may differ slightly from the actual vehicle However key components addressed in the manual are represented as accurately as possible Models covered are shown on the following pages Available Models 4 x 2 Day Cab 8487011 8487012 3878859R2 9 Model Description 6 x 4 Day Cab with Full Aero Package 8487013 Sn ee EP D TO J E mE A lt y 8487014 10 4 x 2 Short Sleeper 56 Inch with Full Aero Package 8487425 See a ey y Vay S She 8487015 3878859R2 Model Description 6 x 4 Short Sleeper 56 Inch with Full Aero Package 4 x 2 Long Sleeper 73 Inch with Full Aero Package 8487431 WAY 8487178 3878859R2 11 Model Description 6 x 4 Long Sleeper 73 Inch with Full Aero Package 12 8487432 Vehicle Identification Vehicle Identification Number VIN NAVISTAR INC WARRENVILLE ILLINOIS NAVISTAR VIN MODEL S3HSDLSMT4BN338110 PROSTAR 125 6x4 DATE MFG W B PD LOC DATE 01 2010 550 LILI MADE IN MEXICO 8487437 The Vehicle Identification Number VIN is located on the driver side door The VIN and model description are necessary when ordering replacement parts or service manuals Feature Cod
289. th the optional Electronic Vehicle Monitoring Driver Information Display DID 202 the DID will act as the user interface and the round SmartWave display is not provided Refer to the Driver Information Display operator reference card supplied in the vehicle for product information Inspection Check condition of tires for abnormal wear patterns and proper inflation pressures Cut or broken tire casings must be repaired or replaced Tires should be inspected for the following conditions If any are present the tire should be removed and repaired retreaded or scrapped as the condition indicates e Any blister bump or raised portion anywhere on the surface of the tire tread or sidewall other than a bump made by a repair These indicate the start of internal separation e Any cut that reaches to the belt or ply cords or any cut that is large enough to grow in size and depth e Any nail or puncturing object e If any stone or object is held by a tread groove and is starting to drill into the tread base remove the object Proper tire inflation toe in adjustment loads and road speeds are important factors governing tire life steering ease maneuverability fuel economy and ride quality 3878859R2 Loads Loading tires beyond their rated capacity decreases tire life requiring more frequent replacement of tires Overloading creates an unsafe condition that may result in sudden air loss from a tire failure resulti
290. th the proper equipment Walk around vehicle and check that all steps and grab handles inside and out as well as behind are tight and clean Use extreme caution and maintain 3 point contact at all times Doors Check door latches for positive closing latching and locking Clutch Gearshift Depress clutch pedal if present and verify transmission is in neutral before turning on starter keep depressed until engine reaches idling speed and vehicle in neutral Oil Pressure Builds Check to see that oil pressure is building to a normal level Engine oil pressure gauge should begin a gradual rise to normal operating range Low Air Alarm The low air pressure alarm may sound immediately after the engine starts but before the air compressor has built up minimum 55 psi 379 kPa pressure The low air pressure alarm should stop when the air pressure reaches 60 to 76 psi 414 to 524 kPa Let the air pressure build to governor cut out pressure which should occur between 115 and 130 psi 793 and 896 kPa Accelerator Depress accelerator pedal and verify that it operates smoothly without any binding or irregular feel Remove foot from accelerator and make sure engine returns to idle immediately 3878859R2 10 Inspection Guide Voltmeter Check the gauge to see if the alternator is charging between 12 5 and 14 5 volts Steering Play Check for smooth operation Check for excessive looseness in the steering linkages The steering w
291. that accompanies out of range gauge readings along with the particular gauge warning indicators The instrument panel WARNING gauge cluster alarms will also sound when any engine sensor sender unit fails when there is an electronics system fault and when the red engine indicator is illuminated The following chart lists the number of alarm beeps for the above conditions or warning states When an alarm sounds stop normal vehicle operation and determine the source of the alarm condition Failure to observe this instruction could result in property damage personal injury or death Alarm Conditions Audible Alarm Pattern Additional Comments Fuel level gauge low only alarms on each 5 BEEPS Instrument panel gauge cluster warning indicator ignition turn on illuminates Voltmeter gauge out of range reading 5 BEEPS Instrument panel gauge cluster warning indicator illuminates Engine oil pressure gauge out of range 5 BEEPS Instrument panel gauge cluster warning indicator reading illuminates Engine oil temperature gauge out of range 5 BEEPS Instrument panel gauge cluster warning indicator reading illuminates Engine coolant temperature gauge 5 BEEPS Instrument panel gauge cluster warning indicator out of range reading illuminates Transmission oil temperature gauge 5 BEEPS Instrument panel gauge cluster warning indicator out of range reading illuminates Rear Rear Axle oil temperature gauge 5 BEEPS Instrument panel gauge cluster wa
292. the air suspension for proper operating ride height The SUSP DUMP switch will operate the IROS system only if the ignition switch is in either ACC or ON positions 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 last set by the SUSP DUMP switch NOTE The suspension will dump when the ignition switch is in the either ACC or ON position but will only fill when the ignition switch is in the ON position NOTE The SUSP DUMP switch functions will be inhibited by either a Traction Control or ABS event In either event for either SUSP or DUMP operation the ASD switch will have to be manually recycled after the event has passed in order to complete the operation 3878859R2 Operation NOTE The electrical system will automatically switch from DUMP to SUSP if the vehicle speed exceeds 5 mph 8 km h Once this occurs the only means to deflate the suspension will be to slow the vehicle to 5 mph and recycle the SUSP DUMP switch to the DUMP position Air Suspension System Faults e The instrument panel gauge cluster will issue an audible 10 beep alarm whenever the driver pushes the DUMP position of the SUSP DUMP switch and the vehicle exceeds 5 mph 8 km h e The SUSP DUMP switch indicator will blink rapidly in the event of a system component failure or a bad system signal status when the S
293. the cab area Press the left button to lower the temperature and the right button to raise the temperature 3 Display Allows the operator to view the settings for fan speed and air temperature as they are being adjusted NOTE The temperature display is a representation of the current temperature set point not actual sleeper temperature 3878859R2 Power Receptacle A 12 Volt power socket is located to the right of the sleeper climate controls This power source provides a location to operate accessories 8487129 Radio Remote Control The radio remote control gives the operator the ability to operate the dash mounted radio from the sleeper compartment For more information on the radio remote control refer to the Radio Manual 3878859R2 Sleeper Features Remote Power Inverter Panel This optional feature allows the operator to control the power inverter if equipped Suen O from the sleeper compartment The Beras OER power Standy o Sal Barge Faut O inverter converts 12 Volt DC compartment 1 2 72 os 3 current to 120 Volt AC current for running fysen system the electrical features in the sleeper tia 1 ON OFF Buttons Press the System ON button to turn the power inverter on and press the System OFF button to turn the power inverter off 8487130 Power Indicator Light The power inverter light will be illuminated green when the power inverter is powered on A blinking green light indicate
294. the control for more than 3 seconds to reset the value of the selected 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 between English and Metric by pressing and holding the control Item No O Quadrant Number and Message Function Message Description 44 Quadrant 4 Transmission Gear Indication Transmission gears for the Allison P R N D L gear selection display or the Eaton Transmission display 54 3878859R2 Controls Features item No Quadrant Number and Message Function Message Description Quadrant 1 Informational 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 Instantaneous Fuel Economy Trip Average Fuel Economy Machine PTO Fuel Used A or B Machine PTO Trip Fuel Used A or B Engine PTO Fuel Used Engine PTO Trip Fuel Used Trip Idle Fuel Used Axle Load Indication Front and or Rear Diesel Particulate Filter Level Quadrant 2 General Text and Warning Displays a variety of messages ranging in priority necessary for vehicle Messages monitoring and operation and vehicle malfunction warnings Some messages are used in conjunction with instrument panel gauge cluster warning indicators see list of messages in the Integral Digital Display
295. the loaded vehicle Operate in a gear that will permit an engine speed below the Maximum Governed Speed or High Idle RPM no load 129 Operation Electrical Alternator Improper usage of fast charger hook up of booster battery or installing battery can cause damage to the electrical system or to the Battery Keep lighted tobacco flames sparks or other ignition sources away from the batteries Gas from the battery cells is flammable and can ignite and or explode This is particularly true when jumper cables are being used Battery fires or explosions could cause personal injury including severe injury to the face eyes limbs and body alternator Many alternators used in International Truck vehicles are of the self energizing type Some engines may need to be briefly revved after starting to turn on the alternator The alternator will 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 In addition inhaling the hydrogen gas produced by the normal operation of the battery could result in partial or permanent damage to the respiratory system which may result in death Whenever disconnecting battery terminals always disconnect ground terminal first When reconnecting always connect ground terminal last Failure to follow this procedure could result in a short to ground and cause property dam
296. the vehicle receives proper care and maintenance to assure high performance Quality International service parts are available through your International Truck Dealer If International service parts are not used the owner must make sure that the parts used are equivalent 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 result in the vehicle not working properly which in turn may result in personal injury or damage to the vehicle or its equipment If you have any question 3878859R2 about performing some service consult your International Truck dealer or have the service done by a skilled technician Maintenance Guidelines WARNING i Failure to perform proper maintenance and service could result in property damage personal injury or death WARNING Making modifications to any part component or system of the vehicle can adversely affect the quality and reliability of your vehicle and must be prevented Modifications to systems could result in property damage personal injury or death WARNING Use only genuine International truck service parts The use of inferior parts can adversely affect the quality and reliability of your vehicle which could result in property damage personal injury or death 171 Maintenance Instructions 172 WARNING
297. they are fully seated Cab Care of Vehicle Washing and Waxing Frequent and regular washing will lengthen the life of your new vehicle s painted finish and bright metal trim Wash your vehicle often with warm or cold water to remove dirt and preserve the original luster of the paint Never wash the vehicle in the direct rays of the hot sun or when the sheet metal is hot to the touch as this may cause streaks on the finish Do not use hot water or strong soaps or detergents as this may etch the paint or exposed metal bright surfaces Do not wipe off dirt when the surface is dry as this will scratch the paint or exposed metal bright surfaces Always make sure that steps and grab handles are clean and free of road grime grease ice and other debris Prior to using any wax or polish the vehicle must be thoroughly washed to avoid scratching the finish Bright Metal Care To preserve the bright look of your vehicle s trim grilles bumpers etc use only mild detergents and lukewarm water 182 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 s chemical compounds become However if high pressure washing equipment and washing compounds are used satisfactory results can be achieved if the solution has a pH value between 4 and 8 and the temperature does not exceed 160 F 71
298. tor 2 cece Er NEE EAAS ERR 30 Right Rear of Tractor cceee cece e eee eeeeeeeeeees 35 Right Side of Cab 00 cece eee eee ceeee eee ee ee ee REE 33 Right Side Under Vehicle 6 cc cee eeeeeeeee eee ees 34 Tractor Trailer Connections ccc cece eee eee eee 166 Connecting Disconnecting a Trailer to a Vehicle with Air DUSPONSION aa eaa ie deere eee dara es 166 Fifth Wheel Operation cece eee 166 247 Index T CONT Tractor Trailer Connections cont Fifth Wheel Jaw Monitoring seee eee e eee eee ees 169 Fifth Wheel Jaw Unlock Control ccee eee eee ee 168 Fifth Wheel Slide Switch Optional 25 167 HOOKUP es uroaren ihar see edeeaeg a seaweeds hl dd iaeeae g 167 UinsOOk E E E E ev A tanta eeaaesec tet 168 Trailer Air Supply and Parking Brake Modular Controls 156 Trailer Brake Hand Control 0 cceeeeeeeeee eee e eens 155 Trans missio Ma ahea un Ean A a A NSN Gane 142 208 Clutch Brake irrar n ERA E TEER EAEEREN ETA 148 Clutch Precautions rrisni rutes IUIN KAER OKER AASS 145 Double Clutch Procedures sccsccsecsesersereereerre 145 Eaton AutoShift Transmissions Optional 146 Eaton UltraShift Transmissions Optional 148 Engaging the Clutch cece eee eee eens 143 Hydraulic Clutch Actuation System cess eee 144 Manual Tran
299. trol Unit ECU to control either four or six wheels of a vehicle ECUs optimize slip between the tire and the road surface by monitoring individual wheel turning motion during braking Roll Stability Functions The control system RSP or RSC helps to mitigate rollovers through advanced sensing engine torque control and automatic application of the vehicle brakes RSP is an all axle ABS solution that helps reduce vehicle speed by applying all vehicle brakes as needed reducing the tendency to roll over RSC is a rear axle ABS solution that helps reduce vehicle speed by applying rear vehicle brakes as needed reducing the tendency to roll over RSP or RSC focuses on reducing the vehicle s speed below the critical roll threshold during direction changing maneuvers 3878859R2 Operation such as at exit ramps lane changing cornering or obstacle avoidance It is most effective on dry high friction surfaces Advanced Stability Functions ESP This function enhances stability by sensing actual vehicle dynamics ESP equipped vehicles add yaw control to the basic roll stability feature Vehicle Stability Control Speed Reduction In the case of a potential roll event the stability system will remove the throttle and quickly apply brake pressure to slow the vehicle combination below the threshold Steering Angle Sensor ESP only This sensor enables the advanced stability system to capture the drivers steering input and intervene if
300. trols allow the operator to adjust the temperature and amount of air circulated through the sleeper compartment 8487127 1 Fan Control Turns the fan on and off and controls the fan speeds NOTE Fan speed will be limited to approximately 50 of maximum when the engine is not running 2 Temperature Control Use the temperature control to regulate the temperature of the air inside the sleeper compartment This temperature is independent of the cab area The blue area indicates cooler temperatures and the red area indicates warmer temperatures 100 Electronic Climate Controller NOTE If sleeper air conditioning is desired and the main cab blower is not enabled the air conditioner will not function and the message Activate Front Blower will appear on the instrument panel gauge cluster The electronic climate controller provides 1 easy adjustments of the sleepers heating DE buttons and air conditioning system by using the C lt e gt 1 Fan Control Buttons Pressing the L l left button repeatedly will lower the fan abl oe speed to minimum then turn the fan OFF Pressing the right button turns the fan ON if currently off then raises the fan speed 2 gis to maximum NOTE Fan speed will be limited to approximately 50 of maximum when the engine is not running 2 Temperature Control Buttons Use these buttons to regulate the temperature of the air inside the sleeper compartment independent of
301. uccessive brake applications and release sometimes referred to as fanning or pumping the pedal should be avoided This is an inefficient way of slowing or stopping a vehicle and inefficient use of air pressure It also defeats the proper operation of the ABS Parking Brake Under no circumstances should the spring brake section of the spring and service brake chamber be disassembled Disassembly will release a powerful spring which could result in property damage personal injury or death All vehicles with air brakes are equipped with spring brake chambers for parking The parking system is operated manually by a single valve which in the case of a tractor also controls the parking system on the trailer The purpose of this brake is to hold the vehicle in a parked position The parking brake should not be used to brake the vehicle during normal driving To apply the parking brake pull out control knob To release the parking brake push in the control knob It should be noted that upon loss of air pressure in both primary and secondary systems partial spring brake application will occur prior to full automatic application of the parking brake control valve at 20 to 45 psi 138 to 310 kPa 154 To release the parking brake after a low pressure occurrence recharge system to at least 70 psi 483 kPa and push in the parking brake control If the system cannot be recharged and the vehicle must be moved the spring brake must be
302. uide Tires Check tread depth tire inflation and note if tread is evenly worn Minimum tread depth is 2 32 inch on all drive tires Look for cuts or other damage to the tread sidewalls See if valve caps and stems are missing broken or damaged Check dual spacing to ensure that dual wheels are evenly separated and that tires are not touching one another Hub Check for obvious leaking on outside 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 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 10 Torque Rods and Shock Absorbers Check to see that torque rods are not cracked broken or missing Check shock absorbers for cracks or leaks There should be no missing or broken mounting bolts or worn bushings Air Suspension if equipped Check for air leaks loose components and damage to air bag Inspect ride height valve and linkage for damage Frame Check for cracks or bends in frame Make sure there are no loose cracked bent broken or missing crossmembers or crossmember fasteners Air Lines and Wiring Check air lines and electrical wiring for proper security damage and chafing Listen for audible air leaks 36 3878859R2 Rear of Tractor 8487010 3878859R2 Ins
303. ure to follow this warning could result in property damage personal injury or death 162 Failure to comply with the following may result in property damage personal injury or death Always chock the wheels when manually releasing the parking brakes or the vehicle can roll For towing make sure the vehicle is securely connected to tow vehicle and tow vehicle parking brakes are applied before releasing the disabled vehicle s parking brakes To ensure release of parking brake always cage the spring in the brake chamber Under no circumstances should the spring brake chamber be disassembled for the purpose of releasing the parking brake Remove tow hooks from their installed position in the front of the vehicle before operating the vehicle Failure to do so could result in the tow hooks becoming unintentionally detached from the vehicle resulting in vehicle and or engine component damage NOTE Important factors to keep in mind when using tow hooks use both tow hooks when retrieving vehicle use a slow steady pull do not jerk on hooks tow hooks are not designed for towing retrieval only 3878859R2 NOTE The tow hooks must be removed to operate the tilt away bumper Before moving the towed vehicle check for adequate road clearance of vehicle components International Truck recommends unloading the towed vehicle prior to towing to reduce any abnormal loads to the vehicle components resulting from the towing pro
304. using the ignition door key The door will remain in a fully opened position To close the door firmly push the door down and to the locked position The door will automatically lock when shut 3878859R2 Model Description Chassis Skirts The optional chassis skirts on the International ProStare Series trucks are available to provide improved aerodynamics The rear driver side chassis skirt on sleeper models can be conveniently removed without tools to gain access to the battery box Removal 8487435 1 Chassis Skirt 2 Keeper Bracket 3 Locking Handle in Unlock Position 21 Model Description 1 Locate the locking handle at the rear inside of the chassis skirt Release the locking handle from the keeper bracket 3 Rotate the locking handle downward 90 to release the chassis skirt 4 Grasp both ends of the chassis skirt and slide the chassis skirt upward under the cab 5 Allow the bottom of the chassis skirt to come outward and remove the chassis skirt from the vehicle 22 Installation NOTE There are two hooks on the back side of the chassis skirt that must be fully engaged on the mounting bar to be secured properly 1 Grasp both ends of the chassis skirt hold the bottom of the chassis skirt away from the vehicle and slide the chassis skirt under the edge of the cab 2 Lower the bottom of the chassis skirt onto the mounting bar and align the chassis skirt on the front chassis skirt
305. viously manufactured Make sure your use of this completed vehicle conforms to all federal state and local requirements and regulations imposed on owners and operators Printed in the United States of America 2010 Navistar Inc All Rights Reserved S OPOW 12 SOld S uvlLSOud 010z 4aquieseq Solid CU6S88Z8E Operator s Manual PROSTAR Series IMPORTANT IT IS IMPORTANT THAT THE VEHICLE IDENTIFICATION NUMBER VIN AND COMPONENT FEATURE CODE AND SERIAL NUMBERS BE RECORDED THESE NUMBERS ARE REQUIRED TO OBTAIN INFORMATION PERTINENT TO THIS VEHICLE VIN VEHICLE IDENTIFICATION NUMBER LOCATION LoneStar 9000i ProStare TranStar PayStar WorkStar DuraStar and TerraStar Series Located left door opening rear post COMPONENT IDENTIFICATION NUMBERS Component Feature Codes appear on the vehicle line set ticket Component serial numbers appear on the components Feature Code Serial Number FRONT AXLE REAR AXLE TRANSFER CASE TRANSMISSION ENGINE ENGINE SERIAL NUMBER LOCATION MAXXFORCE Stamped on pad right side of the crankcase below cylinder head WORLD HEADQUARTERS Navistar Inc 4201 Winfield Road Warrenville Illinois 60555 USA INTERNATIONAL INTERNET SITE internationaltrucks com SALES REGIONS MIDWEST Navistar Inc 4201 Winfield Road PO Box 1488 Warrenville Illinois 60555 630 753 5900 NORTHEAST N
306. ween the nut and washer and spin the washer to spread the oil around the nut to washer contact surface Carefully lubricate the wheel stud threads by wiping them with a freshly oiled cloth Do not get the oil on any 3878859R2 other surfaces or the wheel clamping effectiveness will be reduced To prevent aluminum wheels from getting stuck on the hub due to corrosion apply a thin coat of antiseize compound or disc brake corrosion control grease to the hub pilot pads only Slide the inner wheel if duals or steer wheel over the wheel studs and onto the pilot pads of the hub Care must be taken to avoid damage to the stud threads while positioning the wheel Ensure that the wheel is resting on the pilot pads and is against the brake drum Hand start all wheel nuts to avoid cross threading Starting with the nut at the 12 00 o clock position and using the appropriate star or crisscross pattern see wheel nuts torque sequence diagram run the wheel nuts down the wheel studs with an impact wrench until they are snug against the wheel The purpose of this step is to snug the wheel s in the correct position not to apply the final torque The tightening of each nut should be stopped immediately when the wheel is contacted resulting in a wheel nut torque well below the final specified torque Use a calibrated torque wrench to apply the specified torque to each wheel nut in the sequence specified in the wheel nuts torque sequence diagr
307. when jump starting 6 Connect one end of the first jumper cable to positive terminal of the dead battery or terminal of dead battery jump start stud and then connect the other end of the jumper cable to the positive terminal of the booster battery 7 Connect one end of the second jumper cable to the negative terminal of the booster battery and the other end to chassis frame of the vehicle with the discharged battery Do not attach the other end to the negative battery terminal of the discharged battery because a spark could occur and cause explosion of gases normally present around the battery 3878859R2 Operation 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 above procedure when removing the jumper cables Cold Weather General Information Explosion Hazard Do not use volatile starting aids such as ether propane or gasoline in the engine air intake system Glow plugs and or grid heater will ignite vapors which can cause severe engine damage personal injury or death Cold Weather Starting There are two optional features available on the International ProStare Series truck for frequently operating the vehicle in cold climates Ether Injection System This temperature controlled system is automatically activated at air temperatures below 32 and injects a safe met
308. wn to adjust pull up to lock 2 Hazard Warning Switch Red rocker switch located above multipurpose turn signal lever Push switch to forward position to activate The hazard warning flasher will operate with the ignition switch in the ON or OFF position Use the warning system any time your vehicle becomes a traffic hazard day or night Push switch rearward to deactivate Stop Override Hazard Optional When hazard lights are activated and the brake pedal is depressed all hazard turn signal lights on the front side lights of the truck and the side trailer lights will continue to flash The rear lights of the truck or tractor will burn steadily until the brake is released 3 Trailer 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 the steering wheel 4 Signaling For A Turn When signaling your intention to make a turn move the turn signal lever up or down to the full turn position which is past the point of resistance The switch 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 without locking the switch into the full turn position To use this feature move turn signal lever up or down to the point where resistance
309. wo available jaw versions for the system with monitoring or without 8487209 monitoring The version with monitoring capabilities includes additional indicators to show the driver fifth wheel jaw status NOTE Fifth Wheel Jaw Unlock is only operational when vehicle is stationary parking brake is set and ignition switch is in the RUN position NOTE Outside roadside mechanical jaw release mechanism is still operable regardless of in cab control To unlock the fifth wheel jaw depress and hold the UNLOCK FIFTH JAW switch If the switch is only pressed momentarily jaw unlock will not occur A continuous tone alarm will sound while the jaw is unlocking The continuous tone will then change to a repetitive beep indicating jaw unlocking is complete The red indicator in the switch will turn on when jaw unlocking is complete Release the UNLOCK FIFTH JAW switch and release the parking brake to silence the alarm The red indicator will then turn off If the red indicator flashes fast this indicates a fifth wheel control system error or failure If the red indicator flashes slowly this indicates an interlock problem e g parking brake not set NOTE If the continuous tone alarm shuts off before the repetitive beep is heard jaw unlocking was incomplete 3878859R2 Fifth Wheel Jaw Monitoring The optional fifth wheel jaw monitoring feature is an electronic jaw lock indicator system with two indicators to show fifth wheel jaw status t
310. xle Chamfer or Shoulder Wear with tires inflated properly is a normal tendency of most radial tire designs If both inside and outside shoulders are wearing evenly around the tire no further action is required Overinflation is not effective in correcting this effect 3878859R2 Irregular Wear If irregular wear is present check the axle alignment tire pressure wheel balance shock and suspension component condition and wheel bearing end play This condition not only shortens tire life but will adversely affect the handling of your vehicle Rotating tires from one wheel position to another is a way often used to even out many types of irregular wear or to avoid it altogether See Tires Rotation for more information Some of the more effective tire rotation programs are Irregular wear can be minimized by e Using the right inflation pressure for the load being carried e Maintaining proper front wheel alignment especially toe in to specifications e Maintaining proper tire and wheel balance e Maintaining shock absorbers and suspension components e Maintain proper wheel bearing adjustment Use of Tire Chains Refer to chain manufacturers recommendation for correct tire chain usage installation and removal 3878859R2 Maintenance Instructions Wheels Wheel and Wheel Nut Maintenance and Installation To prevent personal injury or death always follow these instructions when mounting tires on wheel
311. y rear brakes to transfer power from the slipping wheel to the opposite wheel This enables the vehicle to gain momentum and move torque to road surfaces providing more traction The system instantly blinks a dash indicator to advise the driver that wheel spin is occurring If wheel spin occurs at speeds above 25 mph 40 km h the dash indicator blinks and using its link to the engine control module the ATC reduces engine torque to a level suitable for the available traction The brakes are not applied even slightly at any speed above 25 mph 40 km h Both the AntilockBrake System and Automatic Traction Control are features added to the basic air brake system and the loss of either or both should in no way affect the basic brake system ABS and ATC require no changes in driving style and it is best not to change your usual careful driving habits Other than during initial start up when the TRAC CTRL indicator flashes and then goes out the ATC system should not be noticed until it s needed Routine operation of the brakes and accelerator are unchanged ATC System Check At ignition turn on the TRAC CTRL indicator will illuminate steadily for 2 5 seconds and then turn off If not the system is defective or inoperative 160 ATC OFF ROAD or MUD SNOW Switch The optional ATC system comes equipped with one of two switches that perform the same functions of enabling and disabling the ATC system NOTE Be sure to turn the ATC OFF
312. y result in shock damage to the power divider components When encountering slippery highway conditions poor traction the PDL can be engaged at a low even speed Momentarily 3878859R2 Operation letting off the accelerator will engage the differential lock A warning indicator on the instrument panel indicates when the inter axle differential is locked When highway conditions improve good traction the PDL should be disengaged again at a low even speed Letting up on the accelerator momentarily will unlock the inter axle differential Tandem axle power dividers or inter axle differentials in the forward rear axle are controlled by the dash tock mounted Power Divider Lock PDL LOCK switch ra The switch indicator will turn on when the PDL is engaged locked The vehicle may be electronically programmed to provide an alarm when a speed is reached where it is not appropriate to have the power divider locked In this event an alarm will sound 5 beeps and the switch indicator will flash slowly once per second A fast flashing twice per second switch indicator signifies a problem in the PDL system 8487107 Under normal highway conditions good traction the PDL should be disengaged which allows differential action between the forward rear axle and the back rear axle preventing inter axle differential wear due to unequally worn or mismatched tires etc 149 Operation Driver Controlled Differential Lock
313. y shutdown When performing Parked Regeneration make certain vehicle is safely off of the roadway and exhaust pipe is away from people or any flammable materials or structures Failure to follow these instructions may result in a loss of engine power vehicle speed increased exhaust temperatures and may cause an accident or fire resulting in property damage personal injury or death There will be three levels of indication that the vehicle s exhaust filter is accumulating soot and needs to be cleaned each with an increasing urgency for action NOTE A Level 1 indication may disappear or a Level 2 may revert to a Level 1 if the vehicle is driven on highway at highway speeds for an extended period This process of auto regeneration of the exhaust filter is activated when the engine load is increased as a result of highway driving at highway speeds If the DPF indicator does not reduce in level or disappear a Parked Regeneration must be performed NOTE The following table is a typical representation of 2010 DPF emissions procedures See visor for vehicle federal emissions label 139 Operation 2010 Federal Emissions Label i Vehicle r 3 nacation Audible Alarm LCD Text Message Conditions Operation Action Required Scrolls between Drive on highway at highway speeds or start Parked Sa Weer for inte Exhaust filter Regeneration to prevent loss of power 3813052 and Parked Regen regeneration required Solid Require

International Pro Star Operator`s Manual

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